JAI ENGINEERS is manufacturer of Free Cooling Units on CNC Machines for Telecom Infrastructure Companies in India.

We are manufacturer of free cooling unit for telecom in India. FCU - (Free Cooling Unit) is equipped with Microprocessor based control unit to precisely control the operation of the Cooling Unit, Air-conditioner and Generator of a Telecom site. Suitable temperature sensors and intelligent interface with the Air conditioning equipment, Generator ensures these are Switched ON when absolutely necessary to minimize power consumption.Free Cooling Unit is Air handling solution that uses the Outside air to cool the Inside Electronics and Electrical system. It is basically to handle the outside air smartly with our Intelligent “Microprocessor based Controller” to ensure the designated temperature inside the room. We are the manufacturers of free cooling units in India which provide our customers with huge energy savings around the clock and have done so for years. Free Cooling controlled ventilation it removes excess heat from telecom base stations and cools down the shelter or enclosure by use of ambient air. No compressor is involved in free cooling. The free cooling system is significantly more economical in use than air conditioners.

We are into manufacturing of free cooling units for telecom in India. Free cooling units are a simple solution designed for easy installation. It is no longer necessary to have energy and maintenance demanding cooling machines for the telecom shelters. Our energy-saving system of free cooling is easy to handle and ensure an economic operation; apart from that it is a Freon free system.The principle is easy, instead of cooling the warm air the system makes sure the heat is transported out. The cool outdoor air is forced through the filter hoses displacing the hot air in the shelter to the ceiling, where it is transported out through an exhaust grill. Its purpose is to keep the container or room temperature at a desired level by providing cooler ambient air to the container or room interior. Such solution significantly reduces the energy consumption required to maintain the temperature inside the appropriate level.
Tower Site Components
Tower Site consists of :

BTS equipment
VRLA batteries
AC and DC distribution boards
Air Conditioners
Battery Charger – SMPS
Servo/Solid State Voltage Stabilizer
And Now FreeCool
Outside the Shelter
DG Set & AMF panel
Telecom Towe
The functioning of a tower site is very critical for a Telecom business, Any failure of the tower site results in loss of business to a operator hence a 24/7, 365 day fully functional operation is of prime importance. Therefore each of the above equipments must be very reliable for efficient functioning of a Tower site.

Electrical Equipments Description

Electricity Board Supply: This is provided by state electricity board. It will be 3 phase supply. It includes energy meter, input fuses. All the items are property of state electricity board and user don’t need to do any maintenance on it.
DG Set and AMF panel: Each telecom shelter site has a DG set with AMF (Auto Mains Failure) Panel. DG set is used as backup power source to run telecom BTS, air conditioners and to charge the battery bank. The DG operation may be automatic with the help of AMF panel or manual. In auto mode DG set gets automatically ON as power goes off and OFF as power restores. In this mode user can set DG start operation according to site conditions. User may delay the start of the DG set. In manual mode user need to do the DG On-off operation manually.
Main Distribution Board: The electrical power is distributed from this. It includes several rating MCBs. The MCBs are selected according to load requirement. In 3 phase supply the distribution should be in equal level.
Battery Charger–SMPS: SMPS means Switched Mode Power Supply. The function of it is to convert alternating current power into direct current power. It includes rectifier modules to make ac to dc. The DC power is used to run the BTS (Base Tran receiver Station) equipments and to charge the batteries. It has inbuilt surge protection circuit, input MCB and HRC (High Rupturing Capacity) fuses at DC side. It may have DC distribution MCBs according to load requirements
Servo Voltage Stabilizer: This equipment is used to keep the input voltage within the limits. It may be Servo motor based or Thyristor based. In Servo type stabilizers if input voltage falls down or rises above the set point the transformer tap change and voltage gets stabilized.

FreeCool System

FreeCool Assembly:
FreeCool divided into mainly three major parts:
Inlet unit assembly
Outlet unit assembly
Inlet unit consist of fixed louvers frame, filter, gravity louvers frame, rain canopy, mounting nut bolts, washers, spacers, screws, internal temp sensor (Thermo Couple).
Outlet unit consist of front & back fan frame, 48VDC fan, louvers frame, plastic louvers, their mounting nut bolts, spacers and external temp sensor PT 100 type with assembly.
Controller is the microprocessor based electronic part of the unit. According to site conditions installation engineer/technician need to do setting at site
FreeCool Operation
FreeCool General
FreeCool provides a free cooling solution for telecom sites which is efficient, energy saving and protects the environment. FreeCool is free from Freon gas and can endure long period service intervals. FreeCool is specially designed for easy installation in the existing telecom shelters
FreeCool obviates the need to cool hot air generated inside the telecom shelters and instead ensures effective outward transmission of the heat generated. The hot air gets displaced through an air outlet unit and the cool outside air is sucked-in through the air inlet unit filters. This provides an extremely reliable operational system.
FreeCool obviates the need to cool hot air generated inside the telecom shelters and instead ensures effective outward transmission of the heat generated. The hot air gets displaced through an air outlet unit and the cool outside air is sucked-in through the air inlet unit filters. This provides an extremely reliable operational system.
Both the inlet and outlet air units are provided with rain canopies on the outside of the shelter. All the unit housings are fabricated from CRCA steel and powder coated. The air outlet unit is equipped with a prime quality axial flow fan, which is extremely reliable and has a high speed and high air flow volume. The fan has a long operational service life and works on 48 Volts DC power supply, with low energy consumption.
FreeCool is provided with its own intelligent micro-processor based controller unit with LED display and functional buttons, rendering it very easy to use. The controller continuously monitors the temperature inside the shelter and the ambient temperature outside the shelter.
The controller fully automatically controls the operation of FreeCool in all possible conditions in the telecom shelter in Auto Mode.
Normal FreeCool Operation
The controller continuously monitors the real time temperature inside the shelter and ambient temperature outside the shelter, as well as the percentage relative humidity inside the shelter. The controller has the facility to set the normal operating temperature that needs to be maintained inside the shelter, normally which can be set between 22°C to 35°C as per the customer requirement. This is the shelter set point or the operating temperature, normally recommended to be set at 30°C. Whenever the outside ambient air temperature falls below the set point temperature by a pre determined value called ∆T [Settable between 20°C to 90°C normally set at 40°C] then the controller automatically switches off the air conditioners and starts the free cooling system. Under these conditions the FreeCool uses cool ambient air and maintains the shelter temperature at or below set point temperature. Subsequently whenever the shelter temperature rises above set point i.e. operating temperature, the controller will switch off the FreeCool system and switch on the air conditioners.
This system typically can save air conditioners energy in the range of 6 hours to 12+ hours per day depending upon the location and the season thereby contributing substantial saving in OPEX cost.
Emergency Cooling
The controller monitors required parameters and starts emergency operation. When Shelter temperature goes above emergency temperature set point
OR Mains power failureOR Shelter temperature rises above Set point normally 35°C and shows temperature rising trend thereby indicating air conditioners failure.
During emergency cooling the shelter temperature will be maintained at about 3-4°C higher than ambient temperature. This emergency cooling operation is reset to normal cooling if shelter temperature is less than 34°C.

Additional Functionality
During free-cooling at any time if shelter temperature is lesser than the low shelter temperature set point (normally at 17°C) or if shelter humidity is greater than the set percentage relative humidity (Normally set at 80%), the free-cooling is disabled and air conditioners are enabled.