Series 5000 Cooling Tower Specifications
1.0 Cooling Tower 
1.1 General: Furnish and install _____ factory-assembled, induced draft, crossflow cooling tower(s) with vertical air discharge, conforming in all aspects to the specifications, schedules and as shown on the plans. Overall dimensions shall not exceed approximately _____ ft (mm) long X ______ ft (mm) wide X _____ ft (mm) high. The total connected fan horsepower shall not exceed _____ HP (kW). The cooling tower(s) shall be Baltimore Aircoil Company Model _______.
1.2 Thermal Capacity: The cooling tower(s) shall be warranted by the manufacturer to cool _____ USGPM (lps) of water from ______ ºF(°C) to _____ ºF(°C) at _____ ºF(°C) entering wet bulb temperature.  For increased reliability this unit shall be equipped with the ENDURAFLOW™ Heat Transfer System, which includes features designed specifically for dirty water cooling. Units that do not have dirty water features built into the hot water basin, louver section, heat transfer section, eliminator and baffle section and cold water basin shall not be sufficiently reliable and will not be considered acceptable alternatives.  
1.3 Unit Construction: EVERTOUGH™ Construction: All steel panels and structural members shall be protected with a thermosetting hybrid polymer. In addition, the cold water basin shall be protected with the TriArmor® Corrosion Protection System. The system shall consist of G-235 galvanized steel encapsulated with a thermosetting hybrid polymer further protected by a polyurethane barrier applied to all submerged surfaces exposed to circulating system water. The polyurethane barrier shall seal all factory seams in the cold water basin to ensure a corrosion resistant and water tight construction, and shall be warranted against leaks and corrosion for five (5) years. Standard basin accessories shall include: a corrosion resistant make-up valve with large diameter polystyrene filled plastic float for easy adjustment of the operating water level, removable anti-vortexing device to prevent air entrainment, and large area lift out strainers with perforated openings sized smaller than the water distribution system nozzles. The strainer and anti-vortexing device shall be constructed from Type 304 stainless steel to prevent corrosion. A welded Type 316 stainless steel basin shall be an acceptable alternative; provided the basin is warranted against leaks and corrosion for a period of at least 5 years. A bolted Series 300 stainless steel basin shall not be an acceptable alternative. The hot water basins shall be constructed of UV and corrosion resistant pultruded fiberglass reinforced polyester (PFRP) with Type 304 stainless steel covers. Type 304 or 316 stainless steel basin shall be an acceptable alternative. The entire cooling tower, including fan motor, drive system, bearings, and structure, shall be backed by a comprehensive Louver-to-LouverSM Five-Year warranty.
 (Alternate) 1.3 Unless otherwise noted in this specification, all steel basin panels and structural members shall be constructed of heavy-gauge G-235 (Z700 metric) hot-dip galvanized steel with all edges given a protective coating of zinc-rich compound. This standard corrosion protection system will provide reliable protection and long life for most industrial cooling applications. This is the heaviest galvanizing commonly available in the industry, and is the accepted standard for normal evaporative cooling applications.
(Alternate) 1.3 Unless otherwise noted in this specification, all steel panels and structural members shall be protected with a thermosetting hybrid polymer. The system shall consist of G-235 (Z700 metric) hot-dip galvanized steel prepared in a four-step (clean, pre-treat, rinse, dry) process with an electrostatically applied, thermosetting, hybrid polymer fuse-bonded to the substrate during a thermally activated curing stage and monitored by a 23-step quality assurance program. Other coatings must be submitted to the engineer for pre-approval. Approved equals must have undergone testing, resulting in the following results as a minimum: 
1. When X-scribed to the steel substrate it shall be able to withstand 6000 hours of 5% salt spray per ASTM B117 without blistering, chipping, or loss of adhesion;
2. When X-scribed to the steel substrate it shall be able to withstand 6000 hours of exposure to acidic (pH=4.0) and alkaline (pH=11.0) water solutions at 95ºF (35°C) without signs of chemical attack;
3. Shall withstand impact of 160 in-lbs per ASTM D2794 without fracture or delamination of the polymer layer; 
4. Shall withstand 6000 hours of ultraviolet radiation equivalent to 120,000 hours of noontime sun exposure without loss of functional properties;
5. Shall withstand 200 thermal shock cycles between -25ºF and +180ºF (-32°C and 82°C) without loss of adhesion or other deterioration;
6. Shall withstand 6000 hours of exposure to 60 psi (42,184 kg/m2) water jet without signs of wear or erosion.
Type 304 stainless steel shall be considered an acceptable alternative. Uncoated G-235 galvanized steel shall not be considered an acceptable alternative.
 (Alternate) 1.3 JE PREMIER SERIES® Construction: All steel panels and structural members, including the structural frame, hot and cold water basins, distribution covers, fan deck and fan cylinder shall be constructed of Type 304 stainless steel and assembled with Type 304 stainless steel nut and bolt fasteners. All factory seams in the cold water basin shall be welded to ensure watertight assembly and welded seams shall be warranted against leaks for five (5) years. Stainless steel basins with bolted seams are not acceptable. The entire cooling tower, including fan motor, drive system, bearings, and structure, shall be backed by a comprehensive Louver-to-LouverSM Five-Year warranty.  Type 301 Stainless Steel shall not be an acceptable alternative.
1.4 Quality Assurance: The cooling tower manufacturer shall have a Management System certified by an accredited registrar as complying with the requirements of ISO9001:2008 to ensure consistent quality of products and services. Manufacturers that are not ISO9001 Certified shall not be acceptable.
1.5 Wind and Seismic Forces: The structure of this equipment has been designed, tested and independently certified in accordance with the wind and seismic load requirements of the 2015 International Building Code (IBC) and ASCE/SEI 7-10. The structure shall be certified to meet a minimum unrestricted seismic design SDS = ___ g with an Importance Factor of ___ and wind load of  ___ psf. Units not provided with a certificate of IBC 2015 compliance shall not be an acceptable alternative.
2.0 Construction Details 
2.1 Structure: The cooling tower shall be constructed with a sturdy structural frame designed to transmit all wind, seismic and mechanical loads to the equipment anchorage. The frame shall be constructed of heavy-gauge steel angles and channels.

  
2.2 Casing Panels: Casing panels shall be constructed of galvanized steel protected with a thermosetting hybrid polymer. Corrosion resistant Type 304 stainless steel casing panels are an acceptable alternative. Casing panels shall not provide structural support, since the sturdy, structural frame of the tower transfers all loads to the equipment anchorage.
(Alternate) 2.2 Casing Panels: Casing panels shall be constructed of galvanized steel panels. Casing panels shall not provide structural support, since the sturdy, structural frame of the tower transfers all loads to the equipment anchorage.
(Alternate) 2.2 Casing Panels: Casing panels shall be constructed of corrosion resistant Type 304 stainless steel casing panels. Casing panels shall not provide structural support, since the sturdy, structural frame of the tower transfers all loads to the equipment anchorage.
2.3.1 Cold Water Basin: The cold water basin shall be constructed of heavy-gauge steel panels and structural members. The cold water basin shall be unobstructed, free draining and shall allow for inspection during operation for preventive maintenance purposes. The basin floor shall slope towards a depressed center section with a drain/clean-out connection. Additionally, the basin will have a separate and steeper slope at each air inlet side, lowering the amount of water at the inlet. This feature shall minimize the operating volume of water, eliminate stagnant zones by directing water and debris toward outlet, deter biological growth, and improve effectiveness of water treatment. Alternative basins with a single slope or no sloping floor shall not be accepted.
2.3.2 Cold Water Basin: As part of Evertough® Construction, the cold water basin shall be protected with the TriArmor® Corrosion Protection System. The system shall consist of G-235 galvanized steel encapsulated with a thermosetting hybrid polymer further protected by a polyurethane liner factory applied to all submerged surfaces. The polyurethane barrier shall seal all factory seams in the cold water basin to ensure a corrosion resistant and water tight construction, and shall be warranted against leaks and corrosion for five (5) years. Field applied polyurethane or polyurethane applied directly to galvanized steel is not an acceptable alternative.  Standard basin accessories shall include: a corrosion resistant make-up valve with large diameter polystyrene filled plastic float for easy adjustment of the operating water level, removable anti-vortexing device to prevent air entrainment, and large area lift out strainers with perforated openings sized smaller than the water distribution system nozzles. The strainer and anti-vortexing device shall be constructed from the Type 304 stainless steel to prevent corrosion. A welded Type 316 stainless steel basin shall be an acceptable alternative; provided the basin is warranted against leaks and corrosion for a period of at least 5 years. A bolted Series 300 stainless steel basin shall not be an acceptable alternative.
(Alternate) 2.3.2 Cold Water Basin: The cold water basin shall be constructed of heavy-gauge galvanized steel panels and structural members. Standard basin accessories shall include a corrosion resistant make-up valve with large diameter plastic float for easy adjustment of the operating water level, removable anti-vortexing device to prevent air entrainment, and large area lift out strainers with perforated openings sized smaller than the water distribution system nozzles. 
 (Alternate) 2.3.2 Cold Water Basin: The cold water basin shall be constructed of heavy-gauge Type 304 stainless steel panels and structural members. All factory seams shall be welded to ensure watertight construction and welded seams shall be warranted against leaks for a period of five (5) years from date of shipment. Stainless steel basins with bolted seams are not acceptable. Basin shall include a depressed center section with drain/clean-out connection. Standard basin accessories shall include a corrosion resistant make-up valve with large diameter plastic float for easy adjustment of the operating water level, removable anti-vortexing device to prevent air entrainment, and large area lift out strainers with perforated openings sized smaller than the water distribution system nozzles. 
(Alternate) 2.3.1 Cold Water Basin: The unit shall be provided without an integral cold water basin. The unit shall be mounted on a separate concrete cold water basin provided by others, to allow cooling water to pass directly from the fill into the basin.
2.4 Water Outlet: The water outlet connection shall be beveled for welding and grooved for mechanical coupling or bolt hole circle designed to accept an ASME Class 150 flat face flange. The outlet shall be provided with large-area lift out strainers with perforated openings sized smaller than the water distribution nozzles and an anti-vortexing device to prevent air entrainment. The strainer and vortex device shall be constructed of the same materials as the cold water basin to prevent dissimilar metal corrosion.
2.5.1 Water Distribution System: Hot water basin(s) shall be gravity fed and designed for inspection and cleaning during operation. Hot water basin design and nozzle mixes shall be optimized for water pressure, clog prevention, and thermal performance. To ensure proper operation at all times and maximum uptime, the individual nozzles shall be removable for cleaning during operation.  Weir dams shall accommodate a flow range of 50% to 100% of the design flow rate. Lift-off distribution covers shall be constructed of heavy-gauge steel and designed to withstand a 50 psf (244 kg/m2) live load or 200 pound (90.7 kg) concentrated load. The covers shall shield the water from direct sunlight and prevent debris to enter the cooling circuit.. 
2.5.2 Water Distribution Construction: As part of Evertough® Construction, the water distribution basins shall be constructed of corrosion resistant pultruded fiberglass reinforced polyester (PFRP) to provide ultimate protection against harsh water chemistry, basin covers shall be constructed from heavy gauge steel panels made from G-235 galvanized steel encapsulated with a thermosetting hybrid polymer. Type 304 or 316 stainless steel is an acceptable alternative.  
(Alternate) 2.5.2 Water Distribution Construction: The water distribution basins and basin covers shall be constructed from heavy gauge steel panels made from G-235 galvanized steel. 
(Alternate) 2.5.2 Water Distribution Construction: The water distribution basins and basin covers shall be constructed from heavy gauge steel panels made from Type 304 stainless steel.
3.0 Mechanical Equipment 
3.1 Fan(s): Fan(s) shall be heavy-duty, axial flow with aluminum alloy blades selected to provide optimum cooling tower thermal performance with minimal sound levels. Air shall discharge through a fan cylinder designed for streamlined air entry and minimum tip clearance for maximum fan efficiency. The top of the fan cylinder shall be equipped with a conical, non-sagging removable fan guard.
3.2 Bearings: Fan(s) and shaft(s) shall be supported by heavy-duty, self-aligning, grease-packed ball bearings with moisture proof seals and integral slinger collars, designed for a minimum L10 life of 80,000 hours.
3.3 Fan Drive: The fan(s) shall be driven by a one-piece, multi-groove, solid back V- type powerband with taper lock sheaves designed for 150% of the motor nameplate horsepower. The powerband shall be constructed of neoprene reinforced polyester cord and be specifically designed for cooling tower service.
3.4 Sheaves: Fan and motor sheave(s) shall be fabricated from corrosion-resistant materials to minimize maintenance and ensure maximum drive and powerband operating life. 
(Alternate 3.2, 3.3 & 3.4) Fan Drive: Fan(s) are driven by a (Close-Coupled (internal) TEAO fan motor gear drive) (gear drive with the TEFC fan motor mounted outside the airstream). The gear shall be a right angle, industrial duty, oil-lubricated, geared speed reducer. Spiral bevel or spiral bevel/helical gears are designed in accordance with the Cooling Technology Institute STD-111, "Gear Speed Reducers". All gears have a minimum service factor of 2.0 based on design fan horsepower and are suitable for both forward and reverse operation. An oil level fill port and sight glass are located on the gear drive to facilitate routine inspection and maintenance. The gear is doweled in position after alignment of the mechanical equipment.
(Alternate) 3.5 Fan Motor: Fan motor(s) shall be totally enclosed air over (TEAO), reversible, squirrel cage, ball bearing type designed specifically for cooling tower service. The motor shall be furnished with special moisture protection on windings, shafts and bearings. Fan motors shall be premium efficient/inverter duty type designed per NEMA Standard MG1, Section IV Part 31.
(Alternate) 3.5 Fan Motor: Fan motor(s) shall be totally enclosed fan cooled (TEFC) and mounted outside the airstream. The motor shall be furnished with special moisture protection on windings, shafts and bearings. Fan motors shall be premium efficient/inverter duty type designed per NEMA Standard MG1, Section IV Part 31. 
 (Alternate for ENDURADRIVETM Fan System) 3.2, 3.3, 3.4 & 3.5: Fan(s) shall be driven by direct drive TEAO motor(s) with an IP66 NEMA enclosure rating.  Fan system shall be capable of operating at any speed with no minimum requirement.  Motor insulation type shall be Class H and shall be rated at 1850 volts peak. Bearings shall be designed for a minimum L10 life of 100,000 hours.  Motor paint shall be capable of passing a 1000 hour salt fog test.  Motor shall be provided with normally closed thermostats.  Space heater shall be included if drive system does not include automatic protection from moisture for motor windings.  If oil is required, an extended oil fill line, electric oil heater, low oil level switch, and oil level sight glass shall be included.  
Variable frequency drive(s) shall be provided by the manufacturer and designed specifically for the cooling tower motor(s); refer to VFD specification for details.  The drive enclosure shall be provided in (NEMA 1 indoor-rated) (NEMA 12 indoor-rated) (NEMA 3R outdoor-rated) enclosure(s). 
3.6 Mechanical Equipment Warranty: The fan(s), fan shaft(s), sheaves, bearings, mechanical equipment support and fan motor shall be warranted against defects in materials and workmanship for a period of five (5) years from date of shipment. An additional two years of warranty, for a total of seven (7) years, shall be provided for fan motor(s) when space heaters are field-wired at time of initial installation.
(Alternate for ENDURADRIVE TM Fan System) 3.6 Mechanical Equipment Warranty: The motor shall be warranted against defects in materials and workmanship for a period of seven (7) years from date of shipment. The fan(s), fan shaft(s), sheaves, bearings, and mechanical equipment support shall be warranted against defects in materials and workmanship for a period of five (5) years from date of shipment.
4.0 Fill and Drift Eliminators 
4.1 Fill and Drift Eliminators: As part of the ENDURAFLOW(TM) Heat Transfer System, the fill section shall consist of rigid PVC splash bars formed with an internal rib to support the bar and protect against failure from debris build up.  Hollow bars or profiles shall not be an acceptable alternative. 
Fill bars shall be supported by metal sheets constructed of galvanized steel, thermosetting polymer coated galvanized steel or stainless steel.  Support sheets shall be designed to carry the load of fill bars with water and debris.  Wire grids or similar supports introduce a risk of premature failure and shall not be an acceptable alternative.  
Fill bars shall stop no less than 6" above to cold water basin floor to facilitate cleaning and maintenance.  Fill designs that do not have a 6" gap and hinder service of the basin shall be unacceptable.  
Fill shall be arranged in a pattern to optimize heat transfer and prevent against splash out and drift.  Fill should be arranged such that line-of-sight cleaning is possible from the louver face side of the unit. Fill bar spacing that does not facilitate maintenance or fails to protect against splash out and drift shall be unacceptable. 
For thorough maintenance of the unit, it shall be possible to mechanically clean the fill with a power washer. Fill must be designed and tested to withstand water pressure up to 1500 psi.  Fill designs not tested to this pressure shall be unacceptable. Designs that are suited for this type of pressure assisted cleaning, but have fill patterns that prevent the water stream from reaching through the entire fill pack carry the risk of debris build up and shall not be accepted.
To prevent against drift and optimized water management, units shall be equipped with both solid baffles and PVC eliminators prior to the air discharge.  The baffles shall be designed to direct large droplets of water back into the collection basin. Designs without baffles introduce the risk of flooding the eliminators; thus designs without baffles shall be unacceptable.  Between the baffles and the plenum section, the unit shall be fitted with PVC eliminators designed with three changes of direction to strip smaller water droplets from the exiting air.  Two change or simplified eliminator designs shall not be accepted. 
5.0 Air Inlet Louvers 
5.1 Louvers shall be designed to ensure proper water management.  Louvers shall not increase the dimensions of the unit or protrude beyond the basin footprint of the unit. Louvers shall be aerodynamically tested to optimize thermal performance. The louver blades shall be constructed of galvanized steel. Louvers extending beyond the collection basin introduce unacceptable risk for water to escape unit during upset conditions; such designs shall be unacceptable.
(Alternate) 5.1 Air Inlet Louvers: Louvers shall be designed to ensure proper water management.  Louvers shall not increase the dimensions of the unit or protrude beyond the basin footprint of the unit. Louvers shall be aerodynamically tested to optimize thermal performance. The louver blades shall be constructed of thermosetting polymer coated galvanized steel. Louvers extending beyond the collection basin introduce unacceptable risk for water to escape unit during upset conditions; such designs shall be unacceptable. Corrosion resistant Type 304 stainless steel is an acceptable alternative.
(Alternate) 5.1 Air Inlet Louvers: Louvers shall be designed to ensure proper water management.  Louvers shall not increase the dimensions of the unit or protrude beyond the basin footprint of the unit. Louvers shall be aerodynamically tested to optimize thermal performance. The louver blades shall be constructed of stainless steel. Louvers extending beyond the collection basin introduce unacceptable risk for water to escape unit during upset conditions; such designs shall be unacceptable.
6.0 Access 
6.1 Plenum Access: Two hinged access doors shall be provided for access into the plenum section. The doors shall be maximized in size to allow greater ease of entry and egress to the cooling tower. Smaller doors inhibit ease of maintenance, increasing service time. Doors that are smaller than 51 in.  (130 cm) shall not be accepted.
7.0 Sound 
7.1 Sound Level: To maintain the quality of the local environment, the maximum sound pressure levels (dB) measured 50 ft (15240 mm) from the cooling tower operating at full fan speed shall not exceed the sound levels detailed below. If the tower exceeds these conditions the tower must be either oversized and reduced in horsepower, provided with a low sound fan, or provided with sound attenuation.
8.0 Accessories 
8.1 Balancing Valves: Heavy-duty butterfly valves shall be provided at the hot water inlet connections. These valves shall include cast iron bodies, elastomer seat and steel operating stems. There shall be a locking handle to maintain the valve setting in any position. Wafer type field supplied spool piece is required between the inlet connection and the valve.
8.2 Basin Heater(s): The cooling tower cold water basin shall be provided with electric heater(s) to prevent freezing in low ambient conditions. The heater(s) shall be selected to maintain 40°F (4.44°C) basin water temperatures at ____°F (°C) ambient. The heater(s) shall be ______ V /____ phase/ ___Hz electric and shall be provided with low water cutout and thermostat.
8.3 
8.4 Vibration Cutout Switch: Provide a mechanical local reset vibration switch. The mechanical vibration cutout switch will be guaranteed to trip at a point so as not to cause damage to the cooling tower. To ensure this, the trip point will be set in a frequency range of 0 to 3,600 RPM and a trip point of 0.2 to 2.0 g’s.
(Alternate) 8.4 Vibration Cutout Switch: Provide an electronic remote reset vibration switch with contact for BAS monitoring. Wiring shall be by the installing contractor. The electronic vibration cutout switch shall be set to trip at a point so as not to cause damage to the cooling tower. To ensure this, the trip point will be set in a frequency range of 2 to 1000 Hertz and a trip point of 0.45 in/sec (0.0114 m/sec).
8.5 8.6 
8.7 Ladder: An aluminum ladder (with galvanized steel safety cage) shall be provided for access to the fan deck. Access door or service platforms are not acceptable.
8.8 Handrails: 1-1/4" (31.75 mm) galvanized steel pipe handrail shall be provided around the perimeter of the cooling tower cells. The handrails shall be provided with knee and toe rails and shall conform to the requirements of OSHA applicable at the time of shipment.
8.9 Access Door Platform: A galvanized steel platform and aluminum ladder to grade shall be provided at all access doors to access the plenum section of the cooling tower. All working surfaces shall be able to withstand 50 psf (244 kg/m2) live load or 200 pound (90.72 kg) concentrated load. 
8.10 Platform to Access External Motor (available on gear drives equipped with TEFC external motors only): A galvanized steel platform and ladder to grade shall be provided for access to the external fan motor. All working surfaces shall be able to withstand 50 psf (244 kg/m2) live load or 200 pound (90.72 kg) concentrated load.
8.11 Internal Walkway: An internal walkway shall be provided in the plenum section to provide for inspection and maintenance. All working surfaces shall be able to withstand 50 psf (244 kg/m2) live load or 200 pound (90.7 kg) concentrated load. Other components of the cooling tower, i.e. basin and fill/drift eliminators, shall not be considered an internal working surface. Cooling tower manufacturers that promote these surfaces to be used as a working platform shall provide a two-year extended warranty to the Owner to repair any damage to these surfaces caused during routine maintenance.
8.12 Internal Platform:  A full coverage service platform with aluminum ladder in the plenum facilitates access to the fan drive components and inspection of upper level eliminators, baffles and heat transfer components.  Internal platforms that only provide access to drive systems do not allow for compete inspection and maintenance of critical components and shall not be accepted.
8.13 Louver Face Platform: Easy access to the hot water basins for inspection and maintenance of the basins, even during tower operation, shall be provided by louver face platforms. Fan deck ladders and handrails, which add to the overall height of the tower, are not acceptable.
8.14 Fan Cylinder Extension: To extend the height of the tower equal to the surrounding enclosure, the cooling tower shall be provided with _____ft (mm) of fan cylinder extension. The fan cylinder extension shall match the construction of the fan deck.
8.15 Mechanical Equipment Removal Davit: Provide the mechanical equipment removal option to aid in motor removal or gear drive. The davit shall be portable from cell to cell and the heaviest piece shall weigh 60 lbs. The davit shall lower the motor or gear drive from the mechanical equipment supports down to an internal metal working surface.
8.16 Externally Mounted Pre-wired Terminal Box: The cooling tower shall ship from the factory with the fan motor(s) (and vibration cutout switch) wired to terminal blocks encased in a Type 304 stainless steel NEMA 3R enclosure, mounted on the outside of the tower. No casing penetrations shall be permitted in the field.