Notice of Intent to single source Braddock Boat Motor Repair

1. The intention is to award this requirement as a single source to GL Power Inc 450 Riverport Dr. Leetsdale, PA 15056
2. GENERAL REQUIREMENTS.  These specifications establish the requirements to replace and reprogram the electronic propulsion units. The following steps will need performed by the contractor:

The contractor shall install, configure, and test two new Twin Disc EC-300 Engine Control Units (EC-300s) for the dual Cummins marine diesel engines and their transmissions on the Braddock Locks and Dam work boat. This work will include installing the EC-300s, connecting existing wiring, programming the system, and conducting operational testing according to manufacturer specifications. A brief description of the work is detailed below.

 Installation of EC-300s

Install the new EC-300s in the locations previously occupied by the removed EC-300s. Ensure the new EC-300s are securely fastened in their original positions, with minimal movement or vibration during vessel operation.

Electrical Connections

Connect all existing vessel wiring to the new EC-300s. No new wiring installation is expected. Verify that existing power supply connections meet the voltage and amperage requirements specified by Twin Disc to avoid damage to the units. Check the grounding of the system to ensure it is properly configured to prevent potential damage. Verify that signals and communication between the EC-300s and the dual Cummins engines/transmissions are correctly established through existing wiring. This shall include:

1. 1. Ensuring throttle and control signals are properly sent and received.
   2. Confirming communications bus connectivity between the EC-300s and engine/transmission systems.
   3. Verifying all necessary signals related to engine and transmission operation.

Programming and Configuration

Power up the new EC-300s and ensure they initialize correctly without errors. Program the new EC-300s according to the requirements of the dual Cummins marine diesel engines and their transmissions. This includes:

1. 1. Adjusting throttle response parameters to match engine specifications.
   2. Configuring transmission engagement and shift points for smooth operation.
   3. Establishing proper communication between the new EC-300s, engines, and other vessel systems via the communications bus.
   4. Inputting engine type, horsepower, transmission model, and other critical settings into the new EC-300s.
   5. Ensuring all required inputs and outputs are programmed into the new EC-300s for proper communication and control. This includes:
      1. Verifying engine sensors (RPM, temperature, pressure) are accurately reporting.
      2. Ensuring transmission signals (gear position, shift feedback) are correctly processed.
      3. Confirming helm controls (throttle, shift handles) are properly configured.
      4. Checking all auxiliary systems interfacing with the propulsion system (e.g., alarms, diagnostic sensors) are functioning as intended.

System Testing and Calibration

1. Functional Testing: Conduct comprehensive testing of the new EC-300s to verify throttle and transmission controls are functioning correctly. Testing should include:

   1. Throttle Range Test: Ensure throttle operates across its full range and that engine RPM matches the throttle position.
   2. Transmission Test: Verify smooth shifting between forward, neutral, and reverse gears, ensuring compliance with manufacturer specifications.
   3. Diagnostic Monitoring: Use the Twin Disc diagnostic tool to check for error codes or anomalies.
2. System Calibration: Adjust settings such as idle speed, throttle response curves, and transmission shift points to align with the vessel’s operational needs.
3. Sea Trial Testing: Conduct a sea trial with lock personnel to verify that the new EC-300s operate the engines and transmissions correctly under real-world conditions, recording engine RPM, throttle response, and shift performance.