PDM AND ECU SOFTWARE UPGRADE PROCEDURE

PDM AND ECU SOFTWARE UPGRADE PROCEDURE

–––CXO300 – designed for purpose

coxmarine.com

DOCUMENT REVISION HISTORY

Publish Date Version Number Description

06/07/2021 1.3 Initial public release

05/10/2021 1.4 Update to support release of software level E

TABLE OF CONTENTS

PARTS LIST

INTRODUCTION

PDM UPDATE PROCESS

ECU UPGRADE PROCESS

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4

7

23

1.0

2.0

3.0

4.0

4

CXO300 PDM AND ECU SOFTWARE UPGRADE


1.0 PARTS LIST

1.1 REQUIRED PARTS

2.0 INTRODUCTION

This document covers the process for updating the PDM software of a CXO300 outboard.

This document should only be used in conjunction with Cox hardware and software which has been provided for the purpose of this update.

2.1 PDM OVERVIEW

The PDM on the CXO300 comprises of 4 main components which can be updated:

� GSA Software

� PTT Software

� NMEA Processor

� NMEA FPGA

Depending on which software level you are updating to, you may have to update all, some or just one of these components. See section 3, figure 4 to identify which components need to be updated when upgrading from different software levels. Each PDM component requires a different update process, see section 3 for detailed instructions outlining how to update each component.

If you have any doubt about which components require updating, please contact the Cox Aftersales team.

2.2 PDM SOFTWARE COMPATIBILITY

When updating a PDM care must be taken to check the updated software is compatible with the outboard’s ECU calibration and transmission hardware configuration.

No. Part Number and Description Qty

1 909596 - ACTISENSE USB DONGLE 1

2 909568 – PDM UPDATING TOOL 1

3 034393 – ACTISENSE CAN T-CONNECTOR 2

4 034394 – TERMINATING RESISTOR FEMALE 1

5 034395 – TERMINATING RESISTOR MALE 1

5CXO300 PDM AND ECU SOFTWARE UPGRADE

WARNINGBefore performing a PDM update confirm that the update is appropriate for your application. Running PDM software which is not compatible with the ECU calibration, or the transmission

specification of the outboard can lead to poor performance and damage to the outboard. If you have any doubts, contact Cox Aftersales.

Due to the inter-connected nature of the PDM and ECU, care must be taken that the outboard ECU calibration and PDM software are compatible. Figure 1 shows which ECU calibrations and PDM software versions are compatible. If the PDM software level being updated to is not compatible with the outboard’s ECU calibration level, the ECU calibration level should be updated to a compatible version before any running is performed. Running incompatible PDM software and ECU calibration can lead to poor shifting performance and error codes.

Figure 1: ECU Calibration/PDM Software Compatibility Matrix

PD

M S

oftw

are

CPU Version Software VersionECU Calibration

A B C D E F G H

3 A Y Y Y Y Y N N N

8 B Y Y Y Y Y N N N

8 C Y Y Y Y Y Y N N

10 D N N N N Y Y Y Y

14 E N N N N N N Y Y

Transmission Configuration

Pin and Fork Style Spline Style

PD

M S

oftw

are

A Y Y

B Y Y

C Y Y

D Y Y

E N Y

Due to the different torque capacity of the Pin and Fork Style and Spline Style transmission configurations, not all levels of PDM software are compatible with both transmission configurations. Figure 2 shows which levels of PDM software can be run with which transmission style. Before updating the PDM, ensure the PDM software level is compatible with the transmission configuration. Running incompatible PDM software and transmission configuration can lead to damage to the outboard.

Figure 2: PDM Software/Transmission Style Compatibility Matrix.

2.3 PDM SOFTWARE IDENTIFICATION

To identify the level of software currently installed on the PDM, check the software revision sticker on the PDM. The software revision sticker is next to the part number sticker and has the letters A – AD printed on it. The current software version loaded on the PDM is the last letter crossed out on the sticker. For example, the PDM shown in figure 3 is running software level D.

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CAUTIONAfter updating a PDM, always update the software revision sticker by crossing out the current

software level loaded on the PDM as per section 3.7. Failure to do so could lead to the PDM being accidentally run in an inappropriate configuration in the future, causing poor performance or

damage to the outboard.

Figure 3: PDM with software revision sticker showing PDM software level D

3.0 PDM UPDATE PROCESS

The various steps how to update a PDM are detailed in the sections of this chapter as follows:

1 Install software required: 3.1 INSTALLATION SOFTWARE PREPARATION

2 Prepare PDM Updating Kit: 3.2 HARDWARE PREPARATION

3 Connect PDM Updating Kit to PDM: 3.3 PDM PREPARATION

4 Updating the GSA Software: 3.4 UPDATING PDM – GSA SOFTWARE

5 Updating the NMEA Processor: 3.5 UPDATING PDM – NMEA PROCESSOR

6 Updating the NMEA FPGA: 3.6 UPDATING NMEA FPGA

7 Update the PDM Software level label: 3.7 UPDATING PDM SOFTWARE LEVEL LABEL


Depending on the current software level of the PDM and the desired software level of the PDM one or more of steps 4-6 may not be necessary. Please review figure 4 to check which components require updating to perform the software update. If you have any questions, please contact Cox Aftersales for support.

Figure 4: PTT Components which require updating to update PDM to software levels D and E

Components to be Updated to Update PDM to Software Level D

GSA Software NMEA Processor NMEA FPGA

Cur

rent

PD

M

Soft

war

e Le

vel A Y Y Y

B Y Y Y

C Y Y N

D N/A N/A N/A

E N/A N/A N/A

Components to be Updated to Update PDM to Software Level E

GSA Software NMEA Processor NMEA FPGA

Cur

rent

PD

M

Soft

war

e Le

vel A Y Y Y

B Y Y Y

C Y Y N

D N Y N

E N/A N/A N/A

3.1 INSTALLATION SOFTWARE PREPARATION

NOTEThis process will require administrator access on the PC you are using.

NOTEThe PDM update software is only compatible with Windows 10 PCs.

The software required to perform a PDM update can be found on the Cox Partner Resource Portal under Technical>PDM Updates>Flash Software. Once downloaded please perform the following steps to install the software:

1 Unzip the following folders to a memorable file location

1 SOF000023_A PDM PROGRAMMING SOFTWARE DISTRIBUTORS

2 Actisense-NMEA-Reader-v2.102-x86-Setup

2 In SOF000023_A PDM PROGRAMMING SOFTWARE DISTRIBUTORS run driver_setup_1.0.1.1.exe.

1 Click Next on the first screen

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2 Click I accept the agreement and then Next.

3 Leave the directory as default and click Next.

4 Leave as default setting and click Next.

5 Click Next on the next screen.

6 Click Finish to complete the installation.

3 In SOF000023_A PDM PROGRAMMING SOFTWARE DISTRIBUTORS run software-1.3.2.0-windows- installer.exe

1 Click Next on the first screen.

2 Click I accept the agreement and then Next

3 Leave the directory as default and click Next.

4 Click Next.

5 Click Next on the Important Information! screen.

6 Click Finish to complete the installation

4 In SOF000023_A PDM PROGRAMMING SOFTWARE DISTRIBUTORS run fw-upgrade-installer.exe

1 Click Next on the welcome screen

2 Leave the directory as default and click Next

3 Ensure both check-boxes are ticked for the NMEA Upgrade and PTT/GSA Firmware Upgrade.

4 Leave the Start Menu Shortcuts as default, click Next

5 Click Install to start software installation.

6 Click Finish once the software is installed.

5 In SOF000023_A PDM PROGRAMMING SOFTWARE DISTRIBUTORS run Actisense Windows USB Pre-Install v2.12.06 setup.exe

1 Select language as English – this will allow easier debugging by Cox should you face an issue. Click OK


2 Click Next

3 Click I Agree

4 Click Install

5 Click Next on the “Device Driver Installation Wizard” screen

6 Click Finish.

7 Click Finish.

6 In Actisense-NMEA-Reader-v2.102-x86-Setup run Actisense NMEA Reader v2.102 (x86) Setup.exe

1 Select language as English – this will allow easier debugging by Cox should you face an issue. Click OK

2 Click Next

3 Click I Agree

4 Leave the directory as default and click Next

5 Leave selected components as default Install

6 Click Finish

3.2 HARDWARE PREPARATION

1 Ensure you have all the components mentioned in Section 1.0.

2 Assemble components together as shown in Figure 5.

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Figure 5: PDM Updating Kit Schematic

1 033600 - PDM

2 909568 - PDM Updating Tool

3 034395 - Actisense CAN Terminating Resistor Male

4 034394 - Actisense CAN Terminating Resistor Female

5 909596 - Actisense USB Dongle

6 034393 - Actisense CAN T Connector

PTT << >>GSA

PN: 909568COX PDM UPGRADE TOOL

SN: XXXMFG DATE XX/XX/XXXX

Actisense NGT-1NMEA2000 USB

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3 4

5

6 6

3.3 PDM PREPARATION

If you are updating a PDM mounted to an outboard installed on a vessel:

1 Ensure outboard battery isolator switch is set to off.

2 Remove top cowl.

3 Disconnect the main engine connector from the PDM.


Figure 6: PDM Main Engine Connector

4 Connect the PDM Updating Tool to the PDM.

If you are updating a PDM on a full outboard not installed on a vessel, or a powerhead which is not installed on an outboard:

1 If working on a full outboard, remove top cowl and port mid cowl.

2 Disconnect the main engine connector from the PDM

Figure 7: PDM Main Engine Connector

3 Connect the PDM Updating Tool to the PDM

4 Connect a 12v power supply to powerhead bus bar.

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WARNING12v power supply should be capable of delivering 2 amps of current.

WARNING12v power supply should be capable of delivering 2 amps of current.

If you are updating a PDM which is not attached to an outboard or a powerhead:

1 Connect the PDM Updating Tool to the PDM.

2 Connect a 12v power supply as shown in Figure 4 using M6 bolts.

Figure 8: 12v Power Supply Connection to PDM

12V GND

3.4 UPDATINGPDM–GSASOFTWARE

1 Plug USB plug from PDM Update Tool into your PC.

2 If updating a PDM attached to a vessel, turn on the battery isolator but do not turn on the ignition, otherwise switch on the 12v power supply.


WARNINGEnsure switch on PDM Update tool is set to GSA.

3 In Windows search bar type “PTT-GSA Upgrade”, launch PTT-GSA Upgrade app.

Figure 9: Launching PDM Update Software

4 Click the “Port” drop down menu to select the PDM Update Tool (COM11 in this case).

Figure 10: PDM Update Software, Port Selection

5 Click “Program from file” to open the file selection folder.

Figure 11: PDM Update Software, Program From File Selection

6 Navigate to location where the PDM software was downloaded to your PC. Select the brushed-gsa.txt file, click “Open”.

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Figure 12: PDM Update Software, GSA Software Selection

7 The device will now be programmed. After a successful flash a window, as illustrated in figure 13, will appear with a message ending, “Exit Status 0”.

Figure 13: PDM Update Software, Successful Update Notification

8 Switch the battery isolator off or switch off 12v power supply.

9 Disconnect the PDM Update Tool USB plug from your laptop.

3.5UPDATINGPDM–NMEAPROCESSOR

1 Plug USB plug from Actisense USB Dongle into PC.

2 Turn on the battery isolator or switch on the 12v power supply

3 In Windows search bar type “Actisense NMEA Reader”, launch Actisense NMEA Reader.


Figure 14: Launching Actisense NMEA Reader Software

4 In the drop-down menus at top of the window select “115200” and “Actisense NGT”

Figure 15: Actisense NMEA Reader, Network Configuration

5 At the bottom of the screen select “Hardware Config” tab.

Figure 16: Actisense NMEA Reader, Hardware Configuration

6 Ensure that PGNs 61184 and 65240 are selected in the left-hand list.

Figure 17: Actisense NMEA Reader, PGN Selection

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7 Click Apply to save settings.

8 Close the NMEA Reader programme.

9 In Windows search bar type “NMEA Upgrade”, launch NMEA Upgrade.

Figure 18: Launching NMEA Upgrade Programme

10 From the “Actisense Device” drop down menu select the available COM port

Figure 19: NMEA Upgrade Tool, Device Selection

11 From the “PDM device” drop down menu select the available PDM



12 At this point the software version running on both CPUs will be shown.

NOTENote down the software version for both CPU slots, you may need this later.

Figure 21: NMEA Upgrade Tool, Software Version Check

13 Click “Upgrade CPU”, navigate to where the PDM software was downloaded to your PC and select rm46-upgrade.bin. Click “Open”.

14 NMEA Processor will now update

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Figure 22: NMEA Upgrade Tool, CPU Firmware Update In Progress

NOTEWhen update completes you may receive the error message “Timeout receiving firmware checksum from PDM”. This is not a failed flash, this is a known issue which will be resolved in a future release.

15 When the update is complete either switch the battery isolator off or switch off the 12v power supply for 5 seconds. When 5 seconds is complete switch the battery isolator on or switch on the 12v power.

16 Now the first CPU has been updated, the second CPU must be updated. Re-select the available COM port from the “Actisense device” drop down menu.


17 From the “PDM Device” drop down menu select the available PDM


NOTEWhen update completes you may receive the error message “Timeout receiving firmware checksum from PDM”. This is not a failed flash, this is a known issue which will be resolved in a future release.


18 Click “Upgrade CPU”, navigate to where the PDM software was downloaded to your PC and select rm46-upgrade.bin. Click “Open”.

19 CPU will now update

Figure 25: NMEA Upgrade Tool, CPU Firmware Update In Progress

20 Flashing the CPU is now complete. Turn the battery isolator off or switch off the 12v power supply.

3.6 UPDATING NMEA FPGA

1 Plug USB plug from Actisense USB Dongle into PC.

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2 Turn the battery isolator on or switch on the 12v power supply.

3 In Windows search bar type “Actisense NMEA Reader”, launch Actisense NMEA Reader.

Figure 26: Launching Actisense NMEA Reader Software

4 In drop-down menus at the top of the window select “Actisense NGT” and 115200”

Figure 27: Actisense NMEA Reader, Network Configuration

5 At the bottom of the screen select “Hardware Config” tab

Figure 28: Actisense NMEA Reader, Hardware Configuration

6 Ensure that PGNs 61184 and 65240 are selected in the left-hand list.


Figure 29: Actisense NMEA Reader, PGN Selection

7 Click Apply to save settings.

8 Close the NMEA Reader programme.

9 In Windows search bar type “NMEA Upgrade”, launch NMEA Upgrade.

Figure 30: Launching NMEA Upgrade Programme

10 From the “Actisense device” drop down menu select the available COM port.

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11 From the “PDM Device” drop down menu select the available PDM


12 Click “Upgrade FPGA”, navigate to the file unzipped in section 3.1 Software Preparation - SOF000008_D-PDM FIRMWARE, CXO300, PRODUCTION FIELD/fpga_bitstream.mcs. Click “Open”.

13 Programming the device will now commence, it will take around 400 seconds.

14 When programming has completed turn the battery isolator off or switch off the 12v power supply.


3.7 UPDATING PDM SOFTWARE LEVEL LABEL

1 On the PDM unit. there is a strike off label indicating the software level loaded on the PDM. Update this label by striking off the letter which corresponds with the software update performed.


2 Update Salesforce case with details of work performed.

3 Remove the PDM updating tool from the PDM. If working on an outboard or powerhead, re-connect the main engine connector to the PDM

4.0 ECU UPGRADE PROCESS

After performing the PDM update it may be necessary to update the ECU, either for compatibility reasons or because a new PDM software release is accompanied with an ECU calibration update.

ECU calibration updates can be performed via the normal process using EST. Refer to section 2.2 figure 1 to check which PDM software releases and ECU calibrations are compatible.

COX POWERTRAIN LIMITEDThe Cecil Pashley BuildingUnit 8, Cecil Pashley WayBrighton City AirportLancing, West SussexBN43 5FF United Kingdom

+44 (0) 1273 454 424

[email protected]

www.coxmarine.com

V1.4 OCT_2021

Documents

PDM AND ECU SOFTWARE UPGRADE PROCEDURE