This firmware will allow dealers to test Mercury2 and see if all inputs and outputs are functional. It is for use on a Spitronics Simulater2 or 3. It is required before you accept Test 2 on the Portal. Note that this test is not 100% fool proof as the simulator does not have the proper loads like coils etc. connected to them. But it will show the obvious faults that come during manufacturing. This firmware will not alter map data unless you load a new map in. This program is used for all firmware types like ECU, TCU, etc. After the test procedure make sure you load the same firmware in for the customer. This program has firmware lockout if it is loaded in the wrong device.

This process will require the following:

· Mercury2 Device
· USB/UART Spitronics cable to connect to Mercury2 with Device Manager 4.0
· Computer or laptop with internet connection.
· Device Manager Ver 4.01 Software
· Simulator2 with power
· USB Debug Adapter with installed software

The firmware for a device is called:

Mercury2 Simmilater2 30 Test Program In and Out Ver 4.0 (Date).HEX
· Mercury2 – device that is tested
· Simulater2 – the model of simulator that the firmware is developed for
· 30 – Program number to be selected on Simulater2
· Serializer – Description of firmware
· Ver 4.0 – firmware version
· 01_10_2018 – the date of the firmware
· HEX – a file type extension used for programmers

Steps:

· Ensure that all the jumpers are in the prescribed positions. This may affect the outcome of your test 1 results. See further in the manual the Jumper settings.
· Connect the simulator to the Mercury2 and use the correct simulator harness
· Connect the USB Debug Adapter to the laptop
· Connect the Mercury2 to the USB Debug Adapter on the Comms Port
· Connect the simulator to power and switch on
· Open the Silicon Laboratories IDE software
· Load the Serializer Program in the device.
· Switch power off and disconnect the USB Debug Adapter. Connect the USB/UART Spitronics cable and switch on
· Open the Device Manager Ver 4.0 software and connect to the Mercury2

Device Manager

No need for login.

The information on the device and firmware is displayed.
· Device Serial Number is a unique code in the microprocessor and cannot be altered.
· Flash Serial Number. If you use the device with Ver 3.5 firmware and it has an old activation, then the flash serial number is the serial number of the device. Later activations and after the upgrade process, the device serial number will match the flash serial number by the last 3 digits.
· Hardware Type confirms the device and its photo is displayed.
· Hardware Class of your device.
· Firmware Type Locked of your device. This may be some number but it is not used in Ver 3.5 older firmware.
· Firmware number Locked of your device.
· Brand Code
· Firmware Type (the next information is irrelevant in the test firmware).
· Firmware Number
· Firmware Class
· Firmware Version

Click on Tester to go to the Test screen.

With this screen you can test each input to the device. On the simulator is LED’s for each output. Further below is a description of each I/O to be tested.

The flash memory value is always is used to test if the flash is working by saving different maps with different saved. It is the Start prime pulse in the ECU map.

Testing the inputs of the Mercury2 Device

All the analogue bars must be tested for low and high scale. The POT or potentiometer must represent low and high limits. With other words when the POT is close or open the bar must be zero or full scale. Then movement from the POT must indicate movement from the bar. No dead band before the bar moves. That will be a fail.
or

Note that the bar may not reach 255 exactly as it may be variance in simulator voltage. But each similar device will sow the same values.

MAP Potentiometer

TPS Potentiometer

LAMBDA Potentiometer

WAT Potentiometer

AIR Potentiometer

ALT Altitude

POT Potentiometer

Batter Voltage – must be confirmed at ECU input and GND with multi meter.

RPM indicator – it has 2 scales selectable by the PROG button. Low is 2100 max and high is 15600 max. Note that program 30 must be selected on the simulator.

Memory chip operation test. 255 means failure after map is loaded.

Now focus on the Simulator2 and on the ECU for LED flashes. Below is a pattern and each LED must light up in this sequence. If there is a short between outputs, then other LED’s out of sequence will flash. The LED’s on right hand side in the column will flash in random sequence to make running lights on the 4 LED’s on the Mercury2. You may need to put the simulator on low speed and slowest rpm’s.

If you are a dealer and this is a new device, you can confirm that these tests were successful with TEST 2 on the portal. Should the results be different later then I will be traced back to you. So make sure it is correct.
You may now load back the customer firmware program and load another map. This will confirm that the flash memory is also working.