2013-2021 New Flyer R21-005 Inverter Error May Shutdown Electric Drive

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April 7, 2021 NHTSA CAMPAIGN NUMBER: 21V244000

Inverter Error May Shutdown Electric Drive

A sudden loss of power increases the risk of a crash.

 

NHTSA Campaign Number: 21V244

Manufacturer New Flyer of America, Inc.

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 227

 

Summary

New Flyer of America, Inc. (New Flyer) is recalling certain 2013-2021 XE40, 2019-2021 XE35, 2018-2021 XE60, 2016-2019 XHE40, and 2015 XHE60 vehicles. Firmware errors in the inverters may cause the electric drive system to shutdown.

 

Remedy

New Flyer will notify owners, and dealers will update firmware software, free of charge. The recall began on April 19, 2021. Owners may contact New Flyer customer service at 1-204-224-6706. New Flyer’s number for this recall is R21-005.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

 


INSTRUCTION TO SERVICE  

ITS: 59212 April 12, 2021
SECTION: 219-Engine
WRITTEN BY: Dana Carver
SUBJECT: Updating Siemens Software, Vansco and CM0711 Programs
ISSUE: Watchdog faults on the inverters cause them to shut down without warning
SUMMARY: Vansco, CM0711 and Siemens software update

 

ITS59212

 

Ref. NHTSA Recall No. Ref. Transport Canada Recall No.
21V-244 2021-206

 

THIS ITS DOCUMENT SHOULD BE RETAINED AND REFERRED TO FOR FUTURE MAINTENANCE UNTIL THE NEW FLYER PARTS AND/OR SERVICE MANUAL IS UPDATED TO REFLECT WORK DONE AS A RESULT OF THIS DOCUMENT. ENSURE THAT THIS DOCUMENT IS AVAILABLE FOR PARTS AND MAINTENANCE STAFF GOING FORWARD.

 

This is to inform you that your vehicle may contain a defect that could affect the safety of a person.  

 

PROCEDURE:

The following are instructions to update the Vansco, CM0711 and Siemens programs on a bus. The programs have been sent to the New Flyer RPSM and must be updated in the order of Vansco, CM0711 and then Siemens.

 

Vansco Update:

  1. Ensure the Master Run Switch is in Day/Run position and hazard must be on.

 

  1. Ensure laptop battery is fully charged or plugged into a power source.

 

  1. Connect a laptop with VMM software to the under-dash USB A connector located below the right side of the dash, above the pedals.

 

  1. Open the PLC program in the VMM software.

 

  1. Select Tools and Query VMMs.

 

  1. Ensure you are communicating with all the nodes in the query screen prior to downloading.

 

  1. Select Download Logic.

 

  1. Ensure the correct file name and revision appear in the File window.

 

  1. The software will verify the correct number of VMMs are found. Do not download program if all VMMs are not located. If the correct number of VMMs were found, select Yes.

 

  1. After the download is complete, close the download window.

 

  1. Disconnect the USB A cable.

 

CM0711 Update:

 

  1. Ensure VMM 7100 or later is installed because it should have Flash Loader v1.9 or newer on it.
    1. To open flash loader open the VMM software and click Applications → click FlashLoader. See figure 1.
    2. To check the version is v1.9 or later, click Help → click About. See figure 2.

 

Figure 1: FlashLoader location

 

Figure 2: Flashloader version

 

  1. Make sure the bus is NOT in EV MODE. Turn the bus to Day Run or Night Run with EV MODE OFF.

 

  1. Turn hazard lights on, to assure the bus is awake while programming the CM0711.

 

  1. Connect a NEXIQ USB LINK to the 9-pin Vehicle Diagnostic Port behind the driver and USB cable to laptop.

 

NOTE: Make sure the NEXIQ USB LINK is a wired connection (NOT Bluetooth).

 

  1. With the NEXIQ connected, in FlashLoader go to File → RP1210 Settings and make sure NEXIQ USB LINK J1939 Channel 1 is selected. Check this if you are having trouble getting connected.

 

  1. You will see several question marks and other devices on the left-hand side, find source address 0x49, this is the CM0711 (see figure 3).
    1. The version shows what is currently loaded in the CM0711. Take a screenshot of what is currently loaded.
    2. Select the new .vsf file you received and click start (It will take 1-2 minutes to download the program).

 

Figure 3: CM0711 source address and current version

 

  1. After downloading finishes, follow the same process in step 5 and find source address 0x49. The Version # should now be updated to the program you just loaded. The following example in figure 4 is for loading 1019607_NFIL_Electric_Bus_V5.00.vsf. It is also important to notice that it is V5.00 Build 0.

 

Figure 4: CM0711 source address and updated version

 

  1. Turn the master-run switch OFF for at least 20 seconds. It takes at least 7 seconds for the CM0711 to power off after turning off the master-run switch, but 20 seconds is recommended to be safe.

 

  1. Put the bus back into Day Run (not EV mode).

 

  1. Open the rear panel and make sure the light on the CM0711 is flashing green and then orange. This indicates the CM0711 is operating.

 

NOTE: If the CM0711 light is off or steady red, it is bricked and will need to be sent back to NPD.

Unfortunately, the bus will be undrivable without a function CM0711 so please contact NPD as soon as possible.

 

Figure 5: Rear panel and CM0711 module location

 

  1. Make sure the bus can enter EV mode by cycling EV mode “ON” then “OFF”.

 

  1. Download updated PLC program to Vansco.

 

  1. Remove all tools and debris and return the bus to service condition.

 

Please refer to Appendix A for Instructions to Update the Siemens Software

 

Important Note 1: Force the HVIL flag inactive to ensure that the PLC program does not shut off communication prior to searching all nodes (step 1.7 in Appendix A).

 

Important Note 2: The delay time can be changed to allow the technician more time between key-on and searching for nodes. 15 seconds has been used with success.

 

Important Note 3: The DICO, motor inverter(s), auxiliary inverters and parameters need to be updated.

 

Appendix A

1 Instructions

1.1 Use the Siemens Diag in the Rear Panel (see diagram below) to connect the computer containing the software to the system.

 

Image 1.  CAD image showing location of Siemens diagnostic ports

 

1.2 From the computer, navigate to folder where SW package is located

 

Image 2. Screenshot showing the contents of the folder with a .hex file (.hex file for XE40 shown in example)

 

1.3 Start the ELFA WinFlash tool via double click

 

1.4 From the tool choose Select in Hex-File menu

 

Image 3. Image showing ELFA flash tool window

 

1.5 Navigate to the folder where SW package is located ReleasePackSoftwareINV.   Click the .hex file to open

 

Image 4. Image showing .hex file for an XE40 configuration

 

Flash Tool Configuration

Software Flashing

1.6 Switch OFF Key Start (KL15) for all components and wait approximately 30 seconds

 

1.7 Select Search All Nodes and switch ON Key Start (KL.15)

 

Image 5.  Image showing “Search All Node” selection on Flash tool window

 

The process of Resetting node(s) will appear like the image below

 

After successful wakeup, choose the correct Inverter serial number and then click Flash selected nodes.

 

Image 7.  Image showing example of a system containing two Inverters and one DICO 

 

Process of SW flashing is shown below

 

Image 8. Image showing software flashing in progress

 

1.8 Once the SW flashing process finished, choose Start program and click OK.

 

Image 9.  Image showing menu that window that appears when flashing is finished

 

The Inverter with the serial number which has been flashed will show up like the picture below. Close ELFA flash tool.

 

Image 10.  Image showing ELFA flash tool window with serial number of the inverter that has been flashed

 

2 Validation

Perform a final check for the software version.  Refer to Appendix A1 to confirm the software release package for your bus configuration.

 

3 Error Buffer Check

Once the final check for the software has been installed per the instructions, the user should perform a drive test and export the error buffers to confirm proper functionality of the trap 10 software update.  This step only needs to be completed once per bus configuration (e.g. XE40, XE60, etc.).  Once the software release package is confirmed for a specific bus configuration, this test will not need to be repeated for every vehicle within that configuration.

 

1. Key off (restart) the vehicle

2. Test drive the vehicle for 20-30 minutes

3. Pull off to a safe area, stop the vehicle, and turn off bus

4. Connect to the vehicle via PCAN-USB tool (see image below for location of diagnostic port). Open Siadis Expert

 

Image 11. CAD image showing location of Siemens diagnostic ports

 

5. Start SIADIS

6. Within Component Selection, choose Motor 1

 

Image 12. Image of SIADIS tool window showing components

 

7. Navigate to Utility menu → Software version

        Image 13. Image showing SIADIS tool Utility menu

 

Confirm that the appropriate SW version shows (See Appendix A1)

Image 14.  Image showing software version info window (example shown is for an XE40)

 

8. To access the error buffer select click Utility → “document of error buffers”

Image 15.  Image showing to access error buffer in SIADIS tool.

 

9. Once the error buffers are visible, review them and verify that there are no trap 10 errors

1. If there are no trap 10 errors, mark the vehicle as completed, save the error buffer, and register it as complete in the attached and return a copy to Siemens.

11. If there are trap 10 error in the error buffer, verify that the correct software has been flashed (refer to section 6 & 7) according to Appendix A1

 

LABOUR ESTIMATE
Operation Number of Technician(s) Hours Labor Time T X HR
1 Update the Vansco, CM0711 and Siemens software 1 2 2

 


IMPORTANT SAFETY RECALL NOTICE

Subject: Motor Vehicle Safety Recall 21V-244 – Siemens ELFA2 Programming

 

Dear :

 

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

 

New Flyer of America Inc. (New Flyer) has decided, that a defect which relates to motor vehicle safety, exists on specific electric drive vehicles equipped with Siemens Industry Inc. (Siemens) model ELFA2 Inverters. This recall is based on information provided by Siemens.

 

New Flyer has determined that the following vehicles, operated by  are affected by this recall action:

Make:        New Flyer Heavy Duty Urban Transit Bus

Model: SR2484 – 2021 – XE35 VIN, Unit Number:

 

Model: SR2485 – 2021 – XE60 VIN, Unit Number:

 

The Siemens ELFA2 inverter used for both motor power and auxiliary power on the New Flyer electric propulsion system, was found to have a timing issue between the microcontroller and the Static RandomAccess Memory (SRAM).  This non-optimum timing causes the inverter to deliver invalid data, resulting in “Trap10” errors. This nuisance error code may cause the electric drive system to shutdown unexpectedly, requiring an ignition reset. The vehicle may then be restarted again once it is brought to a complete stop.

 

A sudden loss of motive power increases the potential for a vehicle crash and injury.

 

Siemens has provided New Flyer with new drive system programming which corrects the data timing issue and prevents these nuisance errors. Vehicles which have the newer Siemens ELFA3 inverters are not affected, by this issue.

 

New Flyer proposes to install this updated programming on the above vehicles at no cost. Please contact your Regional Product Support Manager Lorenzo Mumphery, to coordinate the recall action. New Flyer anticipates that the reprogramming to correct the issue will take approximately 0.5 hours/bus.

 

If you are a lessor of vehicles which are affected, it is required that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. If you no longer own this vehicle, or it has been removed from operation permanently, please inform the undersigned.

 

If you had this corrective action performed before you received this letter, you may be eligible to receive reimbursement for the cost of obtaining a pre-notification remedy of the problem associated with this recall.

 

If New Flyer is unable to correct this defect within a reasonable time, you may submit a written complaint to the:

Administrator,
National Highway Traffic Safety Administration, 1200 New Jersey Ave. SE,
Washington, DC, 20590,
Or call 1-888-327-4236 (TTY: 1-800-424-9153);
or go t
o https://www.safercar.gov.

 

We regret any inconvenience which this action may cause you. However, we are concerned about the safety of your passengers and employees.

 

Thank you for your attention to this important matter.

 

Sincerely,

NEW FLYER OF AMERICA INC.

 

By:

Kerry Legg
Vehicle Safety & Regulatory Compliance Manager
(204) 224-6706

 

cc:

Scott Halbesma –Vice President, Customer Care
Lorenzo Mumphery – Regional Product Support Manager

 


21 Affected Products

Vehicles

MAKE MODEL YEAR
NEW FLYER XE35 2019-2021
NEW FLYER XE40 2013-2021
NEW FLYER XE60 2018-2021
NEW FLYER XHE40 2016-2019
NEW FLYER XHE60 2015

 


8 Associated Documents

Remedy Instructions and TSB

RCRIT-21V244-0791.pdf 820.634KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-21V244-8302.pdf 168.983KB

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Defect Notice 573 Report

RCLRPT-21V244-5083.PDF 217.886KB

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Recall 573 Report- Amendment 1

RCLRPT-21V244-5420.PDF 217.782KB

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Recall 573 Report- Amendment 1

RCLRPT-21V244-7005.PDF 217.782KB

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Recall Acknowledgement

RCAK-21V244-9819.pdf 645.764KB

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Recall Quarterly Report #3, 2021-4

RCLQRT-21V244-8457.PDF 211.326KB

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Recall Quarterly Report #2, 2021-3

RCLQRT-21V244-1314.PDF 211.24KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V244&docType=RCL

 


 

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2013-2021 New Flyer R21-005 Inverter Error May Shutdown Electric Drive | small light NEXIQ Technologies 124032 USB-Link 2 Connector
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  • 🚛40+ Reset Functions & Bidirectional Control - 2024 newest top truck scanner diagnostic tool, comes with 40+ special services (ECU, Oil Reset, Injector Coding, EPB, ABS, SRS, Suspension, Throttle, etc. and always keep growing), which meet all your various needs for service and maintenance. Please send your VIN# to our 💌 amazon@anceltech.com 💌 to check compatibility.
  • 🚛10 Inch All Systems Diesel Scanner & Full HDOBD/OBD2 Modes - ANCEL X7 HD diesel scanner diagnostic tool supports all systems scan, such as Engine, Brake, Retarder, TECU Transmission, Tachograph, ABS, SRS, TPMS, EPB, SAS, ESP, and other vehicle systems, comes with 10 obd2 service modes: read/erase error codes, Data Stream, I/M Readiness, Vehicle Information, Actuations, DTC Lookup, EVAP, view freeze frame, etc.
  • 🚛OEM DPF Forced Regen & Cylinder Cutout Test & more - ANCEL X7 HD truck scanner not only supports DPF regeneration, DPF reset, DPF related information reset, DPR state reset, DPD forced regeneration etc, which helps you better solve the exhaust aftertreatment system problems, but also supports activate motor to do exhaust air in ABS Automatically. Moreover, it features TPMS activation, cylinder cut-off and learning functions.
Bestseller No. 5
LAUNCH CR-HD Plus Heavy Duty Truck Scanner Diagnostic Full System Scan Tool Fit for Cummins, Caterpillar, International, Volvo, Detroit, Isuzu, Fuso, Diesel Truck & Car 2-in-1 OBD2 Code Reader
  • 🚚【Wide Truck Applications】Heavy duty truck scan tool covers almost J1587, J1708 and J1939 protocols heavy duty trucks and OBD II vehicles. Such as Cummins, Paccar, Detroit, Perkins, International, Peterbilt, Allison, Eaton, Ford duty trucks and so on, Covers class 4 (14,001 lbs) through class 8 (33,000 lbs and over) heavy duty trucks. One that meets all the requirements! NOTE:Compatibility will vary on vehicles model and year, please send V-IN to check the compatibility before purchase.
  • 🔎【Comprehensive Full Systems Diagnostic Tool For Truck】Launch Heavy Duty Truck Diagnostic Tool offers OE-Level diagnosis for all systems of heavy truck/Pickups/Bus/Van in compliance with OBD-II Communication Modes 1-10 and J1587, J1708 and J1939 protocols,Including Engine, Transmission, Drivetrain, Suspension, ABS, ESP, Cluster, E-xhaust, P-articular, Suspension, Braking System, Cab Climate, Body Control, Instrument Panel, Fuel System and more.
  • 🔥【All OBD/EOBD Diagnosis】This truck scanner diagnostic tool supports both most 12V and 24V truck, and it comes with 6 pin, 9 pin and 16 pin adapters for different interfaces. Our truck scan tool can read codes, erase codes, I/M Readiness, Live data, EVAP Test. . . etc for obd2/eobd cars. Built in a DTC lookup library you can find the related code definition to help you determine if your car needs repair.
  • 💡【Friendly Design, Easy of Use】This heavy duty diagnostic scan tool is plug and play, simple and convenient, The excellent 2.8 inch LCD color screen makes it easy to view the displayed results and gives you a better overview of your car's problem areas and the identified codes. In addition, the processor is super-fast and responds without lagging, providing maximum comfort and efficiency in diagnostic and service work.
  • ✨【3 YEARS WARRANTY & FREE LIFETIME UPDATES】The diesel truck scanner is exclusively designed for US truck. it's come With a full service functions and full systems and provides 24/7 technical support, 3 years warranty, 90-days free return for refund or replacement. This diesel scan tool is suitable for auto repair shops and technicians.No subscription fee and free lifetime updates.
Bestseller No. 6
ANCEL Heavy Duty Truck Scanner HD601 PRO All System Diesel Diagnostic Scan Tool fits for Cummins, Detroit, Freightliner, International, Paccar, Check Engine for Truck & Car 2 in 1 Code Reader
  • 【Extensive Compatibility】After the upgrade, the compatibility is wider and more accurate! HD601 PRO heavy duty truck scanner supports all major truck models that comply with standard protocols (SAE J1939, SAE J1708, ISO 14230-4, ISO 15764-4 and ISO 9141-2, ISO 27145-4 and Euro6). Such as Cummins, Paccar, Detroit, Perkins, Freightliner, International, Peterbilt, Ford, Class 4-Class 8 trucks, etc. It also check engine diagnosis on most cars, minivans and light trucks.
  • 【 Full System Diagnostic】HD601 PRO Diesel Scanner supports all system scans of heavy trucks compliant with standard protocols SAE J1939 & J1708, such as Engine, ABS, Transmission, Braking System, ESP, EPS, Fuel System, etc, It is a great scan tool for Cummins, Caterpillar, Detroit, Perkins, Maxxforce, Bendix,Wabash, Wabaco, Haldex, Allison, Eaton heavy trucks, With this truck tool, you can get deep analysis data about the system and do some repairs by yourself, saving much time and money.
  • 【Enhanced Diesel OBD Scanner】The HD601 PRO Diesel OBD Scanner offers unparalleled diagnostic capabilities for heavy-duty trucks. Beyond code reading, clearing, and live data display, it retrieves vehicle information, freeze frames, and DTCs. With 6, 9, and 16 pin cables, it ensures compatibility with various engines. This scanner's real-world testing prowess ensures comprehensive support for a wide array of heavy-duty truck engines, making it an indispensable tool for truck diagnostics.
  • 【DTC Library】+【Life Time Free Update】The built-in DTC library allows you to retrieve the codes directly without searching for the definition in the book. Whether you are a professional mechanic or a DIY car owner, HD601 diesel scanner explains the existing problem, makes it easier for you to understand the codes definition and fix the problem faster. Plus, you get a lifetime free internet updates, so you always have the latest software for diagnostics in English and Spanish languages.
  • 【Friendly Design, Easy of Use】This scanner is plug and play, simple and convenient, and very friendly for beginners. With improved buttons for easy menu navigation. The excellent 2.8 inch LCD color screen makes it easy to view the displayed results and gives you a better overview of your car's problem areas and the identified codes. In addition, the processor is super-fast and responds without lagging, providing maximum comfort and efficiency in diagnostic and service work.

Last update on 2024-07-16 / Affiliate links / Images from Amazon Product Advertising API

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