INSTRUCTION TO SERVICE
ITS:61122

Aug 12, 2024

SECTION:

290-ELECTRICAL SCHEMATICS

WRITTEN BY:

SUMAN SURI

SUBJECT:

FEBS BATTERY PROGRAM UPDATE PROCEDURE – FW 2324

SUMMARY:

AFFECTED SR:

FW2324 offers:
• Improved BMS response to overcharging and other functional safety
mechanisms
• Robust detection of failure modes through DTCs
• Battery Data Recorder (BDR) capabilities
• Streamlined flashing processes.
• Logic improvements for better integration with application
ALL ELFA2 XE Buses

ITS 61122
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 document and the contents discussed herein are the confidential and proprietary information of New Flyer Industries Canada
ULC and New Flyer of America Inc. and are disclosed by New Flyer in confidence. This document and the contents herein are not
to be disclosed by the intended recipient without the prior written authorization of New Flyer. Any unauthorized disclosure,
reproduction or other distribution of this document or information strictly prohibited and may result in action being taken against
the party making the unauthorized disclosure. This document and all copies hereof must be returned to New Flyer upon request.

INSTRUCTION TO SERVICE
ITS61122

Contents
INSTRUCTION TO SERVICE ....................................................................................................................................1
1.

EQUIPMENT REQUIREMENT ...........................................................................................................................3

2.

SET UP/INSTALL THE XST ...............................................................................................................................3

3.

FLASH THE BOOTLOADER ON MCU (INTERNAL CAN) ................................................................................3

4.

FLASH THE BOOTLOADER ON SCU (SERVICE CAN). ..................................................................................4

5.

FLASH THE BMS FILE TO THE MCU (APPLICATION CAN) ...........................................................................4

6.

CLEAR CODE INSTRUCTIONS FOR 2150-2324 XST .....................................................................................5

LIST OF ABBREVIATIONS ........................................................................................................................................6

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1. EQUIPMENT REQUIREMENT
The following equipment is required:
1.1. NEXIQ with USB-Link 2 cable or PCAN tool
1.2. Battery diagnostic cable
1.3. Software package
1.3.1. XALT Service Tool (XST) version 2324.
1.3.2. BOT_2150_02.mot Bootloader.
1.3.3. BMS_00XX_232403_02
Note: Contact Service engineering specialist for software package

2. SET UP/INSTALL THE XST
2.1. Copy and paste the XST_2324.zip file provided by SES.
2.2. Extract the zip folder to the local drive.
2.3. Navigate to the binary folder under the XST_2324 main folder and double click on the XST_2324_01.exe
to install the software. A desktop shortcut will be added to the desktop.
2.4. Refer Xpand service tool user manual in the support documents folder provided with zip folder for any
further information on how to use the xst.

3. FLASH THE BOOTLOADER ON MCU (INTERNAL CAN)
3.1. Cycle the MRS to ON position.
Check for vansco wakeup. If not, press the startup button.
3.2. Before updating, check the following:
•

SOC>30%.

•

LV battery health is good.

•

Constant 24V supply to MCU T30

3.3. Key on the bus with hazards on.
3.4. Cycle the MRS to OFF position.
3.5. MCU T15 vansco output set to true
3.6. Connect the Nexiq CAN interface plug to the Ebus black diag port.
3.7. Connect the Nexiq USB plug to the laptop and launch XST_2324 software.
3.8. On the XST software navigate to the flash tab.
3.9. Set the CAN Channel to Channel 2, Baud rate to 250K and Hardware to Nexiq.

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INSTRUCTION TO SERVICE
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3.10.

Select the “browse” button and navigate to where the BOT_2150_02.mot file is located. Choose

the file and press the Flash button to start flashing the MCU.
3.11.

Wait until the flash progress bar reaches 100%. When done wait for 60 seconds before moving to

the next stage.

4. FLASH THE BOOTLOADER ON SCU (SERVICE CAN)
4.1. Connect the interface harness aka octopus’ cable to the NEXIQ and to the BDU diagnostic port. connect
the NEXIQ to your laptop with a USB cable.
4.2. Within the interface harness, connect CAN 1 to STRING 1 (the NEXIQ with the XST tool only
communicates on CAN 1 – so you’re connecting the NEXIQ to one string at a time).
4.3. On the XST software navigate to the flash tab.
4.4. Set the CAN Channel to Channel 1, Baud rate to 250K and Hardware to Nexiq.
4.5. Select the “browse” button and navigate to where the BOT_2150_02.mot file is located. Choose the file
and press the Flash button to start flashing the MCU.
4.6. Wait until the flash progress bar reaches 100%. When done wait for 60 seconds before moving to the
next SCU.
4.7. After flashing All the SCU’s
4.8. Key the bus OFF (wait until bus fully goes to sleep)

5. FLASH THE BMS FILE TO THE MCU (APPLICATION CAN)
5.1. Connect the Nexiq CAN interface plug to the Ebus black diag port.
5.2. In the XST software, navigate to the Flash tab.
5.3. Change the settings to: CAN Channel - Channel 1; Baud rate – 500K; Hardware – Nexiq.

5.4. Press the browse button and choose the BMS_00XX_232403_02.mot.



NOTE: BMS file is specific to battery type.

5.5. Press the Flash button and wait until the flash bar reaches 100%.
5.6. Once completed successfully – Key OFF the bus for 5 minutes and then Key ON the bus

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5.7. To confirm MCU and SCU have the correct bootloader and software version, click to Live data tab, scroll
to the bottom of the page as shown below.

6. CLEAR CODE INSTRUCTIONS FOR 2150-2324 XST
6.1. Click and highlight the Permanent fault.
6.2. Right click on the permanent fault.
6.3. Select the bottom most option for clear fault in drop down window.
6.4. Insert above clear code into newest pop-up window using CTRL+C (to copy) and CTRL+V (to paste).
6.5. Copy and paste the Authorization Code into the “Authentication Code” window.
6.6. Be sure when copying that no blank or invisible characters populate at the beginning or end of the code.
6.7. You will get confirmation that it was activated.
6.8. You will need to right click on each string and then select “clear fault”.
6.9. It will state something along the lines of code still active.
6.10.

After doing this for all strings key the bus off for 10 minutes.

6.11.

Key the bus back on and then check with XST to ensure no faults remain.

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LIST OF ABBREVIATIONS

Abbreviations
APP
BDU
BMS
CAN
FBPS
HV
LV
MCU
SCU
XST
SES aka TSS

ITS61122

Description
Application
Battery Disconnect Unit
Battery Management System
Controller Area Network
Freudenberg Battery Power Systems
High Voltage
Low Voltage
Master Control Unit
String Control Unit
XPAND Service Tool
Service Engineering Specialist.

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LABOUR ESTIMATE
Operation
1

ITS61122

Rework - Update XALT software to rev 2324

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Number of
Technician(s)
1

Hours
0.25

Labor Time
T X HR
0.25

Aug 12, 2024