ISSUE DATE:

09/29/2023

REVISION DATE:

12/13/2023

SERVICE BULLETIN SUBJECT:

BuSCoM 2.0 800vRR DuoPower Software Update

VINs or MODELS AFFECTED:

Service Specified Buses

COMPLETE BY:

Earliest Service Opportunity

SERVICE BULLETIN #:

SC-23-136

Labor Operation Code:

PP65Z

NOTICE! It is expected that this process may require up to 1.5 hour per bus.
Please schedule appropriately to minimize vehicle downtime.

BuSCoM 2.0 800vRR DuoPower Software Update
Description
This procedure describes the process for updating the DuoPower Vehicle, Powertrain, Body
Controller, ESM and Charge Controller software. This software update enables the following features
when certain fault codes associated with Battery Pack liquid accumulation and/or a thermal event are
detected. (1) prevent the vehicles Battery Pack from being charged, (2) engage a “limp mode” that
imposes limitation on the Battery Pack regen and power discharge levels, and (3) trigger a flashing
red warning light on the driver’s dash display and an audible alarm (collectively, the “Updated
Software Features”).

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Headquarters:
East Coast Manufacturing:
West Coast Manufacturing:

Change Notes
Enhanced Battery Diagnostics:
• Coordinated changes for more robust system diagnostics
• Added distinct audio-visual response for critical battery fault
• Includes fix for external isolation false failure condition
Aux Heat startup bug fix
• Corrects a condition where Aux Heat could start as soon as bus starts before commanded for
temperature control
Charging Robustness Improvements
• Improvements preventing false failure of lock motor failure to retract
Interlock Fault Tuning
• 520821 FMI 1 and 520822 FMI 1
• Tuned interlock low pressure fault to align performance with latest ZX5.A0X buses and
increase robustness.

Tools/Programs Required
Tools Required:
• Laptop Computer
• Nexiq USB-Link 2
• T-30
Programs Required:
• Proterra Diagnostics Tool

Software Files Required / Preparation
IMPORTANT! NEVER access the software from the USB memory device, ALWAYS copy the
software files to your computer hard drive and access the software from this location. Secure
the bus with the Vehicle Master Disconnect in the rear ON.

Component

Part Number

Version

Execution Time

ESM Controller

066124

V3.0.5

Minutes

Charge Controller

065754

V 3.0.1

16 Minutes

Vehicle Controller

065726

V4.10.0

10 Minutes

Powertrain Controller

065645

V4.1.0

12 Minutes

Body Controller

065725

V7.0.1

16 Minutes

Public Link to SW Package: https://business-site7460.my.salesforce.com/sfc/p/Ho000002fy70/a/Ho000000vAww/9QxCNSzgba2FCswVfjL.Ppe0N4GR
YzmdYFH3FCLVuag
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Headquarters: 1815 Rollins Road, Burlingame, CA 94010
East Coast Manufacturing: 1 Whitlee Court, Greenville, SC 29607
West Coast Manufacturing: 383 Cheryl Lane, City of Industry, CA 91789

Procedure:
Preparing the Vehicle to be Programmed
When programming a vehicle, it is critical that the low-voltage batteries remain connected throughout
the process. Ensure that the LV batteries are fully charged before starting the process. If they are
low, use the vehicle to recharge them buy turning on high-voltage or place the bus on a low-voltage
charger for the duration of the process.

ESM Controller Update
1. Power up and login to the Proterra-Supplied laptop or a comparable PC that has the Proterra
Diagnostics Tool software installed with a valid license.
2. Ensure the SW Package is on the computer’s hard drive and unzipped if applicable. For this
section the SW ESM_HV_BMS_RoadRunner_Bootloader_20231204_1354_Full.srec is to be
used.
3. Turn ON the 12/24V rear Vehicle Master Disconnect located at the curbside rear charge port
access panel.
Vehicle Master
Disconnect

4. Connect the Nexiq USB Link2 device to the laptop and to the OBDII Diagnostic Port located in
the streetside wheel well box.

5. Press and hold the streetside wheel well WORK LIGHT switch until the work lights turn on.

3 | Page
Headquarters: 1815 Rollins Road, Burlingame, CA 94010
East Coast Manufacturing: 1 Whitlee Court, Greenville, SC 29607
West Coast Manufacturing: 383 Cheryl Lane, City of Industry, CA 91789

6. On the laptop, double-click on the Proterra Diagnostics Tool software icon to start the software.

7. When the program opens, read and click “OK” for the high-voltage safety prompt.
8. On the Home tab, select the appropriate device from the drop down and click “Connect”.

9. Once the diagnostic tool has connected to the vehicle, a VIN number and connection status
will be displayed on the Home screen, and tabs available to navigate. If you do not see the
Home Screen, check that the low-voltage batteries are connected and that the Nexiq tool is
plugged in.
NOTE: 800V Proterra vehicles are equipped with an automatic battery disconnect that will
protect the low-voltage batteries from a deep discharge.

10. Before beginning the programming process, check the bus for existing faults by clicking on the
“Diagnostics” button below and make a note of any found.
11. Navigate to the “Software Versions” tab and take a screenshot of the current software versions
incase any issues arise.
12. Turn the bus High-Voltage Master Switch to Accessory at the Driver's Workplace and ensure
the Dash screen is ON. Set the Hazard Switch to ON.

4 | Page
Headquarters: 1815 Rollins Road, Burlingame, CA 94010
East Coast Manufacturing: 1 Whitlee Court, Greenville, SC 29607
West Coast Manufacturing: 383 Cheryl Lane, City of Industry, CA 91789

13. Click on the “Configuration Tab” to open the Configuration screen and then click start flash on
the “Battery Master Controller” section.

14. When prompted select file
“ESM_HV_BMS_RoadRunner_Bootloader_20231204_1354_FULL.srec” from your hard drive,
select open.
15. The Proterra Diagnostic Tool will attempt to connect to the device.
NOTE: You may receive an error on the first attempt. If so, retry by clicking the ESM Controller
Start Flash button again.

16. When the software update begins, and the following screens will be displayed.

17. Once the following screen displays the update is now complete.

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Headquarters: 1815 Rollins Road, Burlingame, CA 94010
East Coast Manufacturing: 1 Whitlee Court, Greenville, SC 29607
West Coast Manufacturing: 383 Cheryl Lane, City of Industry, CA 91789

18. Close the Proterra Diagnostic Tool (PDT), turn off work light and cycle the buses power and
verify no faults.

Charge Controller Software Update
1. Ensure the LV batteries and laptop are charged.
2. Power up and login to the Proterra-Supplied laptop or a comparable PC that has the Proterra
Diagnostics Tool software installed with a valid license.
Vehicle Master
Disconnect

3. Turn ON the 12/24V rear Vehicle Master Disconnect located at the curbside rear charge port
access panel.
4. Turn the bus High-Voltage Master Switch to Accessory at the Driver's Workplace and ensure
the Dash screen is ON. Set the Hazard Switch to ON.
5. Connect the Nexiq USB Link2 device to the laptop and to the OBDII Diagnostic Port located in
the streetside wheel well box.

6 | Page
Headquarters: 1815 Rollins Road, Burlingame, CA 94010
East Coast Manufacturing: 1 Whitlee Court, Greenville, SC 29607
West Coast Manufacturing: 383 Cheryl Lane, City of Industry, CA 91789

6. Press and hold the streetside wheel well WORK LIGHT switch until the work lights turn on.
7. Click on the “Configuration Button” to open the Configuration screen and then click Charge
Controller “Start Flash” Button.

8. The following screen will be displayed. Navigate to the location where you save the software
package and select “cc-production_CC_RoadRunner_20230910_2128.srec”. Select the file
and click “Open” to the load the file.

7 | Page
Headquarters: 1815 Rollins Road, Burlingame, CA 94010
East Coast Manufacturing: 1 Whitlee Court, Greenville, SC 29607
West Coast Manufacturing: 383 Cheryl Lane, City of Industry, CA 91789

9. The Proterra Diagnostic Tool will attempt to connect to the device. NOTE: You may receive an
error on the first attempt. If so, retry by clicking the Charge Controller Start Flash button again.

10. When the software update begins, and the following screens will be displayed.

11. The software update may take several minutes to complete. When the update is complete the
following screen will be displayed. Click the “OK” button to complete the update process.

12. Software update is complete. Please close diagnostic tool and turn off work light, turn off the
bus at the rear master switch located at the rear curbside access panel.

Vehicle Controller Software Update
1. Ensure the LV batteries and laptop are charged.
2. Power up and login to the Proterra-Supplied laptop or a comparable PC that has the Proterra
Diagnostics Tool software installed with a valid license.
3. Turn ON the 12/24V rear Vehicle Master Disconnect located at the curbside rear charge port
access panel.

8 | Page
Headquarters: 1815 Rollins Road, Burlingame, CA 94010
East Coast Manufacturing: 1 Whitlee Court, Greenville, SC 29607
West Coast Manufacturing: 383 Cheryl Lane, City of Industry, CA 91789

Vehicle Master
Disconnect

4. Turn OFF the bus High-Voltage Master Switch at the Driver's Workplace and ensure the Dash
screen is OFF.
5. Connect the Nexiq USB Link2 device to the laptop and to the OBDII Diagnostic Port located in
the streetside wheel well box.

6. If vehicle is equipped with overhead charging, please use the Proterra diagnostic tool to
navigate to the “Overhead Charging” page and record the vehicle tag number. This will be reentered at the end of this section.

7. Navigate to the “Configuration Tab” then Click Start Flash for the Vehicle Controller Sections.

9 | Page
Headquarters: 1815 Rollins Road, Burlingame, CA 94010
East Coast Manufacturing: 1 Whitlee Court, Greenville, SC 29607
West Coast Manufacturing: 383 Cheryl Lane, City of Industry, CA 91789

8. When prompted select file “SW_VIC_4.10.0_065726.hex” from your hard drive, select open.

9. The Programming window will come up and will take several minutes to complete. Its important
to note do not switch screens or have any CAN tools to be running in the background.

10. Once the software update is complete navigate to the Overhead Charging screen and set the
Vehicle Tag Number previously recorded.
11. Close the PDT, turn off work light, turn off the bus at the rear master switch located at the rear
curbside access panel.

Powertrain Controller Update
1. Ensure the LV batteries and laptop are charged.

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Headquarters: 1815 Rollins Road, Burlingame, CA 94010
East Coast Manufacturing: 1 Whitlee Court, Greenville, SC 29607
West Coast Manufacturing: 383 Cheryl Lane, City of Industry, CA 91789

2. Power up and login to the Proterra-Supplied laptop or a comparable PC that has the Proterra
Diagnostics Tool software installed with a valid license.
3. Power ON the 12/24V rear Vehicle Master Disconnect located at the curbside rear charge port
access panel.
Vehicle Master
Disconnect

4. Turn the Driver’s Master Switch to the “ACC” position.

5. Connect the Nexiq USB Link2 device to the laptop and to the OBDII Diagnostic Port located in
the streetside wheel well box
6. On the PDT navigate to the configuration tab. Next, click the powertrain Firmware “Start Flash”
Button.

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Headquarters: 1815 Rollins Road, Burlingame, CA 94010
East Coast Manufacturing: 1 Whitlee Court, Greenville, SC 29607
West Coast Manufacturing: 383 Cheryl Lane, City of Industry, CA 91789

7. The following screen should pop up. Select file “065645.hex” from the software package on
your hard drive.

8. The PDT will attempt to connect to the device.

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Headquarters: 1815 Rollins Road, Burlingame, CA 94010
East Coast Manufacturing: 1 Whitlee Court, Greenville, SC 29607
West Coast Manufacturing: 383 Cheryl Lane, City of Industry, CA 91789

9. When the software update begins, the following screens will be displayed.

10. The Software update may take several minutes to complete. When the software update is
complete the following screens will be displayed. Click “OK” button to complete the update
process.

11. Power down the bus by selecting the off on the Driver Switch.

12. The Software update is now complete. Close the diagnostic tool and turn off power at the rear
master disconnect.

Body Controller Update
1. Ensure the LV batteries and laptop are charged.
2. Power up and login to the Proterra-Supplied laptop or a comparable PC that has the
Proterra Diagnostics Tool software installed with a valid license.

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Headquarters: 1815 Rollins Road, Burlingame, CA 94010