NHTSA ID Number: 11007755
Manufacturer Communication Number: SC-23-135
TSB/Document Date: 2024-09-13
Summary
This procedure describes the process for updating the 800VRR Prodrive Vehicle, Powertrain, Body Controller, ESM and Charge Controller software to BuSCoM 2.0.
Vehicle Master
Disconnect
3. Turn 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. Turn the Hazard Switch 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. Navigate to the Configuration tab and click the” Get Parameters” button. This will download
the latest parameter set the “C:\Logs” folder on your machine.
14| 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
7. In the windows file explorer, navigate to the “C:\Logs” folder. Copy the latest downloaded
*.zip file to a folder for the specific customer and vehicle.
8. Navigate back to the PDT and the configuration tab. If this is a replacement controller,
select the “SET VIN” and program the controller to match the VIN. Proceed to the next
step.
9. Select the “START FLASH” on the Body Firmware.
15| 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
10. In the popup window select the software file “Body_7_0_1_065725.ZR32A_A” from your
harddrive.
11. The Programming window will come up and will take serval minutes to complete. While the
flashing is occurring do not change screens.
12. After the controller is updated, the tool will automatically upload the previous EEPROM
values. Please verify that the EEPROMs values match the parameters that was exported
above. If they do not match you may reimport the previous values. The bus might be
buzzing and flashing faults. Cycle the buses power.
16| 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. At this point the software update is complete. Close the PDT, turn the drivers switch to off
and turn off the bus at the rear curbside master switch.
14. Remove all programming equipment and return vehicle to service.
17| 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
Proterra EV Battery Fire Safety Guide
Thermal Event Diagnostics, Prevention & Response
LEGAL DISCLAIMER
PLEASE READ
This document provides general guidance to the owner/customer (“Owner”) to develop
its own safe work procedures related to Proterra’s electric vehicle and electric vehicle battery
pack (individually and collectively, the “Product”). Any reference to standards, regulations or
laws is not exhaustive, nor intended to advise the Owner of its legal duties or compliance
obligations.
This document is not based on a specific Product configuration. Proterra assumes that
all who purchase the Product have expertise to properly and safely receive, handle, store, use,
and service the Product. Accordingly, this document is intended as a helpful supplement for
the Owner and not a substitute for the Owner’s expertise or responsibility regarding these
topics. If any Owner lacks such expertise or does not agree to the foregoing limited purpose,
such Owner should immediately notify Proterra in writing and should not procure, take
delivery of, or use the Product.
This document is provided “as is,” and Proterra assumes no liability or responsibility for any
loss, damage or expense resulting from the Owner’s, or any agent or affiliate of the Owner’s,
reliance upon, or use of, this document. Proterra makes no warranty or representation, and
expressly disclaims any such warranties or representations, that the content of this document
is complete, accurate, reliable or error free, to the fullest extent permitted by applicable law.
Each Owner assumes the entire risk as to its reliance upon, or use of, this document. Proterra
is not responsible to update the content of this document at any time, including based on
changes, combinations, or conversions of the Product.
1|Page
SEPTEMBER 2023
1 FIRE-SAFETY GUIDELINES FOR AN EV BATTERY
a) In the event there is a battery fire, immediately stop operating or working in/around the vehicle.
All individuals should move at least twenty feet away from the vehicle.
b) Immediately call the local emergency number (e.g., “911”) to report the battery fire and ask for
assistance from fire, police, and medical departments. See First Responder Guide below.
c) It requires specialized training and personal protective equipment (“PPE”) to safely extinguish a
battery fire. The Owner should establish a site-specific safety plan related to EV vehicles and all
on-site first responders should be trained to execute the safety plan. The safety-plan should take
the following factors into consideration:
i)
A battery fire may require application of large amounts of water to the battery pack
for a
long period of time from a safe distance to extinguish a battery fire.
Do not:
•
•
•
•
Stand close to the vehicle while attempting to extinguish a battery fire.
Attempt to open a battery pack for purposes of cooling it with water.
Attempt to extinguish a battery fire with a small, limited quantity of water.
Use an “ABC” rated fire extinguisher to put out a battery fire.
ii) Always wear the appropriate PPE, including full body covering fire-fighting clothing and selfcontained breathing apparatus. Hot metals may be ejected from the battery during a fire,
and materials contained inside the battery pack are flammable, corrosive, and should not be
inhaled or allowed to contact the eyes or skin.
iii) The battery pack may vent hot gases composed of volatile organic compounds such as alkylcarbonates, methane, ethylene, and ethane, as well as hydrogen gas, carbon dioxide, carbon
monoxide, soot, and particulates containing oxides of nickel, aluminum, lithium, copper, and
cobalt. Vented gas temperatures may exceed 600°C. The gases may cause burns upon
contact. The gases may ignite unexpectedly creating a fire or explosion.
iv) Battery pack fires may require up to 24 hours to extinguish. It may be necessary to allow the
battery pack to burn while protecting structures or other objects in the vicinity. When all
smoke and fire has visibly subsided and cleared, a thermal imaging camera should be used to
actively measure the temperature of the high voltage battery and monitor temperature
trends — i.e., is the battery consistently cooling down over time, or is it heating up again?
v) The battery pack must be completely cooled and there must not be fire, smoke, or heat
present in the high voltage battery for at least one hour before the vehicle can be released to
second responders (such as vehicle transporters). Second responders must be advised that
2|Page
SEPTEMBER 2023
there is a risk of battery pack re-ignition. Damaged high voltage lithium ion batteries require
special transportation measures, and therefore are prohibited from regular transportation.
vi) Do not contact any high voltage components and always use insulated tools during overhaul.
vii) A battery fire may damage the vehicle’s airbag inflators, stored gas inflation cylinders, gas
struts, and other components which can result in an unexpected explosion. A full “knock
down” procedure should be performed.
d) First Aid Measures
i)
Electric Shock/Electrocution: Seek immediate medical attention (suspected or confirmed);
call 911.
ii) Contact with Leaked Material (Electrolyte, Coolant): The contents of an open or broken
constituent battery cell may cause skin irritation and/or chemical burns. In the event of
contact, immediately flush skin with water and wash affected area with soap/water. Seek
immediate medical attention if a burn or other irritation does not resolve. For eye contact,
immediately flush with a significant amount of water for at least 15 minutes without rubbing
and seek immediate medical attention; call 911.
iii) Vapor or Gas Inhalation (Electrolyte Vapor, Vent Gas): Immediately move to fresh air source.
If not breathing, perform artificial respiration and call 911.
3|Page
SEPTEMBER 2023
2 FIRST RESPONDER GUIDE
Information for first responders to respond to a battery fire involving an electric vehicle can be found at
the National Fire Protection Association website:
https://www.nfpa.org/Training-and-Events/By-topic/Alternative-Fuel-Vehicle-SafetyTraining/Emergency-Response-Guides/Proterra
A sample of the information for first responders located at this website is shown below for reference.
First responders may also contact Proterra at [email protected] if they have any questions.
4|Page
SEPTEMBER 2023
3 BACKGROUND
3.1 THERMAL EVENT VS. THERMAL RUNAWAY.
Each Proterra battery consists of multiple battery cells. Proterra’s diagnostic system is set up to detect a
battery “thermal event” where a single battery cell fails in a manner that may cause an unintended
chemical reaction to occur inside the cell. The battery pack is designed to contain a single battery cell
“thermal event” and prevent a “thermal runaway” (or fire) that involves neighboring battery cells. A
“thermal runaway” may occur if other abnormal conditions exist such that the single cell “thermal event”
is not contained (e.g., physical impact that causes significant damage to the battery pack). A “thermal
runaway” is detectable by smoke, a burning smell, a flame, and other indications of a fire.
If there are any signs that the battery pack may be experiencing a “thermal runaway,” or fire (e.g. smoke,
a burning smell, abnormal popping or whistling noises, a flame, etc.), then you must immediately
discontinue use of the vehicle and follow the emergency guidelines outlined in the above Fire-Safety
Guidelines for an EV Battery.
3.2 DIAGNOSTICS, DRIVER NOTIFICATION & VEHICLE RESPONSE
Proterra vehicles have battery sensors and diagnostics used to detect signals related to temperature,
humidity, internal pack air pressure and isolation. If an abnormal battery condition is detected, Proterra’s
diagnostic system will transmit a message on the vehicle CAN bus. This information will be communicated
to the driver via the vehicle dash as described below.
Critical battery faults which indicate the potential for a thermal event will result in a Fast Flash Red Stop
Lamp in the vehicle dash that blinks at a rate of two times per second, and an audible alarm that pulses
twice per second (collectively, the “Critical Battery Fault Warnings”). Critical Battery Fault Warnings
indicate a critical battery failure which could result in a thermal event. When the Critical Battery Fault
Warnings are active, please immediately follow the procedures set forth in the Operator/Driver Guidelines
section below, as well as the instructions in any applicable sections of the Proterra Driver’s manual.
For any other types of driver’s dash display warning lights (including but not limited to solid, non-flashing
red or yellow “warning” lights) and/or audible alarms, please refer to the vehicle owner’s manual for an
explanation of these warnings and recommended actions.
Figure 1 below shows the Red Stop Lamp as presented on the original Proterra dash. Figure 2 below shows
the Red Stop Lamp as presented on the updated Proterra digital dash.
5|Page
SEPTEMBER 2023
Figure 1 – Red Stop Lamp on Original Dash
Figure 2 – Red Stop Lamp on Digital Dash
6|Page
SEPTEMBER 2023
OWNERS SHOULD ALWAYS MONITOR AND RESPOND TO DASH FAULT LIGHTS AS PART OF THE VEHICLE
OPERATION AND MAINTENANCE ROUTINE. OWNERS MUST PERFORM FOLLOW-UP INVESTIGATION
WHEN DASH FAULT LIGHTS PRESENT. DO NOT IGNORE A DASH FAULT LIGHT.
In addition to the Critical Battery Fault Warnings, a critical battery fault will prevent the vehicle from
charging and cause the vehicle to immediately enter a “limp home” state where the propulsion system
is limited to 50 kW. The “limp home” state will provide enough power to launch the vehicle and
maintain 35 mph on a flat road with an unloaded bus. In addition to the Critical Battery Fault Warnings,
the Owner’s service technicians should be trained by Proterra in use of Proterra’s diagnostic tool to
identify and detect abnormal battery conditions (see https://www.proterra.com/proterra-diagnosticstool/ to download the tool and access training material). The Owner’s consistent and routine use of the
Proterra diagnostic tool is recommended to identify and monitor issues that may require further
investigation.
7|Page
SEPTEMBER 2023
4 OPERATOR/DRIVER GUIDELINES
Prior to operating the vehicle, the driver must perform all recommended safety checks set forth in the
Proterra Driver’s Manual. This inspection includes, but is not limited to, a visual inspection for signs of
damage/malfunction and confirmation that the fault lights in the dashboard display are not illuminated.
If there are any signs of fire prior to operation or while the vehicle is in use (e.g., smoke, a burning smell,
abnormal popping or whistling noises, a flame, etc.), the driver must immediately stop the vehicle in a
safe location and evacuate all passengers in accordance with the emergency guidelines in Fire-Safety
Guidelines for an EV Battery (Section 1). Note -- the vehicle may be in a “limp home” state with limited
propulsion as described above.
If the Critical Battery Fault Warnings are active as described in Section 3.2 (but there is no smoke, burning
smell, abnormal popping or whistling noises, flame, etc.), the vehicle should be promptly parked in a safe
outdoor location at least 20 feet away from other objects such as buildings, trees and other vehicles, and
at least 100 feet away from highly flammable items such as gas stations or propane tanks. Once the
vehicle has been moved to a safe location, the operator and passengers may exit the vehicle and the
vehicle should be removed from service.
The vehicle high voltage system may be left in either state; on or turned off. However, DO NOT open the
12/24 Master Disconnect Switch or Battery Saver Switch (if equipped). Keeping these switches closed will
allow the battery coolant pumps to operate as intended to mitigate heat buildup as well as providing
power to telemetry systems for remote data review.
Next Steps
•
•
•
•
Call the Proterra Regional Field Service Representative (FSR) as soon as possible to report the
issue. Proterra will respond within 2 hours (Mon- Fri between 6 am-6pm ET) or by 9 AM ET the
following business day.
DO NOT attempt to charge the vehicle.
Continue to monitor the vehicle for signs that there could be a thermal runaway (smoke, burning
smell, abnormal popping or whistling noises, flame, etc.).
DO NOT operate or work on the vehicle until Proterra’s service personnel have had the
opportunity to assess the situation and the parties have an agreed action plan.
If there are any signs of a fire (e.g., smoke, a burning smell, abnormal popping or whistling
noises, a flame, etc.), follow the emergency guidelines outlined in Fire-Safety Guidelines for an
EV Battery (Section 1).
5 MONITORING BATTERIES WITH DIAGNOSTIC TOOL
The Proterra Diagnostic Tool (the “Diagnostic Tool”) enables customers to monitor the humidity and
isolation levels of a battery pack that may indicate a critical battery safety condition. These metrics are
used by the software systems described above. As part of a customer’s routine maintenance program,
the Diagnostic Tool should be used every three months to monitor the humidity and internal isolation
levels of each battery pack as described below. If a vehicle has been turned off for three months or
8|Page
SEPTEMBER 2023
more, the customer must use the Diagnostic Tool to check each battery pack prior to starting,
operating or charging the vehicle.
Steps to Use Diagnostic Tool to Check Humidity and Internal Isolation of Battery Packs
Step 1: Connect the Diagnostic tool to a vehicle diagnostic port that has BCAN access. NOTE: The
diagnostic port location varies based on the vintage of the vehicle.
Step 2: View the “Battery Thermal” screen on the left-hand side. Example:
Step 3: View the humidity level of each module per battery pack; the pack ID is located on the graphic
of the A-Bay. If the module humidity levels are less than 70%, the battery pack check is complete. If
there is one or more module(s) that exceeds 70% humidity, you must proceed to the next step.
Example: S1P1, S1P2, S2P1 and S2P2 as shown below. NOTE: your screen and Pack ID may look
different based on the vintage of vehicle.
9|Page
SEPTEMBER 2023
Step 4: (i) View the “Battery Packs” screen (see the “Battery Thermal” screen on the left-hand side
below); and (ii) select the Pack ID of any battery pack(s) with a humidity level that exceeds 70% (see the
pull-down menu in the upper right-hand corner below).
Example: If S2P2 has humidity of 70%, select “String 2 Pack 2” in the pull-down window.
10 | P a g e
SEPTEMBER 2023
Step 5: With the relevant Pack ID selected in the pulldown menu, the internal isolation value should be
recorded.
Step 6: If either of the following conditions are met, proceed to Step 7 below.
a. Condition 1:
• Humidity greater than 90%
b. Condition 2:
• Humidity greater than 70% AND
• Internal Isolation less than 20,000 Kohms
If neither of these conditions are met, no issue has been found with respect to the recorded battery
pack(s) humidity and internal isolation levels, and the battery pack check is complete.
Step 7: If Condition 1 or 2 are present:
The vehicle should be promptly parked in a safe outdoor location at least 20 feet away from other objects
such as buildings, trees and other vehicles, and at least 100 feet away from highly flammable items such
as gas stations or propane tanks. Once the vehicle has been moved to a safe location, the operator and
passengers may exit the vehicle and the vehicle should be removed from service.
The vehicle high voltage system may be left in either state; on or turned off. However, DO NOT open the
12/24 Master Disconnect Switch or Battery Saver Switch (if equipped). Keeping these switches closed will
allow the battery coolant pumps to operate as intended to mitigate heat buildup as well as providing
power to telemetry systems for remote data review.
11 | P a g e
SEPTEMBER 2023
•
•
•
•
Call the Proterra Regional Field Service Representative (FSR) as soon as possible to report the
issue. Proterra will respond within 2 hours (Mon- Fri between 6 am-6pm ET) or by 9 AM ET the
following business day.
DO NOT attempt to charge the vehicle.
Continue to monitor the vehicle for signs that there could be a thermal runaway (smoke, burning
smell, abnormal popping or whistling noises, flame, etc.).
DO NOT operate or work on the vehicle until Proterra’s service personnel have had the
opportunity to assess the situation and the parties have an agreed action plan.
If there are any signs of a fire (e.g., smoke, a burning smell, abnormal popping or whistling noises, a
flame, etc.), follow the emergency guidelines outlined in Fire-Safety Guidelines for an EV Battery
(Section 1).
12 | P a g e
SEPTEMBER 2023
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TSB/Document ID: SC-23-135
Replacement Service Bulletin Number:
MFR Communication Date: 2023-10-14
MFR Internal Campaign ID/Software Version: SC-23-135
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: POWER TRAIN
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MFR Component Subsystem:
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