Proterra Catalyst BE40

Proterra Catalyst BE40
Years of manufacture	2014 to 2020
Length	42 feet
Width	102 inches
Power/Fuel	Electricity

The Proterra Catalyst is the company's second generation battery electric low floor transit bus. It was first launched as the 40-foot Catalyst BE40 at the 2014 APTA Bus and Paratransit Conference in Kansas City. Foothill Transit, the launch customer for the first generation bus, was the first to order the latest generation bus.

The Catalyst uses a monocoque structure composed of E-glass fibre stitched non-crimp fabric and unidirectional carbon fibre in a vinyl ester resin. It is moulded using the Seeman Composites Resin Infusion Molding Process (SCRIMP), a vacuum-assisted closed infusion molding method, by TPI Composites. A gel-coat layer is first placed in the mould followed by triaxl glass fibre fabic. Unidirectional carbon fibre fabric is used to add strength at key areas. Quadriaxial quasi-isotropic glass fibre fabric is used where strength and stiffness are especially critical. The materials are vacuum bagged and infused with catalyzed vinyl ester resin. The resulting compsoite structure is lightweight and can absorb a large amount of energy in a collision.

The upper body from the roof down to the lower window line, which includes the entire windshield and rear window, is on section. The lower body from the lower window line to the floor is another. The upper section of the roof and the ceiling are glass fibre sandwich structures with a balsa wood core. Components such as doors and interior fittings are attached by either molding stainless steel inserts into the laminate or by bonding.

For the 2019 model year forward, the roofline towards the rear was reshaped. In addition, the vent above the rear window was no longer separated into three sections. An option that was first noted on the buses for the Toronto Transit Commission, is a rear window that can open for emergency egress.

The Catalyst can travel up to 55 miles before the standard fast charge (FC) batteries, now lithium–titanate instead of lithium-ion, need to be recharged. In February 2015, Proterra introduced an extended range (XR) option that allows the bus to travel up to 180 miles between charges. A year later, Proterra introduced an enhanced XR battery that holds 28 percent more energy at 330 kWh, allowing the bus to travel up to 193 miles. At the 2016 American Public Transit Association (APTA) Annual Meeting, Proterra unveiled their E2 (Efficient Energy) battery option with a capacity of 440 to 660 kWh that allows the bus to travel between 194 and 350 miles. This range is able to meet a full day's worth of service for some agencies.

At the 2017 American Public Transit Association EXPO in Atlanta, Proterra introduced their DuoPower drivetrain. It integrates two 190 kWh electric motors and two-speed transmission into a planetary axle from AxleTech. It boasts almost twice the horsepower as the standard ProDrive drivetrain and is five times more efficient than a standard diesel bus. With the DuoPower drivetrain, the Catalyst E2 max has a nominal range of 426 miles.

The bus's batteries can be charged enroute with a proprietary overhead charging station, which features automatic docking. The standard FC option can be fully charged in ten minutes, while the XR option can be fully charged in approximately one hour. The bus can also be plugged in using a J1772 CCS charger at the garage. The E2 is only charged this way while the bus is out of service, typically when it is parked overnight, at the garage and is fully charged in three to five hours. In May 2018, to improve interoperability with other battery-electric buses, Proterra introduced compatibility with the SAE J3105 (OppCharge) overhead charging standard. The roof rails to accommodate OppCharge charging are mounted on the roof near the front of the bus on trapezoidal blisters.

In 2020, Proterra restyled their line of battery-electric buses. The roofline was made more streamlined with provision for room-mounted battery packs, and additionally, integrated Oppcharge charging rails at the front of the bus. The tail light clusters on the 40ft vehicle were updated to the same design as used on the 35ft vehicle. The vehicle styling was made more angular with a flatter front end, and a recess was added under the windshield. The rated power of the powertrain options have also been increased. Edmonton Transit System was the launch customer for the redesigned vehicle. The redesigned buses were formally launched as the ZX5 on September 15, 2020.

Specifications

Dimensions
Length: 42' 6"
Width: 102"
Height: 135.5"
Wheelbase: 24’ 8"
Turning Radius: 41.9'
GVWR: 43,650 lbs
Traction motor				Availability
ProDrive drivetrain	UQM HD220 220 kW peak permanent magnet motor			2014 to present
DuoPower drivetrain	Dual independent 190 kW motors			2017 to present
Transmission
Eaton EEV-7202 2-speed auto-shift EV transmission
Suspension
Independent front suspension and multi-link air-ride rear suspension
Brakes
Four wheel disc brakes w/ ABS and optional traction control
Battery options
Series	Model	Nominal range	Standard charge time	Curb weight
ProDrive FC (Fast Charge)	FC	55 miles	<1 hour	28,324 lbs
	FC+	72 miles	<1 hour	29,900 lbs
DuoPower FC (Fast Charge)	FC	49 miles	<1 hour	26,446 lbs
	FC+	62 miles	<1 hour	29,900 lbs
ProDrive XR (eXtended Range)	XR	136 miles	<2.5 hours	26,750 lbs
	XR+	193 miles	<2.5 hours	28,324 lbs
DuoPower XR (eXtended Range)	XR	164 miles	<2.5 hours	26,750 lbs
	XR+	238 miles	<2.5 hours	28,324 lbs
ProDrive E2 (Efficient Energy)	E2	251 miles	<3 hours	29,900 lbs
	E2+	303 miles	<3.5 hours	31,574 lbs
	E2 max	350 miles	<4.5 hours	33,150 lbs
DuoPower E2 (Efficient Energy)	E2	305 miles	<3 hours	29,900 lbs
	E2+	367 miles	<3.5 hours	31,574 lbs
	E2 max	426 miles	<4.5 hours	33,150 lbs

Other Photos

• 

  40ft Catalyst with ProDrive drivetrain; rooftop charging via Proterra's proprietary system

• 

  40ft Catalyst with DuoPower drivetrain; rooftop charging via Proterra's proprietary system

• 

  40ft Catalyst with ProDrive drivetrain; no rooftop charging provisions

• 

  40ft Catalyst with DuoPower drivetrain; rooftop charging via OppCharge

Demonstrator and engineering units

Below is a list of known demonstrator and engineering buses.

Fleet number	Thumbnail	Year	VIN	Motors	Notes
		April 2014	1M9TH16J0ES816064		Altoona test bus from June 19, 2014 to April 10, 2015
		2014			White, green and black wrap Grey USSC Gemini seats with grey and green fabric Demo with Metro Transit in 2015
		December 2016	1M9TH16JXGS816124		White exterior Charcoal American Seating InSight seats with multi-colour crescent patterned inserts. Altoona test bus from June 2, 2017 to July 27, 2017 Demo with TTC April 16 to 21, 2018
		c. 2017			Green, blue and black wrap Charcoal American Seating InSight seats with blue patterned inserts Shuttle for 2017 APTA Expo in Atlanta
		March 2018	1M9TH16J2JS816240	Dual independent 190kW motors	Green, blue and black wrap in 2018 Blue and purple wrap in 2019 Grey and blue interior with USSC Gemini seats Demo with TTC November 12, 2018 Displayed at 2018 CUTA Transit Show in Toronto Displayed at 2019 CUTA Transit Show in Calgary License Plate: MA2587

Operators

Canada

• Roam - Banff Region, AB (on order)
• Toronto Transit Commission - Toronto, ON

United States

• Alabama A&M University - Huntsville, AL
• Arvin Transit - Arvin, CA
• Baltimore Gas Electric - Baltimore, MD
• Clemson Area Transit - Clemson, SC
• Chicago Transit Authority (CTA) - Chicago, IL (on order)
• Citibus - Lubbock, TX
• DC Circulator - Washington, DC
• Detroit Department of Transportation (DDOT) - Detroit, MI (on order)
• Duke University Transit - Durham, NC (on order)
• Duluth Transit Authority (DTA) - Duluth, MN
• Everett Transit - Everett, WA
• Foothill Transit - San Gabriel & Pomona Valleys, CA
• GoRaleigh - Raleigh, NC (on order)
• Green Mountain Transit Authority - Burlington, VT (on order)
• Greenlink Transit - Greenville, SC
• Greensboro Transit Authority (GTA) - Greensboro, NC
• Humboldt Transit Authority (HTA) - Humboldt County, CA
• JTB Hawaii - Honolulu, HI
• King County Metro Transit - Seattle, WA
• LexTran - Lexington, KY
• MetroLINK - Rock Island, IL
• Metropolitan Transportation Authority (MTA) - New York City, NY
• Modesto Area Express - Modesto, CA
• New Jersey Transit - Newark, NJ (on order)
• Park City Transit - Park City, UT
• Pierce Transit - Pierce County, WA
• Pioneer Valley Transit Authority (PVTA) - Springfield, MA
• Port Authority of New York and New Jersey - New York, NY
• Sacramento International Airport - Sacramento, CA
• Raleigh-Durham Airport Authority - Morrisville, NC
• San Francisco Airport - San Francisco, CA (on order)
• San Joaquin Regional Transit District (RTD) - Stockton, CA
• San José International Airport (operated by Transdev - San José, CA
• San Mateo County Transit District (SamTrans) - San Mateo County, CA
• Southeastern Pennsylvania Transportation Authority (SEPTA) - Philadelphia, PA
• Santa Clara Valley Transportation Authority - San Jose & Santa Clara County, CA
• SporTran - Shreveport, LA
• Suburban Mobility Authority for Regional Transportation (SMART) - (Suburban) Detroit, MI (on order)
• The Fleet (leased by JLL, operated by SP+ Transportation) - Chicago, IL
• Tompkins Consolidated Area Transit (TCAT) - Ithaca & Tompkins County, NY (on order)
• Transit Authority of River City (TARC) - Louisville, KY
• Tri-Delta Transit - Eastern Contra Costa County, CA
• University of Georgia Campus Transit - Athens, GA (on order)
• University of Montana UDASH - Missoula, MT
• Visalia Transit - Visalia, CA
• Worcester Regional Transit Authority (WRTA) - Worcester, MA
• Yolo County Transportation District - Woodland, CA
• Yosemite Valley Shuttle (operated by Aramark) - Yosemite National Park, CA
• Zion National Park Shuttle (operated by RATP Dev) - Springdale, UT