New Flyer adds 120-mile extended range option to hydrogen fuel cell bus
NFI Group’s New Flyer brand has launched an extended range option for its 40-foot Xcelsior CHARGE FC™ hydrogen fuel cell-electric bus, adding up to 120 miles of additional range thanks to a new four-tank hydrogen module.
The upgrade boosts onboard fuel capacity by 17.5 kilograms, bringing the total to nine hydrogen tanks – five standard and four optional – all mounted transversely along the roofline.
According to New Flyer, that’s enough hydrogen to push the CHARGE FC’s real-world range well beyond 300 miles, depending on terrain and load.
Tested in the hills of Humboldt
The configuration is already in service with Humboldt Transit Authority in Northern California, where the additional range has proved useful for challenging, steep routes and longer-duty cycles.
“Performance in both fuel economy and range has exceeded our expectations,” said Greg Pratt, General Manager at Humboldt. “It’s enabled more dependable service for our community.”
New Flyer says the upgrade was designed with transit operators in mind who require extended range between refuelling stops – especially in areas with sparse hydrogen infrastructure or long rural service routes.
“With zero-emission buses, range matters,” said Chris Stoddart, President of NFI’s North American Bus and Coach division. “This upgrade is a game-changer.”
Efficiency under the bonnet
The extended range system builds on the Xcelsior CHARGE FC’s existing architecture, which includes a high-efficiency, lightweight fuel cell power module and a high-power battery system with energy recuperation rates of up to 90%.
Other recent enhancements include improved waterproof battery enclosures and a more powerful electric drive.
Based on figures from Penn State’s Altoona Bus Testing Program, the CHARGE FC achieves around 7 miles per kilogram of hydrogen.
That means the extra 17.5kg of storage equates to roughly 120 miles of additional range, depending on conditions.
New Flyer says the option will help operators reduce refuelling frequency, improve operational resilience, and meet the demands of more aggressive duty cycles and harsher climates.
The CHARGE FC is part of a broader zero-emission platform from New Flyer, which also includes battery-electric and trolleybus variants.
In total, NFI supports more than 1,900 zero-emission buses in service across North America, and over 35,000 heavy-duty units across its wider fleet.
