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Modular configuration –
The core components of the HY-80 Fuel Cell System
The NuCellSys HY-80 Fuel Cell System has a modular design and can thus be configured for various vehicle platforms.
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Power distribution unit (PDU)
352 mm x 231 mm x 251 mm (L x W x H)The power distribution unit distributes the current of the fuel cell module to the drive motor as well as other vehicle and system units such as the fan, compressors and the coolant pump. It contains the fuel cell measurement unit (FCM), heavy-current contactors and fuses.
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Ballard fuel cell module
805 mm x 375 mm x 250 mm (L x W x H)
Humidified, compressed air and hydrogen are fed from the system to the fuel cell module. The fuel cell module generates electric power as a result of the electrochemical reaction of these gases. The waste heat is removed by the cooling circuit. This module also contains the cell voltage monitoring unit.
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Fuel cell control unit (FCU)
80 mm x 181 mm x 168 mm (L x W x H)
The central control unit communicates with the vehicle and further system control units via CAN connections. It receives commands such as the power demand of the electric traction motor and monitors and controls the fuel cell system's sensors and actuators. The control unit also provides diagnostic functionality.
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System module
800 mm x 600 mm x 244 mm (L x W x H)
The system module supplies the fuel cell module with reaction gases, ensuring correct flows, humidification levels, and pressure. It recirculates unconsumed hydrogen and recovers water from air leaving the fuel cell module. The main components of this module are the air compressor, the condenser, the humidifier, and the hydrogen as well as water recirculation loops. -
Coolant pump
124 mm x 246 mm x 145 mm (L x W x H)
The coolant pump contains the motor and its inverter. The pump feeds coolant (water/glycol mixture) through the fuel cell module and auxiliary units in order to remove their waste heat via the vehicle radiator.
