New Flyer introduces extended-range option to its Xcelsior CHARGE FC™ fuel cell bus, designed for rural and long-distance transit

New Flyer has unveiled a major range-boosting innovation for its Xcelsior CHARGE FC™ fuel cell electric bus, which is powered by Ballard. The new optional four-hydrogen-tank module significantly extends vehicle and operational flexibility, incorporating an additional 17.5kg of onboard fuel capacity.

This augmented system has already been integrated into Humboldt Transit Authority’s (HTA) hydrogen-powered vehicle in California, where the zero-emission technology is proving successful on challenging, steep, real-world duty cycles.

As the first agency to deploy the extended range option in its fleet, HTA has enjoyed performance that has exceeded expectations in both range and reliability.

[Footage courtesy of HTA]

Providing an optimal solution for transit agencies operating in rural areas that face adverse terrain, conditions, and longer routes, the advanced Xcelsior CHARGE FC™ utilizes the bus’s remaining roof space for additional transverse-mounted hydrogen tanks to bolster fuel capacity by 50%, which supports an overall operational driving range of up to 640 miles (1030km) – an improvement of 120 miles (195km) on the original model.

This enhancement significantly improves the Xcelsior CHARGE FC™’s service performance and efficiency, reduces the need for frequent refueling, and streamlines overall transit operations.

"We are excited to be the first public transit agency in North America to adopt this extended range feature from New Flyer. Performance in both fuel economy and range has exceeded our expectations, enabling more dependable service for our community. We are proud to showcase New Flyer's technology here and demonstrate how forward-thinking solutions can benefit both the environment and the people we serve."

Greg Pratt General Manager, HTA

HTA received New Flyer’s pilot bus in March 2025 and commenced route testing around Humboldt the following month. The bus was tested with and without passengers, and with and without the HVAC system on demanding routes that included steep roads and high elevation.

The 40-foot model achieved 320 miles under average operating conditions, demonstrating its reliability for long-distance travel; 75 miles at a sustained speed of 60 mph, showcasing its highway performance; and 50 mph over an eight-mile stretch with a 6% grade, underlining its climbing capability.

HTA's hydrogen-powered bus integrates Ballard's FCmove-HD+ 100kW fuel cell engine, which delivers proven performance and reliability, and the compact, durable, easy-to-install configuration provides an advanced decarbonized solution for public transit mobility. 

As well as a lighter, high-efficiency fuel cell engine, the enhanced Xcelsior CHARGE FC™ also features recyclable high-power batteries, improved waterproof battery enclosures, and a more powerful electric drive system with up to 90% energy recovery through features such as regenerative braking.

The extended range fuel cell bus gives rural transit operators the ability to transition to a zero-emission fleet - with no compromise on service or performance.