Fuel Cell DC-DC Converter Integrated PCU FRF FRC Series 80-420kW SiC IP67 Protection

Fuel Cell DC-DC Converter / Integrated PCU FRF/FRC Series 80-420kW System Efficiency >98.5% SiC Design IP67 Protection

Quick Detail:

• DC-DC converter and integrated PCU developed specifically for proton exchange membrane fuel cell (PEMFC) systems
• Applicable power range: 80~420kW (covering commercial vehicles, passenger vehicles and stationary power stations)
• Two product series:
  • FRF series: FRF130/FRF140 (boost), FRF150 (buck-boost), FRF160 (isolated)
  • FRC series: FRC4X series (boost PCU), FRC5X series (buck-boost/boost PCU)
• FRF series peak working efficiency >99%, system efficiency at rated power >98.5%
• Uses a SiC wide-bandgap semiconductor design, high frequency and high efficiency, reducing input/output current and voltage ripple
• Proprietary reverse current suppression algorithm, improving fuel cell safety
• Integrated 0~6 channel optional BOP power distribution output, simplifying vehicle system design
• Optional stack AC internal resistance monitoring module
• Active and passive residual hydrogen discharge function, with faster and smoother discharge rate
• Protection class: IP67
• Cooling method: liquid cooling
• Working temperature: -40C~85C
• Communication: CAN2.0B (250kb/500kb)

Description:

The DC-DC converter is a key component of a fuel cell engine system; it is responsible for boosting the low-voltage DC power output by the fuel cell to a high-voltage DC output, providing power for the vehicle and charging the power battery at the same time. Unlike a DC/DC for a pure electric vehicle, which mainly performs voltage step-down, a DC/DC for a fuel cell vehicle mainly operates in boost mode: the input voltage is usually in the low-voltage range of 20V to 60V, while the output voltage needs to be raised to the high-voltage range of 200V to 800V.

The FRF series DC-DC converter is a dedicated product launched for the FCEV market and can meet the stringent requirements of various FCEVs. FRF130 and FRF140 are boost DC-DC converters; FRF150 is a buck-boost DC-DC converter; FRF160 is an isolated DC-DC converter. The product integrates 0~6 channels of optional BOP power distribution output, and can be optionally equipped with a stack AC internal resistance monitoring module.

The core features of the FRF series products include:

• High-frequency, high-efficiency SiC design, reducing input/output current and voltage ripple
• Proprietary reverse current suppression algorithm, improving fuel cell safety
• Application of wide-bandgap semiconductors, improving system conversion efficiency
• Highly integrated anti-bias magnetic device design, expanding the working current range
• Complete protection and diagnosis circuit design, ensuring stable system operation
• Highly integrated input/output power distribution function, simplifying vehicle system design
• Optional input pre-charging, 0~6 channels of auxiliary high-voltage ports
• Active and passive residual hydrogen discharge function, with faster and smoother discharge rate

The FRC series multi-in-one fuel cell PCU converter integrates a fuel cell DC/DC boost converter (DCF), a 24V output DCDC converter, a high-speed air compressor controller (ACC) and a high-voltage power distribution unit (PDU), greatly saving the space of the high-voltage electrical system and simplifying the design and installation of the power system. Among them, FRC4X is a series of integrated boost PCUs; the FRC5X series integrates buck-boost PCUs and boost PCUs.

The core advantages of the integrated PCU products include:

• Developed as an integration based on existing mass-produced products, with high product maturity
• Deep integration and reasonable layout, greatly improving product power density
• Excellent product electromagnetic compatibility performance
• Application of wide-bandgap semiconductors, improving system conversion efficiency
• High-voltage power distribution can be flexibly configured according to customer needs
• Full-series integrated air compressor controller
• The FRC4X series offers stack copper bar direct connection, connector connection and through-wall terminal versions
• The full series can be optionally equipped with an integrated fuel cell AC impedance online monitoring module

Through deep integration, the PCU product can save more than 20% of system space, reduce cost by more than 10%, and reduce system weight by more than 15%.

Specifications:

Electrical / Optical Characteristics (Ta=25C +/-3C). See product specification image.

Applications:

This product is widely used in various proton exchange membrane fuel cell (PEMFC) systems, specifically including:

• Hydrogen fuel commercial vehicles (heavy trucks, city buses, logistics vehicles)
• Hydrogen fuel passenger vehicles (sedans, SUVs)
• Stationary fuel cell power stations (backup power, distributed energy systems)
• Hydrogen fuel cell ships
• Fuel cell forklifts and construction machinery

Typical application position: the DC-DC converter is installed between the fuel cell stack and the vehicle high-voltage bus, boosting the low-voltage DC power output by the stack to high-voltage DC to supply power to the vehicle drive system and charge the power battery. The integrated PCU further integrates the DC/DC converter, air compressor controller and high-voltage power distribution unit into one, installed within the fuel cell system integration frame.

Company Advantages:

Shanghai Yibaijia Hydrogen Energy Technology Co., Ltd., as a professional hydrogen energy parts supply platform, distributes the FRF/FRC series DC-DC converters and integrated PCUs dedicated to fuel cells. The Shanghai Yibaijia team has more than 10 years of hydrogen energy industry experience and can provide full-process technical support from product selection and system matching to installation and commissioning.

FAQ

Q1: Can you provide samples for testing?
A: Yes, we support sample orders for vehicle installation testing and performance verification, and also accept mixed-model sample orders.

Q2: What is the delivery lead time?
A: Sample orders usually take 5-7 working days; bulk orders (depending on order quantity) generally take 15-30 working days.

Q3: Is there a minimum order quantity (MOQ) limit?
A: There is no strict MOQ limit; 3-piece sample trial orders are supported, and bulk order prices are more favorable.

Q4: Why does a fuel cell system need a DC-DC converter?
A: The output voltage of a fuel cell stack fluctuates greatly with the load and is usually lower than the requirement of the vehicle high-voltage bus. The role of the DC-DC converter is to boost the low-voltage DC power output by the fuel cell to a stable high-voltage DC output, providing power for the vehicle and charging the power battery at the same time. Unlike a DC/DC for a pure electric vehicle, which mainly performs step-down, a DC/DC for a fuel cell vehicle mainly operates in boost mode.

Q5: What is the difference between the FRF series and the FRC series?
A: The FRF series are independent DC-DC converters, including FRF130/FRF140 (boost), FRF150 (buck-boost) and FRF160 (isolated). The FRC series are multi-in-one integrated PCUs, integrating a DC/DC boost converter, a 24V output DCDC converter, a high-speed air compressor controller and a high-voltage power distribution unit, saving more than 20% of system space and reducing cost by more than 10%.

Q6: What components does the FRC integrated PCU integrate?
A: The FRC series multi-in-one fuel cell PCU converter integrates a fuel cell DC/DC boost converter (DCF), a 24V output DCDC converter, a high-speed air compressor controller (ACC) and a high-voltage power distribution unit (PDU); the full series can be optionally equipped with an integrated fuel cell AC impedance online monitoring module (EIS).

Q7: What communication methods does the DC-DC converter support?
A: It supports CAN2.0B communication, with a baud rate of 250kb/500kb.

Q8: How to handle product failures?
A: We implement a strict quality control system, with an out-of-factory defect rate below 0.2%. During the warranty period, small batches of defective products will be replaced with new ones in the next order; batch quality problems will be negotiated for repair or replacement to ensure customer rights.