Achievements in Fuel Cell Buses – Pursuing FTA Objectives & Zero-Emission Transit Users Group 2010 NHA Hydrogen Conference & Expo Transportation 11:30 a.m. Session Long Beach, CA May 5, 2010 Lawrence Wnuk PhD, Senior Director Copyright CALSTART 2010 Clean Transportation Technologies and Solutions

Copyright CALSTART Multi-Path Strategy for H 2 in Transit System Developments Components Development 40’ Bus Direct Path Projects Component Path Evolutionary Path FTA Performance Objectives Bus Cost – <5x –Comparable Size Transit Bus Durability – 4 to 6 Years/ 20,000 to 30,000 hours Fuel Efficiency – 2x Comparable Transit Bus FC Bus Performance = or > Commercial Transit Bus 2010 HD Emissions Standards Increase Public Acceptance for FC Bus Technology Foster Competitiveness in FC Bus Technologies

Copyright CALSTART IAM CALSTART National FC Bus Programs BDC AC Transit HyRoad SunLine AFCB (Pending) BAE Systems BUS 2010 US Hybrid BDC, IAM 40’ Bus

Copyright CALSTART Direct Path Vehicle & Systems Development AC Transit - Accelerated Fuel Cell bus operations underway UTC Power - Engineer next generation Fuel Cell with a reliability increase times Transit Bus - 40’ Heavy Duty Fuel Cell Power Plant Hybrid Design with Energy Storage High Efficiency Drive Systems FC Bus Targeted Electronic Designs Weight Reduction in Advanced Bus –Vehicle and Sub-systems AC Transit HyRoad Program - Van Hool, UTC Power, ISE Corp

Copyright CALSTART AC Transit Fuel Economy ~ 1.7 x Diesel GTT BOP H/W & S/W + CSAs Upgrades to retain performance

Copyright CALSTART AC Transit Line 18 – On-Road Challenge for FC & Propulsion 2.5 mile grade at approximately 5% Albany Berkeley Oakland UC Campus

Copyright CALSTART ,000 Pounds Lighter OEM Integration Energy Storage (Li-ion) Lower profile Enhanced Electronics and Fuel Cell –Performance –Reliability –Durability AC Transit HyRoad – Doubled FC Durability, On a Path to a 5x Increase

Copyright CALSTART AC Transit HyRoad Passenger Survey – 429 Passengers ACT’s Fuel Cell Program – 84% Positive Program’s Effect on Opinion of Local Government – 70% Improved Importance of Considering Alternative Fuels – 90% Yes Support Expanded Fuel Cell Bus Program at AC Transit – 81% Yes

Copyright CALSTART Evolutionary Path Vehicle & Systems Development Scalable Designs/Applications are the Focus Variety of Buses and Lengths –Shuttle, School and Transit –20’, 30’, 40’ and 60’ Articulated Scalable Fuel Cell Power Plant Hybrids or APU Designs Conventional Internal Combustion Engine (ICE), Battery or H 2 ICE Scalable Drive Systems Selected Subsystem Designs Targeted Industry Software BUS 2010 Program Team - BAE Systems - Hydrogenics - EMP - SFMTA - Orion - Diversified Services

Copyright CALSTART BUS 2010 Evolutionary Path - Enhancing a Successful HEV Better fuel economy Lower emissions Reduced maintenance Better reliability Path to future Propulsion Control Electronics Hydrogenics Fuel Cells for APU and H 2 Storage System Electrified Accessories Propulsion Cooling Package Lithium-Ion Energy Storage System

Copyright CALSTART BUS 2010: Advanced E-Accessories & Power Management; Broad Product Suite Seamless Operation of Fuel Cell APU with Energy Storage and Propulsion System across operating duty cycle Optimized Power Management –Maximize Total Fuel Economy –Minimize Diesel Fuel Consumption –Minimize total Emissions Demonstrate benefits of electrified accessories Enhance Public awareness and acceptance

Copyright CALSTART American Fuel Cell Bus (AFCB) - Direct Path Program Re-aligned Full Size Fuel Cell Bus Hybrid Drive System Program Manager - SunLine Transit Agency Supplier Partners - BAE Systems, ElDorado, Ballard FTA NFCBP Development Award New purpose design fuel cell bus –North American chassis –Lightweight bus body/chassis design for H 2 fuel components –U.S. sourced drive components –Latest-generation U.S. sourced fuel cell (12,000 hr warranty) –New power electronics and advanced energy storage –Unique hi-efficiency accessory electronics Zero Emission Bus vehicle demo in a very hot desert climate Side-by-Side Comparisons of a Van Hool UTC Bus and BAE System - Ballard Design √ √ √ √ √ √ √ √

Copyright CALSTART American Fuel Cell Bus (AFCB) – Direct Path Program New purpose design fuel cell bus –North American chassis –Lightweight bus body/chassis design for H 2 fuel components –U.S. sourced drive components –Latest-generation U.S. sourced fuel cell –New power electronics and advanced energy storage –Unique hi-efficiency accessory electronics Zero Emission Bus vehicle demo in a very hot climate

Copyright CALSTART US Hybrid Efficient, Low-cost, Compact, Bi-directional DC-DC(BDC) Converter $60/kW in low production VDC / VDC Input Voltage Range 400A Input Current Output –Vin < Vout < 900 VDC –Power 60 kW to 200 kW New Design Component Path Project Replaces functions now custom designed for fuel cell and electric drive buses

Copyright CALSTART Component Path - BDC Plug-n-Play Electronics for Multiple Applications Programmable, plug-and-play, with diagnostics User reconfigurable via RS232 interface Tailored unit performance, speeds, simplifies integration User performs Configuration Management

Copyright CALSTART In-Service Trials Demonstrate BDC Power Converter Smoothes Fuel Cell Transients Improving FC Durability Fast Response Captures More Regen Energy Low Standby Power & High- Efficiency Reduces System Cooling Requirements Features Together Improve Vehicle Fuel Economy Fuel Cell Battery Drive System BDC High-frequency, Multi-phase DC-DC Power Conversion – Why Important BDC fast dynamic response & current/voltage mode agility optimizes energy flow between fuel cell, energy storage and drive system

Copyright CALSTART Component Path Program - US Hybrid Integrated Auxiliary Module (IAM) Low cost, $55/hp for motor drives and $15/A for DC-DC Single Unit eases vehicle integration, increases reliability 94% Rated Efficiency, for Motor Drives and DC-DC Converter Motor Control –Speed, torque and Sensor-less –Hydraulic and/or Air System Pressure Regulation –CAN Command or Analog Configuration User Managed Motor Drive 1 10 hp Motor Drive 2 10 hp DC-DC Converter 200A 12/24 VDC Aux Battery Hydraulic System Air System Input: , VDC Cooling: Liquid WEG < 60°C

Copyright CALSTART US Hybrid BDC, IAM - Getting Hardware on the Road Proterra Bus Application - Fuel Cell Series Hybrid Technology –Bi-directional dc-dc –DC-DC Converter –Power Converter Module Benefits –Handling and Performance –Fuel Saving 18 UTC PureMotion 120® Application - Fuel Cell Technology - Integrated Motor Drive

Copyright CALSTART Achievements vs. Performance Objectives FTA Performance Objectives Bus Cost – <5x –Comparable Size Transit Bus Durability – 4 to 6 Years/ 20,000 to 30,000 hours Fuel Efficiency – 2x Comparable Transit Bus CALSTART Team Achievements BUS 2010, US Hybrid BDC, IAM –Bus alone < $2M UTC – 4 + yrs/8,000 hrs w/10,000 hr incentives Fuel Efficiency – 1.7x Diesel AC Transit FC Bus 40’ Bus Goal - Facilitate Viable FCB Technologies MetricsExamples of How We’re Doing Program Objectives

Copyright CALSTART Achievements vs. Objectives (2) FTA Goals and Objectives FC Bus Performance = or > Commercial Transit Bus 2010 HD Emissions Standards Increase Public Acceptance for FC Bus Technology Foster Competitiveness in FC Bus Technologies CALSTART Team Achievements Acceleration, gradeability, range, top speed (close) Verifying for Criteria Pollutants AC Transit Public Survey, SunLine Public Events Encouraged Entry of Integrator Team & Buy America Compliant FC Manufacturer MetricsExamples of How We’re Doing

Copyright CALSTART Lessons Learned So Far Support Essential –Technical (People to Diagnose/Change Parts) –Logistics (Spare Parts) Integration –Teamwork and Coordination Over-all Poised for the Next Step –Beyond Demo Stage –On-Road Pilot Production Fleets (10’s of Buses) Needed –Supplier Focus on Production Configurations to further Reduce Cost and Increase Durability/Reliability –Both Fuel Cell and Electronics Need More On- Road Testing

Copyright CALSTART A unique partnership with the –U.S. Federal Transit Administration (FTA), –South Coast Air Quality Management District –Member agencies (CNG fuel) –CALSTART Z-TUG Members - Represents > 5,000 Buses

Copyright CALSTART Z-TUG Fleet Inventory Model Input Sheets Inventory Fuels/Propulsion Emissions Capital/Operating Costs Select Criteria Emissions GHGs Graphical Results Emissions by year GHGs Costs

Copyright CALSTART Fuel / Technology Combinations Achieve Criteria Evaluate Paths –Fuel/Tech Options –Emissions –Costs

Copyright CALSTART Z-TUG Vision: Forging a Compliant H 2 Pathway in Transit Production IntentEarly Production Zero-emission motoring Pre-Production Some Zero- Emission 40’ Vehicles Evaluate Various Technology Paths In-Service Trials Validate for Quantity Purchase Develop Compatible Propulsion for Balance of Procurement Lt-Wt High-Cap. FCB Battery Bus Infrastructure HCNG Bus CNG HEV New Procurement Z Bus Compliant 50% fuel use reduction Low Carbon Fleet Z Bus Infrastructure

Copyright CALSTART Clean Transportation Technologies and Solutions SM