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This article presents the FCEV power supply system configuration scheme, and proposes a topology of high power bi-directional DC-DC converter suited to FCEV. The operating principle of the converter is analyzed thoroughly. In order to guarantee the power flowing smoothly in both directions, a mode-switching unit is designed and a novel mode switching method is proposed. A 5 kW bi-directional DC-DC converter is constructed, which is controlled by the DSP-TI320F243. In addition, the design of circuit parameters and power devices are discussed. The experimental results show that the converter have excellent electrical characteristics, and it can be applied in the EV as well as the distributed power station and energy storage system.