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Electrical Test


High voltage testing is an essential operation in the PEMFC stack production process, since it ensure the quality of electrical assembly of the product and its safety once it is subjected to very high voltages, which is a possible condition that may occur under operation.

After the complete assembly of the PEMFC stack, a crucial step is to verify two parameters, in order to evaluate the electrical behavior of the component:

  • Insulation resistance
  • Dieletric strength, under a voltage greater than the insulation resistance test

Both tests procedure might by carried out either with cooling circuit filled or not, giving different results but also a complete overview about the quality of the product.

Electrical Test

Single station HV test for PEMFC SAM (Stack Assembly Module), Single Stack and Two Single Stacks, with manual loading/unloading.

Principle of measurement: Insulation resistance and Dielectric strength (using High Voltage supply), by way of a Hipot tester.

The bench provides a single station, assembled on a welded painted steel frame with cover panels and automatic door. The cabinet containing the electric switchboard is on the left-hand side of the bench, while the process components, including the measuring devices, are located on the right-hand side. The access to the stations is protected by safety light curtains. Only electrical supply and air supply are needed to run the machine.

The measuring device is installed in the bench, with its panel on the front. It allows to give the stack the required supply in terms of voltage and to measure the electrical response, either in terms of resistance or current.

The fixture is automatically actuated and allows the coupling between the bench and the interface of the stack under test, by way of a multi-coupling plate (which also includes the high voltage connection).


The bench incorporates an industrial PC which performs HMI functions while supervision of the process is made by a PLC. The software is configurable so that it is possible to:

  • Set machine parameters
  • Create different recipes, according to required test parameters
  • Manage the automatic cycle as well as the manual cycle
  • Set counters and production data
  • Manage levels of access

The bench is also provided with a master OK, which integrates two different certified resistances (one for each test), so that it is possible to guarantee the accuracy of the measurement performed by the machine.

The master cycle can be done at the starting of the machine, at the beginning of each shift or whenever it should be better to carry out this calibration procedure.


  • Dedicated electric cabinet
  • Easy access to process circuit by way of front doors
  • Configurable HMI touch screen interface
  • Push button panel and light signals for easiness of the operator
  • High accuracy of the system
  • RFID System and Datamatrix reader for traceability purposes
  • Test performed in DC with a single electronic device
  • IT Interfaces are provided and MQTT (Message Queue Telemetry Transport) and TCP/IT (Transmission Control Protocol/Internet Protocol) transmission protocols are implemented
  • Insulation test resistance voltage: 1000 VDC
  • Insulation resistance limit at 1000 V: >200 MΩ
  • Dielectric strength test voltage: 2150 VDC
  • Dielectric strength limit at 2150 V: <1.0 mA
  • Cycle time: approx. 80 s

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