Optimal design and proper operation are important to get aimed output power of a polymer electrolyte membrane fuel cell (PEMFC) stack. An air cooling fuel cell stack is widely used in sub kW PEMFC systems. The purpose of this study is to analyze operating conditions affecting the performance of the air cooling PEMFC which is designed for portable application. In portable applications, air cooling stack is difficult to maintain well balanced operating conditions. The importart parameters are the relative humidity, the temperature of the stack, the utilization of reactant gas and so on. in this study, a 500W air cooling PEMFC was fabricated and tested to evaluate the design performance and to determine optimal operating conditions. Moreover, basic modeling also is carried out. These results can be used 3s design criteria and optimal operating conditions for portable PEMFCs