Mobile Aviation 400Hz Load Bank, air-cooled and water-cooled versions, 5–180 kVA.

Introduction

The Neometrix Mobile Aviation 400 Hz Load Bank is an advanced test and validation platform designed specifically for aerospace power systems. It is offered in two distinct versions: an air-cooled unit — lightweight, compact and manually towable, suitable for low-to-medium power testing where mobility and quick deployment are essential — and a water-cooled unit — heavy-duty, tractor/vehicle towable, designed for continuous duty and high-capacity applications, providing stable long-duration performance under extreme environmental and load conditions.

Both versions are engineered to test 115/200 V, 400 Hz Ground Power Units (GPUs) and aircraft starter-generators, which are the backbone of modern aviation power infrastructure. Manufactured to aerospace and defence standards, the units are already in successful operation with Indian Air Force squadrons, Hindustan Aeronautics Limited (HAL), and multiple global aerospace clients.

Key features

• Configurable load steps: modular increments (5, 10, 20, 30... up to full rated capacity) allow precise adjustment of load for varying aircraft electrical demands.
• Advanced control & monitoring: PLC/HMI touchscreen, multifunction LED meters for voltage, current, power factor, frequency and kW output, programmable test timers, and optional Ethernet/USB data logging.
• Safety systems: triple thermal protection with automatic trips, fan-failure and (water-cooled) pump-failure alarms, over-current/voltage/frequency trips, illuminated emergency stop, and phase sequence and grounding interlocks.
• Resistive elements: NiCr/FeCrAl stainless steel alloy resistors optimized for 400 Hz operation, corrosion-resistant and mechanically robust for repeated heavy load cycles.
• Build quality: industrial-grade steel frame with powder-coated finish, IP54–IP65 protection, and modular construction for quick maintenance.
• Support: supplied with a 2-year spares and service kit, designed for a 10+ year lifecycle in continuous deployment environments.

Applications

The dual-version design ensures wide applicability across civil and military aviation environments:

• Ground Power Unit (GPU) validation: full-range validation (5–180 kVA) of 115/200 V, 400 Hz GPUs, ensuring power quality, voltage stability and overload response meet aviation standards.
• Aircraft starter-generator testing: supports both generator mode (simulating electrical output to aircraft systems) and starter mode (accepting power input to drive turbine starter motors).
• Engine decarbonization & conditioning: running diesel-driven GPUs at sustained high loads prevents carbon buildup, improves efficiency and extends service life.
• Load rejection & transient stability testing: simulates sudden load application and shedding, validating GPU and generator stability, response times and protective relay functions.
• Factory Acceptance Testing (FAT) for OEMs: essential for OEM workshops producing GPUs, alternators and power equipment before dispatch to end-users.
• Field deployment & workshop maintenance: air-cooled models are easily transported inside workshops or hangars; water-cooled models are rugged, tractor-towable units for runways, military bases and remote airfields.

Advantages over conventional load banks

• Dual-version availability: flexible choice between air-cooled portability and water-cooled durability.
• Operational flexibility: simulates real-world aircraft electrical loads under stable and transient conditions.
• Reliability in harsh conditions: proven performance from −30°C to +50°C, designed for rugged military environments.
• Ease of maintenance: modular resistors, accessible components and quick-swap cooling elements reduce downtime.
• Global deployment proof: successfully used by defence forces and international aviation industries.
• Cost efficiency: lower lifecycle costs compared to static test equipment, with portability enabling multi-site utilization.

Conclusion

The Neometrix Mobile Aviation 400 Hz Load Bank stands as a benchmark in aviation power testing technology. The air-cooled version offers a compact, mobile, low-cost solution for smaller capacity and portable testing needs; the water-cooled version is a robust, heavy-duty system built for continuous operation, high capacity and military-grade performance. Together, these versions cover the complete spectrum of GPU and starter-generator testing, ensuring accuracy, safety and reliability across civil airports, defence airbases, OEM production lines and MRO workshops worldwide.