Details

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:
1. Air-Cooled Mobile Load Bank – lightweight, compact, and manually towable, suitable for low-to-medium power testing requirements where mobility and quick deployment are essential.
2. Water-Cooled Mobile Load Bank – heavy-duty, tractor/vehicle towable systems 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. With a focus on accuracy, reliability, and safety, Neometrix ensures these load banks can replicate the exact electrical stresses experienced by aircraft systems during operation.

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. Their field-proven reliability makes them an indispensable asset for maintenance depots, MROs (Maintenance, Repair & Overhaul), and OEM testing facilities.

Applications
The dual-version design ensures wide applicability across civil and military aviation environments:
Ground Power Unit (GPU) Validation
Load banks provide full-range validation (5–180 kVA) of 115/200 V, 400 Hz GPUs, ensuring power quality, voltage stability, and overload response meet required aviation standards.

Aircraft Starter-Generator Testing
The system supports both generator mode (simulating electrical output to aircraft systems) and starter mode (accepting power input to drive turbine starter motors), covering the full lifecycle of starter-generator validation.

Engine Decarbonization & Conditioning
Diesel-driven GPUs require periodic descaling and conditioning. By running GPUs at sustained high loads, the load bank 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 under real-world conditions.

Factory Acceptance Testing (FAT) for OEMs
Essential for OEM workshops producing GPUs, alternators, and power equipment, ensuring systems are tested before dispatch to end-users.

Field Deployment & Workshop Maintenance
  ▹ Air-Cooled models: Easily transported inside workshops or hangars, rapidly deployable with minimal setup.
  ▹ Water-Cooled models: Rugged, tractor-towable units ideal for runways, military bases, and remote airfields where continuous operation is required.

Versions
1. Air-Cooled Mobile Load Bank
• Target Use: Low-to-medium power GPU testing (typically up to 60 kVA).
• Cooling: Forced-air cooling with high-efficiency industrial blowers.
• Mobility: Compact, trolley-based chassis, manually towable by two operators.
• Advantages:
  ▹ No plumbing or water infrastructure required.
  ▹ Reduced lifecycle cost and maintenance overhead.
  ▹ Rapid setup and teardown for field engineers.
• Ideal For: Small airports, MRO workshops, and operators needing portable GPU testers.

2. Water-Cooled Mobile Load Bank
• Target Use: Heavy-duty continuous operation up to 150–180 kVA.
• Cooling: Closed-loop water circulation system for efficient heat dissipation, preventing resistor overheating under extended duty cycles.
• Mobility: Robust trailer-mounted chassis, tractor/vehicle towable (example: 150 kVA unit weighing ~2300 kg).
• Advantages:
  ▹ Handles long-duration continuous testing without overheating.
  ▹ More compact footprint relative to equivalent air-cooled designs.
  ▹ Capable of withstanding high ambient temperatures (up to +50 °C).
• Ideal For: Defence bases, OEM production lines, and continuous-duty testing at large aviation hubs.

Key Features
Configurable Load Steps
Modular increments (5, 10, 20, 30... up to full rated capacity) allow precise adjustment of load, enabling accurate simulation of varying aircraft electrical demands.

Advanced Control & Monitoring
  ▹ PLC/HMI touchscreen for operator-friendly interface.
  ▹ Multifunction LED meters displaying voltage, current, power factor, frequency, and kW output.
  ▹ Programmable timers for test duration, runtime logging, and reporting.
  ▹ Optional data logging & remote monitoring interface (Ethernet/USB).

Safety Systems
  ▹ Triple thermal protection with automatic trips.
  ▹ Fan-failure and (for water-cooled) pump-failure detection alarms.
  ▹ Over-current, over-voltage, and over-frequency trip systems.
  ▹ Emergency stop with illuminated status indicators.
  ▹ Phase sequence monitoring and grounding interlocks.

Resistive Elements
  ▹ NiCr/FeCrAl stainless steel alloy resistors optimized for 400 Hz operation.
  ▹ Long service life, corrosion-resistant, mechanically robust.
  ▹ Maintains thermal stability for repeated heavy load cycles.

Build Quality & Protection
  ▹ Industrial-grade steel frame with powder-coated finish.
  ▹ Protection class: IP54–IP65 (suitable for outdoor use).
  ▹ Modular construction for quick maintenance.

Support & Lifecycle
  ▹ Supplied with a 2-year spares and service kit.
  ▹ Designed for 10+ years lifecycle in continuous deployment environments.

Technical Specifications (Typical Range)

  

    
Parameter
    
Air-Cooled Version
    
Water-Cooled Version
  
  

    
Rated Capacity
    
5 – 60 kVA (modular)
    
Up to 180 kVA (continuous duty)
  
  

    
Operating Voltage
    
115/200 V, 400 Hz AC
    
115/200 V, 400 Hz AC
  
  

    
Load Step Resolution
    
5, 10, 20, 30 kVA
    
5, 10, 20, 30… up to full capacity
  
  

    
Cooling
    
Forced-air fans
    
Closed-loop water cooling with pump & radiator
  
  

    
Mobility
    
Trolley-based, manually towable
    
Trailer-based, tractor/vehicle towable
  
  

    
Weight
    
~200–400 kg (depending on rating)
    
~2300 kg (150 kVA model)
  
  

    
Control System
    
PLC/HMI touchscreen + multifunction meters
    
PLC/HMI touchscreen + multifunction meters
  
  

    
Safety Features
    
Overload, thermal, over-voltage/frequency
    
Overload, thermal, over-voltage/frequency, water-cooling alarms
  
  

    
Deployment
    
MRO workshops, hangars, smaller airports
    
Military bases, OEM facilities, major airports
  
  

    
Accessories
    
2-year spares & service kit
    
2-year spares & service kit
  


Advantages Over Conventional Load Banks
• Dual-Version Availability – Flexible choice between air-cooled portability and water-cooled durability.
• Operational Flexibility – Can simulate 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, ensuring compliance with aerospace testing protocols.
• Cost Efficiency – Lower lifecycle costs compared to static test equipment; portability ensures multi-site utilization.

Conclusion
The Neometrix Mobile Aviation 400 Hz Load Bank stands as a benchmark in aviation power testing technology.
• Air-Cooled Version: compact, mobile, low-cost solution for smaller capacity and portable testing needs.
• Water-Cooled Version: 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.