How to Extend the Lifespan of Your Ground Power Unit (GPU): 5 Simple Tips
Tips to Keep Your GPU Running Longer
Ground Power Units (GPUs) are essential for powering aircraft safely and efficiently while on the ground. With proper care, you can significantly extend their service life, reduce operating costs, minimize downtime, and support sustainability goals. Whether you operate at a busy international airport, a regional airfield, an MRO facility, or a military base, these five practical tips will help you get the most out of your GPU investment.
Overview
Ground Power Units (GPUs) are the backbone of modern aviation ground support. They provide reliable 28V DC or 400Hz AC power to aircraft parked on the apron or inside hangars, keeping essential systems such as avionics, lighting, cabin climate control, and onboard electronics fully operational without the need to run the APU.
Because GPUs are used in challenging environments, from hot desert runways to freezing northern airports, proper maintenance is essential to maximize their performance, safety, and cost efficiency. A well-maintained GPU ensures uninterrupted power supply, minimizes the risk of technical delays, and reduces stress on sensitive aircraft systems. Extending the lifespan of your GPU not only saves money on costly repairs and replacements but also guarantees smoother day-to-day operations. For airlines and airports, it helps reduce operating costs, cut unnecessary fuel burn from APUs, and meet sustainability goals by lowering energy waste and emissions.
Below, we outline five simple yet powerful tips that any operator, from regional airfields to major international hubs, can implement today to extend the service life of their GPU.
1. Perform Regular Preventive Maintenance
ike any industrial equipment, aircraft Ground Power Units (GPUs) thrive on preventive care. Waiting until something breaks often leads to costly downtime and in aviation, every minute counts, as unplanned failures can delay flights, disrupt schedules, and increase operational costs.
- Scheduled inspections: establish a maintenance routine, typically every 250-500 operating hours, or at least quarterly, depending on manufacturer guidelines and usage intensity.
- Oil and filters: for diesel or hybrid GPUs, regularly replace engine oil, air filters, and fuel filters. Clogged filters can cause overheating, reduced fuel efficiency, and even complete engine failure.
- Connections and cables: inspect power connectors, cables, and hoses for wear and tear. Cracked insulation or damaged plugs not only reduce efficiency but also create safety hazards for ground staff and aircraft systems.
- Software updates: modern GPUs, such as ElectroAir’s APA-ECO series, include smart digital monitoring. Keeping firmware and diagnostic software updated ensures accurate performance tracking and early fault detection.
2. Operate Within Recommended Load Limits
One of the most common causes of aircraft GPU damage is running the unit outside its designed operating capacity. Exceeding safe limits not only stresses components but can also lead to overheating, unstable voltage supply, and potential damage to sensitive aircraft systems.
- Respect the ratings: always match the GPU’s output (28V DC or 400Hz AC, and the maximum kVA rating) with the aircraft’s requirements. Overloading accelerates wear on rectifiers, inverters, and cooling systems.
- Avoid unnecessary idling: leaving a diesel GPU running without load wastes fuel, causes carbon buildup, reduces engine life, and increases emissions, which may conflict with airport sustainability programs.
- Use battery/hybrid modes wisely: for battery-powered or hybrid GPUs, follow recommended charge/discharge cycles. Over-discharging can shorten battery lifespan by up to 30%, while improper charging increases downtime and replacement costs.
3. Keep Your GPU Clean and Protected
Airports, ports, and military bases are tough environments for Ground Power Units. Dust, sand, moisture, and salt not only accelerate wear but can also trigger overheating, unstable output, or premature electronic failure if left unchecked.
- Regular cleaning: remove accumulated dirt from ventilation grilles, filters, and cooling fans to prevent overheating and airflow restriction. Blocked air channels can raise internal temperature by more than 15°C, reducing component lifespan.
- Protect against weather: if a GPU is not in active use, always store it under a canopy, in a hangar, or inside a protective enclosure. Rain, snow, or direct UV exposure accelerate paint degradation and damage electrical systems.
- Corrosion prevention: for maritime or coastal operations, apply anti-corrosion sprays and regularly check enclosure integrity. Salt exposure can corrode connectors within weeks and compromise insulation resistance.
4. Train Your Operators
Even the most advanced Ground Power Unit (GPU) can suffer damage if not handled correctly. In aviation, where safety and efficiency are critical, human error is one of the most common causes of equipment downtime. Investing in proper operator training is one of the simplest and most cost-effective ways to extend the lifespan of your GPU and ensure smooth day-to-day operations.
- Start-up and shutdown procedures: always follow the correct sequence when powering up and shutting down a GPU. Incorrect handling can cause dangerous voltage spikes, damage sensitive aircraft electronics, and shorten component life.
- Cable management: properly winding, storing, and inspecting power cables prevents internal conductor breakage, reduces wear, and avoids overheating at connectors. Good practices also improve safety on the apron by reducing trip hazards.
- Error recognition: train staff to quickly identify warning lights, unusual noises, or abnormal vibrations. Early detection of faults allows maintenance teams to intervene before small issues turn into costly repairs.
5. Embrace Digital Monitoring and Smart Diagnostics
The future of ground power is undeniably digital. Modern GPUs are no longer just power suppliers, they are becoming intelligent tools that can predict issues, optimize performance, and extend equipment life. By embracing digital monitoring, operators can transition from reactive maintenance to a truly proactive strategy.
- Telematics & IoT: real-time data on energy consumption, load profiles, operating temperature, and usage hours allow maintenance teams to act with precision rather than assumptions.
- Predictive maintenance: advanced analytics highlight wear patterns and potential failures before they occur, enabling targeted interventions that save both time and money.
- Remote support: solutions such as ElectroAir’s APA-ECO and EACR series integrate smart diagnostics, allowing technicians to identify and even resolve issues remotely, reducing downtime and minimizing costly onsite troubleshooting.
Final Thoughts
Ground Power Units (GPUs) are more than just equipment, they are the backbone of efficient and reliable ground operations. Like any long-term investment, they require care and attention to deliver maximum returns. With preventive maintenance, correct usage, operator training, and smart monitoring, your GPU can provide dependable service for many years while reducing total cost of ownership.
For over 19 years, ElectroAir has been pioneering innovative ground power solutions, from hybrid and battery-powered APA-ECO units to advanced stationary EACR combined systems. Our mission is to help airports, airlines, and MROs achieve greater efficiency, meet sustainability targets, and ensure uninterrupted ground support under any conditions.
Ready to extend the life of your GPU fleet?
From audits and operator training to predictive maintenance and remote monitoring, ElectroAir provides full lifecycle support for your ground power units. Let’s work together to reduce downtime, optimize costs, and keep your operations running smoothly.