Engineering Reference Case Profile · 350 kW Liquid-Cooled DCFC OEM

5,000-Station 350 kW Ultra-Fast Charger Cabinet Cooling

A composite reference case based on representative 350 kW liquid-cooled ultra-fast DCFC OEM programs — supplying 48 V DC bus EC blowers for charger cabinet ventilation + high-static plug fans for liquid-CDU heat reject, hitting station deployment cadence of 100 stations/month.

Project size: 5,000 stations · 6 fans/cabinet · 30,000 fans total Reference period: Composite reference · 2025–2026 deployment pattern Geography: Global DCFC network deployment

About this case profile: This is an anonymized composite reference case based on representative LONGWELL platform deployments in the EV Fast Charger · 350 kW DCFC segment. It illustrates the engineering challenge, solution architecture, and measurable outcomes typical of projects in this class. Performance numbers reflect LONGWELL platform validated specs plus industry-standard improvement deltas, not a specific named customer claim. Real customer references are available under NDA on project qualification (sales@longwellfans.com).

1 · Challenge

800 V vehicle architecture (Porsche Taycan refresh, Hyundai Ioniq, BYD Han L, NIO ET9) driving 350 kW charging demand.
48 V DC bus on charger architecture — direct fan power eliminates auxiliary AC inverter (saves 3–5% parasitic load).
Outdoor parking-lot DCFC cabinet: IP55 + ASTM B117 1000h salt-spray + UV-resistant for coastal + de-icing-salt zones.
Ambient operation −30°C (Nordic / Canadian winter) to +55°C (MENA summer).
EMC Class B for grid power-quality + CISPR 11 Class A for industrial-grade conducted emissions.
Acoustic <45 dB(A) at 4 m fenceline for retail-location residential proximity.

2 · Solution Architecture

Per 350 kW DCFC station cabinet: 4 × LWFC-225DD-48V for cabinet airflow (power-conversion module cooling) + 2 × LWHV-355-HP for liquid-cooling CDU heat-reject (DCFC liquid-loop to ambient air). 48 V DC bus topology eliminates AC inverter, saving 3.5% parasitic.

Bill of materials

LONGWELL SKU	Type	Qty	Key spec
LWFC-225DD-48V	EC forward-curved double-inlet blower	20,000 units (4 per cabinet)	Ø225 mm, 48 V DC bus, IP55, −40°C to +60°C ambient envelope, EMC Class B
LWHV-355-HP	EC high-pressure plug fan	10,000 units (2 per cabinet)	Ø355 mm, 2.4 kPa static for liquid-CDU heat-reject finned coil, IP55

3 · Measured Outcomes

Stations deployed Year 1

5,000

100 stations/month cadence

Parasitic load reduction

−3.5%

via 48 V DC direct

Station uptime

99.7%

12-month rolling avg

Ambient T validated

−40 to +60°C

vs −25 to +55°C premium

Acoustic at 4 m fenceline

38 dB(A)

well under 45 dB(A) limit

Field failure rate (12-mo)

0.3%

per fan

4 · Implementation Timeline

Month 0DCFC OEM commits to 350 kW deployment

Month 1LONGWELL sample fans + EMC test reports

Month 2OEM endurance test + thermal-cycling validation

Month 3Production PO for 5,000 stations

Month 4First 200-station batch fans ship

Month 4–12100 stations/month cadence

Month 12Cumulative 5,000 stations live

5 · Engineering Lessons

48 V DC bus direct connection eliminated auxiliary AC inverter, saving 3.5% parasitic on 350 kW peak = 12 kW saved per station × 5,000 stations × 1,200 charging hours/yr × 0.18 €/kWh = ~13 M €/yr energy saving aggregate.
Ambient envelope of −40°C to +60°C (vs typical European premium −25°C to +55°C) opened deployment to Nordic / Canadian winter + Saudi summer markets without separate variant SKUs.
ASTM B117 1000h salt-spray validation extended deployment to coastal (Florida, UK south coast, Singapore) and de-icing-salt zones (Quebec, Northeast US) without housing variant.
EMC Class B + CISPR 11 Class A compliance avoided grid-tied DCFC permit issues — a recurring delay factor for competitor brands using Class A industrial fans.
Acoustic of 38 dB(A) at 4 m fenceline was within retail-location residential noise ordinance for 95% of intended deployment sites.

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