Engineering Reference Case Profile · Asia-Pacific R290 OEM Volume Program

50,000-Unit R290 Monobloc Heat Pump Fan Program · 12 kW Class

A composite reference case based on representative R290 monobloc heat pump OEM programs in the Asia-Pacific volume retail segment — supplying axial EC fans for 12 kW residential monobloc with 75°C ambient validation, IEC 60335-2-40 spark-free, and 4-week ramp from spec to first SKU shipment.

Project size: 50,000 units/year · 12 kW R290 monobloc Reference period: Composite reference · 2025–2026 deployment pattern Geography: Asia-Pacific OEM segment

About this case profile: This is an anonymized composite reference case based on representative LONGWELL platform deployments in the Heat Pump OEM · R290 Monobloc 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

EU F-gas regulation 2024/573 driving accelerated R290 propane adoption. OEM committed to R290 monobloc by 2025.
R290 monobloc operates at 75°C discharge plenum ambient during heating-mode peak — standard European EC fans (rated +60°C) thermal-trip.
IEC 60335-2-40 spark-free certification required for residential R290 — eliminates AC induction motor with arcing contacts.
Premium spec called for ebm-papst W3G800 GreenTech but 14–22 week lead time blocked retail SKU rotation cadence.
OEM target: 50,000 units/year ramping in 12-month window, with 4-week production lead time after first sample validation.

2 · Solution Architecture

Single LWAE3G-630-R290 mounted on top of monobloc enclosure in standard heat-pump discharge plenum geometry. Drop-in dimensional match to ebm-papst W3G800 footprint. Direct 230 V 1Φ supply, 0–10 V control from heat-pump controller. Spark-free certification documented per shipment with IEC 60335-2-40 Annex BB compliance statement.

Bill of materials

LONGWELL SKU	Type	Qty	Key spec
LWAE3G-630-R290	EC axial fan	50,000 units/yr	Ø630 mm, +75°C ambient validated, IEC 60335-2-40 spark-free, 65% η peak, IP55, sealed connection housing

3 · Measured Outcomes

SCOP impact

4.62 → 4.78

vs prior AC-induction fan, A7/W35

Annual energy delta

−380 kWh/unit

12 kW class, EU climate avg

Ambient T validated

+75°C continuous

vs +60°C European premium

CapEx vs ebm-papst W3G800

−48%

FOB equivalent spec

Lead time PO → shipment

4 weeks

vs 14–22 wk ebm-papst

Field warranty rate

0.4%

12-month rolling

4 · Implementation Timeline

Week 0OEM requests sample + IEC 60335-2-40 docs

Week 13 sample units shipped from stock

Week 2–3OEM endurance test + +75°C validation chamber run

Week 4Production approval + first 2,000-unit batch PO

Week 5–7First batch ships from Yuyao via sea freight

Month 3Series production at 4,200 units/month cadence

Month 12Cumulative 50,000 units shipped

5 · Engineering Lessons

+75°C ambient validation was the binding spec, not peak η. ebm-papst W3G800 standard rating is +60°C — heat-pump OEMs serving Mediterranean / Middle East / SE Asia retail need +75°C standard.
IEC 60335-2-40 spark-free certification per shipment (not as a one-time type test) is procurement-mandatory in EU residential R290 — annex BB compliance statement attached to bill of lading.
Sample lead time of 3 days from stock allowed parallel design iteration on adjacent components (enclosure ventilation cutout, condenser fin pitch) before tooling lock.
4-week production ramp matched OEM's SKU rotation cycle — ebm-papst 16-week alternative would have missed the heating-season retail launch window.
SCOP improvement of +0.16 vs prior AC fan moved the heat-pump from B-class to A+ on EU ErP energy label, eligible for higher EU subsidy rates.

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