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 · Modelled Outcomes — Typical Range

How to read these figures: the values below are modelled for this composite scenario. They are a planning range, not measured results from one named project. Verified data from real deployments is in Section 6.

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.

6 · Verified Project Evidence

Everything below is drawn from actual project correspondence. Model numbers, duty points and certification basis are stated as they occurred. Customer names are withheld; no pricing is published.

Germany — R290 cabinet, EC axial with ETL/UL matching

Sampling

Why R290 changes the fan selection: propane is flammable, so the certification basis of the motor and its enclosure has to match the appliance approval route. Airflow and pressure are the easy part.
EC axial fans were selected against the customer’s ETL / UL requirement and sampled for their unit.

New Zealand — heating heat-pump manufacturer, low-noise blade

Custom tooling · sampling

Developed: a closed-hub axial impeller specifically for low noise, tooled and sampled for the customer’s outdoor unit.
The closed hub reduces recirculation at the blade root, which is where a large share of the broadband noise in an outdoor unit is generated.

United Kingdom — heat-pump heating unit, plastic axial blade

Sampling

Sampled: a 493 × 143 mm plastic axial impeller matched to the unit’s existing motor and shroud.

Europe — heat pump and fan-coil terminals, DC cross-flow

Custom motor position · sampling

DC cross-flow fans developed with left- and right-hand motor positions so one terminal design can be mirrored without a second fan part number.

LONGWELL AC axial fan sample with wire guard on the production bench — Axial fan sample on the bench during evaluation build.

LONGWELL factory floor with racks of motor stators, assembly stations and balancing test benches — The motor line behind these programmes: racks of wound stators feeding assembly stations, with balancing and electrical test benches in the same bay. Building the motor in-house is what makes a low-noise closed-hub impeller or a wide-input DC board a development project rather than a sourcing problem.

Fan performance figures are quoted from LONGWELL controlled datasheets and are tested per AMCA 210/211 methods; third-party reports available on request. EC versus AC energy saving is approximately 30%, higher under strongly varying load — confirm against your own load profile. Final selection must be confirmed against the actual duty point (airflow / static pressure / voltage / control method) and project validation.

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