WFCO WF-68100 Series - User Manual

The WF-68100 Series Deckmount Converter-Charger is a crucial component for recreational vehicles (RVs), serving as the "heartbeat" of their electrical systems. Its primary function is to convert AC power from a shore power source into DC power, which is then used to operate 12-volt DC appliances within the RV and to charge the house battery. This device ensures that RV owners have a reliable power supply for their lights, radios, refrigerators, and other electronics, whether they are connected to an AC source or operating off-grid.

One of the key usage features of the WF-68100 Series is its Three-Stage Smart Charging capability. This intelligent charging system continuously monitors the battery voltage output and regulates the amount of charge using three distinct modes: Absorption, Bulk, and Float. This sophisticated approach not only ensures efficient charging but also plays a vital role in extending the life of the RV's battery.

The Absorption Mode is the default or normal operation, providing an output of 13.6 volts DC. In typical usage, RVs are designed to receive ample DC output power in this mode, making it the most frequently used stage. When a battery is connected, the converter supplies power for charging whenever its output voltage is greater than the battery's voltage level. If the battery is significantly discharged, the current draw from the converter to the battery will be high, gradually decreasing as the battery approaches a full charge. This mode is efficient enough to charge a completely discharged battery to a fully charged level within a few hours, even with additional DC loads connected.

The Bulk Mode is designed for situations where the battery is significantly discharged and requires a faster charge than Absorption Mode can provide. The converter's microprocessor continuously monitors the DC line voltage. When a preset voltage level is detected, the converter boosts its output to 14.4 VDC. This increased voltage accelerates the charging process while simultaneously supplying power to the RV's DC appliances. The converter will remain in Bulk Mode for a maximum of four hours or until the total amperage draw from the converter drops to a preset point, indicating the battery is charged. This feature is crucial for quickly re-energizing a depleted battery, ensuring that RV users can get back to full power swiftly.

Finally, the Float Mode is the third stage of operation, providing a trickle charge to the battery. If the converter observes no significant variations in current draw for approximately 44 continuous hours, it will reduce its output from 13.6 VDC to 13.2 VDC. This lower voltage maintains the battery's charge when the RV is not in active use, preserving battery life and keeping it ready for use. A change in DC current will cause the converter to exit Float Mode and return to the default Absorption Mode. Even in Float Mode, the converter continues to supply a trickle charge, making it suitable for long-term storage, though periodic checks of battery fluid levels are recommended.

The WF-68100 Series also incorporates several important safety and maintenance features. One such feature is Reverse Battery Protection. The unit is equipped with three reverse polarity fuses located on the rear panel near the AC power cord. These fuses protect the converter circuitry from permanent damage if the RV battery is accidentally connected backward. If a reverse connection occurs, these fuses will blow, preventing harm to the converter. This feature is critical for both the longevity of the converter and the safety of the RV's electrical system. Replacing these fuses with the correct type and amperage rating is a simple maintenance task that can be performed by a qualified technician.

Another key maintenance feature is the Automatic Cooling Fan. Unlike traditional temperature-controlled fans, the WF-68100 Series uses a 2-stage load-controlled fan. An on-board microprocessor adjusts the fan speed based on the current drawn from the converter to the applied load. As the total load increases, the fan speed increases, and vice versa. This load-controlled design provides superior component cooling by preventing temperature spikes, which can lead to premature component failure. This proactive cooling mechanism enhances the reliability and lifespan of the converter.

The device also includes Over-Temperature Protection. If the internal temperature of the converter exceeds a critical threshold, the unit will automatically shut down to prevent damage to sensitive components. Once the internal temperature drops to a safe level, the unit will restart, ensuring continuous protection against overheating.

Electronic Current Limiting is another protective feature. In cases where the output current exceeds the maximum rating, the converter will maintain a constant output current while the output voltage begins to drop. The unit will recover once the loads are reduced, preventing overload damage.

For further safety, Short-Circuit Protection is integrated. If a short circuit occurs in the RV's electrical system, the WF-68100 Series Converter-Charger will drop its voltage output to zero volts. Once the short-circuit condition is resolved and no other faults are detected, the converter will resume normal operation. However, due to the inherent dangers of short circuits, an RV experiencing such an event should be inspected by a qualified service technician.

The Front Panel Features provide quick visual indicators of the converter's operating status. A Green LED indicates normal operation when connected to 110 VAC. An Amber LED, when steady ON, signifies that the battery is discharging while operating on battery power only; if flickering, it indicates that the battery is approaching a low level. A Red LED illuminates if a fault has been detected in one of the protection circuits, such as overload, over-temperature, or short-circuit. Notably, the Red LED does not light up for battery reverse polarity, as that condition is handled by the fuses. Additionally, a Manual Override switch is provided to force the converter into Bulk Mode for quick battery charging, though caution is advised to avoid overcharging a fully charged battery.

Installation of the WF-68100 Series Converter-Charger requires careful consideration. The enclosure should be mounted in an accessible area, such as a wall or within a cabinet, away from excessive heat, water, moisture, dust, and dirt. A minimum of two cubic feet of clear airspace or additional venting is necessary to prevent overheating and ensure proper airflow for the cooling fan. An 8AWG copper conductor must be used to bond the converter-charger to the vehicle frame for safety. DC connections involve connecting a Red 2 AWG wire to the POS+ lug and a Black 2 AWG wire to the NEG- lug on the distribution center's fuse board, ensuring proper torque. For AC connections, the unit receives power via a 20 Amp power cord, and the corresponding 20 Amp receptacle must be wired back to the fuse box using a minimum of 12AWG wire.

The Battery Select Switch is a 2-position slide switch that allows users to select between Lead Acid/AGM and Gel battery types. In the Lead Acid/AGM position, the converter outputs both Absorption and Bulk Mode voltages. When set to the GEL position, the output remains in Absorption Mode, disabling Bulk Mode to prevent potential damage to Gel batteries, which require different charging profiles.

Troubleshooting is made easier with a comprehensive guide. If there's no DC output, checks include verifying the RV's connection to a 110 Vac source, ensuring ceiling lights and other DC items operate, and inspecting the reverse polarity fuses. If fuses are blown, it indicates a reversed battery connection, which must be corrected before replacing the fuses. Loose wiring connections are also a common issue to check. If these steps don't resolve the issue, and the converter output remains at 0.0 VDC, the converter may be defective and require replacement.

The WF-68100 Series Converter-Charger is UL-Listed and cUL-Listed (Canadian), ensuring compliance with safety standards. It also adheres to FCC Compliance Class B limits, designed to provide reasonable protection against harmful interference in commercial environments, and users are advised to correct any interference in residential settings at their own expense.

In summary, the WF-68100 Series Deckmount Converter-Charger is a robust and intelligent power management solution for RVs, offering advanced charging capabilities, comprehensive safety features, and user-friendly indicators, all designed to ensure reliable and efficient operation of the RV's electrical system.

WFCO WF-68100 Series Specifications

General

Cooling	Fan Cooled
Input Frequency	60Hz
Number of Stages	3
Absorption Voltage	14.4 VDC
Charging Stages	Bulk, Absorption, Float
Output Voltage	13.6 VDC
Output Current	100A
Float Voltage	13.6 VDC
Battery Compatibility	Lead-Acid, AGM, Gel
Protection Features	Over Temperature
Operating Temperature	0°C to 40°C