WFCO WF-8540-AD-MBA - User Manual

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Summary

General Information

Automatic Cooling Fan

Details the fan's control mechanism based on current drawn from the converter to the applied load.

Over-Temperature Protection

Explains the unit's shutdown mechanism to prevent damage from excessive internal temperature.

Circuit Protection

Electronic Current Limiting

Describes how output current remains constant as voltage drops when exceeding maximum rating.

Short-Circuit Protection

Explains the converter's response to short circuits, dropping voltage to zero volts.

Reverse Battery Protection

Details fuses protecting the MBA circuitry from reverse battery connections.

Operational Features

Auto Detect

Explains the feature that evaluates and selects the correct charging program for batteries.

Smart Charging Modes

Explains 3-stage (Bulk, Absorption, Float) and 2-stage charging for different battery types.

Troubleshooting Instructions

Checking Converter Output Voltage

Provides steps to measure output voltage and diagnose issues using a voltmeter.

Checking for Reverse Polarity Battery Hookup

Guides on checking reverse polarity fuses and battery connections when no DC output is present.

AC Reverse Polarity (Audible Alarm)

Explains the audible alarm feature for incorrect AC wiring connections.

Replacing the Converter Section (MBA)

Details the step-by-step procedure for removing and installing the converter section.

General Compliance Information

Agency Listings

Details UL and cUL certifications for the product.

FCC Compliance Class B

Covers the device's compliance with FCC rules for digital devices.

Installation and Mounting

Refers to the procedure for removing and installing the converter section.

Consumer Limited Warranty

Exclusions and Limitations

Lists conditions under which the warranty is not applicable.

Consumer Warranty Claim Procedure

Outlines the steps required to file a warranty claim with WFCO.

Specifications

WF-8500-AD-MBA Specifications Table

Presents detailed technical specifications for the WF-8500-AD-MBA series.

Summary

General Information

Automatic Cooling Fan

Details the fan's control mechanism based on current drawn from the converter to the applied load.

Over-Temperature Protection

Explains the unit's shutdown mechanism to prevent damage from excessive internal temperature.

Circuit Protection

Electronic Current Limiting

Describes how output current remains constant as voltage drops when exceeding maximum rating.

Short-Circuit Protection

Explains the converter's response to short circuits, dropping voltage to zero volts.

Reverse Battery Protection

Details fuses protecting the MBA circuitry from reverse battery connections.

Operational Features

Auto Detect

Explains the feature that evaluates and selects the correct charging program for batteries.

Smart Charging Modes

Explains 3-stage (Bulk, Absorption, Float) and 2-stage charging for different battery types.

Troubleshooting Instructions

Checking Converter Output Voltage

Provides steps to measure output voltage and diagnose issues using a voltmeter.

Checking for Reverse Polarity Battery Hookup

Guides on checking reverse polarity fuses and battery connections when no DC output is present.

AC Reverse Polarity (Audible Alarm)

Explains the audible alarm feature for incorrect AC wiring connections.

Replacing the Converter Section (MBA)

Details the step-by-step procedure for removing and installing the converter section.

General Compliance Information

Agency Listings

Details UL and cUL certifications for the product.

FCC Compliance Class B

Covers the device's compliance with FCC rules for digital devices.

Installation and Mounting

Refers to the procedure for removing and installing the converter section.

Consumer Limited Warranty

Exclusions and Limitations

Lists conditions under which the warranty is not applicable.

Consumer Warranty Claim Procedure

Outlines the steps required to file a warranty claim with WFCO.

Specifications

WF-8500-AD-MBA Specifications Table

Presents detailed technical specifications for the WF-8500-AD-MBA series.

This document is the operator's manual for the WF-8500-AD-MBA Series Main Board Assembly (MBA) power converters, specifically covering the WF-8540-AD-MBA and WF-8560-AD-MBA models. These devices are designed for Recreational Vehicle (RV) applications, providing DC power and battery charging capabilities.

Function Description:

The WF-8500-AD-MBA Series power converters serve as the central power management unit in an RV, converting AC shore power (105-130Vac, 60Hz) into regulated DC power (13.6V nominal) to operate 12-volt appliances and charge the RV's house battery. A key feature is the exclusive "Auto-detect" technology, which automatically identifies the battery type (Lead Acid, AGM, or Lithium) and selects the appropriate charging program (profile) for optimal battery performance and longevity.

For Lead Acid and AGM batteries, the converter employs a Three-Stage Smart Charging system:

Bulk Mode: Initiated when the battery is discharged, the converter outputs 14.4 volts to rapidly restore energy. This mode is current-limited and will maintain 14.4V until the current draw drops to approximately five Amps or a four-hour timer expires.
Absorption Mode: The normal operating mode, providing a constant target output voltage of 13.6 volts (nominal) to power branch circuits and maintain the battery. This mode is current-limited, and if the output current reaches its maximum, the output voltage will drop to hold the maximum current level.
Float Mode: Designed to provide a "trickle charge" to the battery after prolonged periods of no significant current draw. The voltage reduces from 13.6V to 13.2V, helping to preserve battery life while keeping it charged and ready for use. A change in DC current will cause the converter to exit Float Mode and return to Absorption, and then to Bulk if needed.

For Lithium batteries, the converter uses a Two-Stage Smart Charging system:

Bulk Mode: Boosts the output voltage to 14.6 VDC, allowing maximum current flow to quickly restore energy and balance lithium cells. This stage can last from one to four hours, with a minimum of one hour for balancing and a maximum of four hours for empty batteries. Cycling power will reset the timers for larger battery banks.
Absorption Mode: Reduces the output voltage to 13.6 VDC, providing a safe operating voltage for all RV loads. This is the default or normal mode of operation for lithium batteries and has no timer associated with it.

Important Technical Specifications:

Model No.	WF-8540-AD-MBA	WF-8560-AD-MBA
Converter Input Power:
Voltage	105-130Vac	105-130Vac
Frequency	60Hz	60Hz
Max. Input Current @105Vac	8A	12A
Max Power	685 watt	1030 watt
Converter Output Power:
Continuous Power	550 watt	820 watt
Rated DC Output Voltage	13.6V	13.6V
Rated DC Current	40A	60A
Charging Control:
Charging Modes	3-stage Intelligent charge/2 stage intelligent charge	3-stage Intelligent charge/2 stage intelligent charge
Intelligent Charge Mode	Absorption, Bulk and Float (Storage)/Absorption & Bulk	Absorption, Bulk and Float (Storage)/Absorption & Bulk
Battery Adaptability	LA & AGM/Lithium Ion	LA & AGM/Lithium Ion
Absorption Charge Voltage	13.6V	13.6V
Bulk Charge Voltage (4 Hrs)	14.4V	14.4V
Storage Charge Voltage	13.2V	13.2V
Regulation	± 1% accuracy against input or load changes	± 1% accuracy against input or load changes
Cooling Fan	Speed according to the DC load amperage	Speed according to the DC load amperage
VA Efficiency	> 80% (under 70% of load condition)	> 80% (under 70% of load condition)
Protection:
Overload	Current-limiting & shut down; auto recovery upon return to normal load	Current-limiting & shut down; auto recovery upon return to normal load
Short-circuit	Shut down & auto recovery upon return to normal	Shut down & auto recovery upon return to normal
Over-temperature	Shut down & auto recovery upon return to normal	Shut down & auto recovery upon return to normal
Battery Reverse Polarity	Protected by Fuse; same rated fuse replacement required	Protected by Fuse; same rated fuse replacement required
Mechanical:
Dimension: W x H x D	174.5 x 86 x 179 mm / 6.86 x 3.38 x 7.01 inch	174.5 x 86 x 179 mm / 6.86 x 3.38 x 7.01 inch
Weight	2.43 kg/5.36 lbs.	2.63 kg/5.8 lbs.
Environmental Condition:	20~90% Non-condensing	20~90% Non-condensing
Safety:	UL458/UL67 certified; FCC Class B compliant	UL458/UL67 certified; FCC Class B compliant

Usage Features:

Automatic Cooling Fan: The fan speed is controlled by the current drawn out of the converter, increasing with load and decreasing as the load reduces. This load-controlled fan provides better component cooling compared to traditional temperature-controlled fans, preventing temperature spikes.
Over-Temperature Protection: If the internal temperature exceeds a critical point, the unit will shut down to prevent damage to sensitive components. It will restart once the temperature drops.
Electronic Current Limiting: If the output current exceeds the maximum rating, the output current remains constant, but the output voltage drops. The unit recovers once loads are reduced.
Short-Circuit Protection: In case of a short circuit in the RV, the converter drops the output voltage to zero volts. It resumes normal operation once the short-circuit condition is removed and no other faults are detected.
AC Reverse Polarity (Audible Alarm): The power center is equipped with an alarm that sounds if the incoming AC neutral and lead wires are connected backward, continuing until the AC wires are correctly connected.

Maintenance Features:

Reverse Battery Protection: Two reverse polarity fuses protect the MBA circuitry from damage if the RV battery is accidentally connected backward. These fuses are located along the left-center edge of the DC fuse board below the VCC+ lug. The fuse values vary by model: WF-8540-AD-MBA uses two 25A fuses, and WF-8560-AD-MBA uses two 35A fuses. These fuses also serve as the main connection between the MBA and the DC fuse board.
Fuse Replacement: Circuit fuses and Reverse Battery Protection fuses should be replaced with ATC or ATO automotive type fuses (e.g., Littelfuse type 257, Bussmann type ATC).
Troubleshooting Guide: The manual provides a detailed troubleshooting flow chart for diagnosing issues with the converter output voltage and reverse polarity fuses.
Replacing the MBA: Instructions are provided for removing and installing the converter section (MBA), including steps for disconnecting DC and AC wiring. This process involves loosening screws to remove the door assembly, disconnecting negative (NEG) and VCC+ wires from the fuse board, removing the converter's black wire from the breaker, white wire from the neutral bus bar, and green wire from the ground bus bar. Finally, two screws holding the MBA in place are removed, and 4-pin and 3-pin connectors are disconnected to fully remove the MBA. Installation is the reverse of these steps.
Warranty Information: A two-year limited product warranty is provided for WFCO electronic products used in Recreational Vehicle applications within the continental United States, Alaska, Hawaii, and the Provinces of Canada. The warranty covers defects in material and workmanship under normal use and service. Exclusions apply to products repaired or altered by unauthorized persons, damage from misuse or faulty installation, products in commercial vehicles, defaced serial numbers, installations not in accordance with WFCO instructions, consequential damages, and products sold through unauthorized internet sources. A Return Goods Authorization (RGA) number is required for warranty claims.