WFCO WF-8900-AD-REP Series

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Summary

General Information

WF-8900-AD-REP Kit Features

Details the components included in the converter replacement kit for easy upgrades.

Operational Features

WF-8900-AD-REP Performance Features

Lists key performance attributes like quiet operation and filtered power.

Installation Instructions

Tools Needed for Assembly

Lists all necessary tools required for the installation process.

Step-by-Step Installation Overview

Provides an overview of the installation process, including removal and mounting.

Removing the Original Converter Section

Instructions for safely dismantling the existing converter unit from the power center.

Removing AC (110 Volt) Side of Converter

Step-by-step guide to disconnect the AC power components of the original converter.

Removing the Converter MBA (Main Board Assembly)

Procedures for detaching the main circuit board assembly of the old converter.

Installing New Converter (MBA) Into Housing

Guidance on fitting the new converter's main board assembly into the designated housing.

WF-8900-AD-REP DC Fuse Board

Description of the DC fuse board layout and connections for the replacement kit.

Installing DC (12 Volt) Side of Converter

Instructions for connecting the 12-volt DC wiring of the new converter.

Installing AC (110 Volt) Side of Converter

Steps for connecting the 110-volt AC wiring of the new converter.

Troubleshooting Instructions

Troubleshooting the WF-8900-AD-REP Series

Procedures for diagnosing and resolving issues with the WF-8900-AD-REP series converter.

Safety & Protection Features

Reverse Battery Hookup Protection

Explanation of the feature that prevents damage from incorrect battery polarity connection.

Automatic Cooling Fan Operation

Details on the fan's operation and its role in component cooling.

Over-Temperature Protection

Describes the unit's shutdown mechanism to prevent damage from overheating.

Electronic Current Limiting

Explains how the converter manages output current to prevent overload damage.

Short-Circuit Protection

Details the converter's response to short-circuit conditions to protect the unit.

DC Fuses (12 Volts)

Information on the types and amperage ratings of DC fuses used in the converter.

Operational Features

Auto Detect Battery Feature

Explains the automatic battery type detection for optimal charging cycles.

Lead Acid & AGM Three-Stage Charging

Details the three-stage charging process for Lead Acid and AGM batteries.

3-Stage Charging Modes

Overview of the three-stage charging modes: Bulk, Absorption, Float.

Benefits of Three Stage Charging

Rationale for the benefits of WFCO's three-stage charging system.

Absorption Mode

Describes the normal operation mode providing 13.6 VDC for charging and powering loads.

Bulk Mode

Explains the mode for quickly charging discharged batteries, boosting voltage to 14.4 VDC.

Float Mode

Details the trickle charge mode (13.2 VDC) for maintaining battery charge during storage.

Lithium Two-Stage Smart Charging

Explains the two-stage charging process tailored for Lithium batteries.

Lithium Bulk Mode

Describes the lithium bulk charging mode, boosting voltage to 14.6 VDC for rapid charging and balancing.

Lithium Absorption Mode

Explains the lithium absorption mode, maintaining 13.6 VDC for safe operation and load support.

Checking Converter Operation

Checking Converter Output Voltage

Steps to verify the converter's output voltage using a voltmeter at the battery terminals.

Checking Reverse Battery Hookup

Procedure to check reverse polarity fuses for signs of incorrect battery connection.

Troubleshooting Guide

AC Reverse Polarity Alarm

Describes the audible alarm feature for incorrect AC wiring polarity.

WF-8500-AD-MBA Series Main Board Assembly Troubleshooting

A guide for diagnosing issues with the WF-8500-AD-MBA series main board assembly.

General Compliance Information

Agency Listings and Certifications

Lists certifications like UL, cUL, and FCC compliance for the product.

Product Specifications

WF-8500-AD-MBA Model Specifications

Detailed technical specifications for the WF-8500-AD-MBA model, including input/output power and dimensions.

Consumer Limited Warranty

Warranty Exclusions and Limitations

Outlines conditions and damages not covered by the product warranty.

Warranty Claim Procedure

Steps for initiating and processing a warranty claim for the product.

Warranty Assistance Contacts

Contact information and procedures for obtaining warranty support.

Dimensional Drawing

WF-8900-AD-REP Dimensions

Provides detailed measurements and diagrams for the WF-8900-AD-REP converter replacement kit.

The WF-8900-AD-REP Series Converter Replacement Kit is designed to upgrade existing power centers by replacing the lower section of certain power center brands with a high-performance three-stage charging powerhouse. This kit provides an easy way for technicians to enhance the charging capabilities of recreational vehicles (RVs).

Function Description:

The core function of the WF-8900-AD-REP Kit is to convert AC power from a shore power cord or on-board generator into 12-volt DC power for an RV's DC components and to charge the house battery. It replaces older, single-stage chargers with a sophisticated "Auto-detect" three-stage or two-stage smart charging system, depending on the battery type. This intelligent charging optimizes battery life and performance.

Important Technical Specifications:

The WF-8900-AD-MBA Specification table outlines the following for the WF-8540-AD-MBA and WF-8560-AD-MBA models, which are part of the WF-8900-AD-REP Series:

Converter Input Power:
- Voltage: 105-130Vac
- Frequency: 60Hz
- Max. Input Current @105Vac: 8A (WF-8540-AD-MBA), 12A (WF-8560-AD-MBA)
- Max Power: 685 watt (WF-8540-AD-MBA), 1030 watt (WF-8560-AD-MBA)
Converter Output Power:
- Continuous Power: 550 watt (WF-8540-AD-MBA), 820 watt (WF-8560-AD-MBA)
- Rated DC Output Voltage: 13.6V
- Rated DC Current: 40A (WF-8540-AD-MBA), 60A (WF-8560-AD-MBA)
Charging Control: Automatically controlled by microprocessor.
Charging Modes: 3-stage Intelligent charge/2 stage intelligent charge.
Intelligent Charge Mode: Absorption, Bulk and Float (Storage) for Lead Acid & AGM; Absorption & Bulk for Lithium Ion.
Battery Adaptability: Lead Acid & AGM/Lithium Ion.
Charge Voltages:
- Absorption Charge Voltage: 13.6V
- Bulk Charge Voltage (4 Hrs): 14.4V
- Storage Charge Voltage: 13.2V
Regulation: ± 1% accuracy against input or load changes.
Cooling Fan: Speed according to the DC load amperage.
VA Efficiency: > 80% (under 70% of load condition).
Protection:
- Overload: Current-limiting & shut down; auto recovery upon return to normal load.
- Short-circuit: Shut down & auto recovery upon return to normal.
- Over-temperature: Shut down & auto recovery upon return to normal.
- Battery Reverse Polarity: Protected by Fuse; same rated fuse replacement required.
Mechanical:
- Dimension (WxHxD): 174.5 x 86 x 179 mm / 6.86 x 3.38 x 7.01 inch.
- Weight: 2.43 kg/5.36 lbs. (WF-8540-AD-MBA), 2.63 kg/5.8 lbs. (WF-8560-AD-MBA).
Environmental Condition: 20~90% Non-condensing.
Safety: UL458/UL67 certified; FCC Class B compliant.

Usage Features:

The WF-8900-AD-REP Kit offers several key usage features:

Auto-Detect Feature: This exclusive feature evaluates the battery's charging cycle, determines the battery type (Lead Acid, AGM, or Lithium), and automatically selects the appropriate charging program. This ensures optimal performance and maintenance for the specific battery installed.
Three-Stage Smart Charging (for Lead Acid & AGM): This system continuously measures battery voltage and regulates charge using three modes:
- Absorption Mode (13.6 VDC): The default and normal operation mode, providing power for DC loads and charging the battery. It's designed for everyday use and can charge a significantly discharged battery to 12.7 VDC in under three hours, even with a 20 Amp lighting load.
- Bulk Mode (14.4 VDC): Activates when the microprocessor detects a preset voltage level, boosting converter voltage to charge a significantly discharged battery faster while still powering DC appliances. This mode can last up to four hours.
- Float Mode (13.2 VDC): Provides a trickle charge to the battery if no significant current draw variations are observed for approximately 44 continuous hours. This lower voltage maintains the battery charge when the RV is not in use, preserving battery life.
Two-Stage Smart Charging (for Lithium Ion): This system uses two modes:
- Bulk Mode (14.6 VDC): Quickly restores energy to the battery and balances lithium cells. It allows maximum current flow and can last from 1 to 4 hours, depending on battery and load.
- Absorption Mode (13.6 VDC): Provides a safe operating voltage for all loads in the RV, maintaining this voltage until power is cycled.
Quiet Operation: Designed to minimize noise during operation.
Filtered Power: Provides clean and stable DC power to sensitive electronics.
FCC Class B Approval: Ensures the device meets standards for electromagnetic interference.

Maintenance Features:

The WF-8900-AD-REP Kit incorporates several features for protection and ease of maintenance:

Reverse Battery Hookup Protection: Two reverse polarity fuses are installed to protect the converter circuitry from damage if a battery is connected backward. These fuses are located on the rear panel of the enclosure. If blown, they indicate an incorrect battery connection, which must be corrected before replacing the fuses with the same type and amperage rating.
Automatic Cooling Fan: The fan speed is controlled by the current drawn by the converter, increasing with load and decreasing with reduced load. This load-controlled fan provides better component cooling and helps prevent premature component failure.
Over-Temperature Protection: The unit will shut down if its internal temperature exceeds a critical point, protecting sensitive components from excessive heat. It restarts automatically 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 the event of a short circuit in the RV, the converter-charger drops the voltage output to zero volts. It resumes normal operation once the short-circuit condition is removed and no other fault conditions are detected.
AC Reverse Polarity (Audible Alarm): This feature sounds an alarm if the incoming AC neutral and lead wires are connected backward at the power center, ensuring correct AC wiring.
DC Fuses (12 Volts): The converter has a receptacle for one or two Reverse Battery Protection fuses (ATC or ATO automotive type fuses) on the rear panel, which are easily replaceable.
Troubleshooting Guide: A comprehensive guide is provided to assist in diagnosing and resolving common issues, including no DC output, blown fuses, and incorrect wiring.