WFCO WF-68100-AD Series User manual

OPERATOR’S MANUAL
WF-68100-AD SERIES
DECKMOUNT CONVERTER-CHARGER
ARTERRA DISTRIBUTION
[phone]
wfcoelectronics.com
WARRANTY
[email protected]
Fax [phone]
Distributed by Arterra in the U.S.A. and Canada

2
SAFETY INFORMATION ...................................................................................................... 3
GENERAL INFORMATION
Reverse Battery Protection............................................................................................... 3
Automatic Cooling Fan .................................................................................................... 4
Over-Temperature Protection.......................................................................................... 4
Electronic Current Limiting .............................................................................................. 4
Short Circuit Protection .................................................................................................... 4
CIRCUIT PROTECTION
DC Fuses............................................................................................................................ 5
OPERATIONAL FEATURES
Auto Detect ..................................................................................................................... 5
Three Stage Smart Charging .......................................................................................... 5
Two Stage Smart Charging ............................................................................................. 6
Front Panel Features........................................................................................................ 8
TROUBLESHOOTING INSTRUCTIONS
Converter Output Voltage ............................................................................................... 9
Reverse Polarity Fuses ...................................................................................................... 9
Battery Select Switch ...................................................................................................... 10
Troubleshooting Flow Chart .......................................................................................... 10
GENERAL COMPLIANCE INFORMATION
Agency Listings ............................................................................................................... 10
INSTALLATION INSTRUCTIONS
Mounting the Enclosure................................................................................................. 11
DC Connections.............................................................................................................. 11
AC Connections .............................................................................................................. 12
SPECIFICATIONS ................................................................................................................... 3
WARRANTY INFORMATION.............................................................................................. 14
TABLE OF CONTENTS

3
GENERAL INFORMATION
WF-68100-AD Series Converter-Charger Safety Features
REVERSE BATTERY PROTECTION
The WF-68100-AD Series Converter-Chargers will charge the 12-volt house battery if installed. A
battery does not have to be installed for WF-68100-AD Series Converter-Charger’s operation. When
a battery is installed, three reverse polarity fuses are installed to protect the converter circuitry. The
fuses are located on the rear panel of the enclosure near the AC power cord (Refer to Figure 1
on the following page). This feature prevents permanent damage to the converter from a battery
connected into the circuit backwards. In addition to protecting the converter-charger, the reverse
polarity fuses are the main connection between the converter-charger and the DC fuse board of a
distribution center.

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AUTOMATIC COOLING FAN
The cooling fan in the WF-68100-AD Series Converter-Chargers is 2-stage and is controlled by
the current drawn out of the converter to the applied load. The on-board microprocessor
increases fan speed as the total load increases and decreases fan speed as the load decreases.
Unlike traditional temperature-controlled fans, the load-controlled fan provides better
component cooling by avoiding temperature spikes which can lead to premature
component failure.
OVER-TEMPERATURE PROTECTION
If the internal temperature of the converter exceeds a critical point, it will shut down. This
protects the unit from excessive heat that may damage sensitive components. The unit will
restart once the temperature inside has dropped.
ELECTRONIC CURRENT LIMITING
If the output current exceeds the maximum rating for the WF-68100-AD Series
Converter-Charger, the output current will remain constant, but the output voltage will begin to
drop. If this occurs, the unit will recover once loads are reduced.
SHORT-CIRCUIT PROTECTION
Should a short circuit occur in the RV, the WF-68100-AD Series Converter-Charger will drop the
voltage output to zero volts. If the short-circuit condition is removed and no other fault
conditions are detected, the converter will resume normal operation. However, short- circuit
conditions are dangerous, and an RV will require inspection by a qualied service technician.
Figure 1
DC FUSES (12 VOLTS)
The DC fuse receptacle on the rear panel of the WF-68100-AD Series Converter-Charger has
space for 3 (three) identical Reverse Battery Protection fuses (see Figure 1 above). These
fuses should be replaced with ATC or ATO automotive type fuses, such as Littelfuse type 257 or
Bussmann type ATC. The fuses are 35 Amp.
CIRCUIT PROTECTION
WF-68100-AD Series Converter-Charger Fuses

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AUTO DETECT
This product includes the exclusive “Auto-detect” feature for the charging of batteries. With
this new technology, the power converter will evaluate the charging cycle of a battery, determine
the type of battery being used, and then choose the appropriate charging program (prole) to
provide for the best performance and maintenance of that battery.
Because of the differences of Lead Acid, AGM and Lithium type batteries, a system that
provides a charge to the battery or batteries must be able to accommodate the different
charging requirements. With the use of the “Auto-detect” product, the charging requirement
is able to be “detected” and is then automatically set for the type of battery being used. For
standard Lead Acid and AGM batteries, WFCO power converters still use the Three-Stage Smart
Charging to effectively maximize battery life by monitoring through the different phases of the
charge cycle. On the other hand, Lithium batteries will prefer the use of only two stages when
charging, and therefore the power converter will charge using the WFCO Two-Stage Smart
Charging system.
LEAD ACID & AGM THREE-STAGE SMART CHARGING
In order to maximize battery life for lead acid and AGM batteries, it is best to charge batteries
slowly, keep them topped off with a trickle-charge when the RV is not being used. The 3-Stage
“smart” charger continuously measures the battery voltage output and regulates the amount of
charge using three modes of operation: Absorption, Bulk and Float modes.
All WFCO power converters have automatic three-stage switching power supplies. The converter
senses which mode it needs to be in by checking the RV system voltage.
ABSORPTION MODE
The converter normally provides a constant target output voltage of 13.6 VDC (nominal) to power
all the branch circuits. However, it is current limited, and if the output (load) current reaches its
maximum, the output voltage will drop as necessary to hold the converter’s maximum output
current level (the Amperage rating) without exceeding it.
BULK MODE
If the output current is high (normally caused by a discharged battery), this will cause the
converter to go into Bulk Mode, which means the target output voltage will change to 14.4 VDC
and a timer will start. Although the converter is outputting 14.4 VDC, you will not be able to read
that on a voltmeter due to the voltage-current relationship. From the paragraph above, as load
current increases, output voltage decreases. The actual output voltage will not rise until the load
current is reduced, which happens naturally as the battery charges or if 12 VDC appliances are
turned off.
Bulk Mode will be maintained until the current draw drops to approximately ve Amps, or until
the timer reaches four hours (whichever happens rst). Then the target output voltage is changed
back to 13.6 VDC for Absorption Mode. Lights that are powered from the output may change
brightness slightly at that time.
Note: For a detailed explanation of the charging modes, please refer to our publication “Theory of Operation”, document #AD-TD-0001-0.
OPERATIONAL FEATURES

6
FLOAT MODE
The third mode of charging is what is called the “oat” charge. This mode is designed to
provide a “trickle charge” to the battery after the system observes no signicant variations in
current draw over a long period of time. When in “oat” mode, the voltage will reduce from
13.6V to 13.2V and supply the “trickle charge” which helps to preserve the life of the battery
while keeping it charged and ready for use. A change in DC current will cause the converter to
exit the mode and return to the Absorption mode and then to Bulk mode if required.
LITHIUM TWO-STAGE SMART CHARGING
The two-stage “smart” charger continuously measures the battery voltage output and
regulates the amount of charge using two modes of operation: Bulk and Absorption mode.
TWO-STAGE CONVERTER VOLTAGE OUTPUT MODES
Figure 3
Figure 4

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BULK MODE
This mode is designed with two purposes in mind. First, to quickly restore the energy back into the
battery. Second, to ensure the lithium cells inside the battery remain balanced. This is accomplished
by boosting the output voltage to 14.6 VDC and allowing the maximum current to ow as required
by the loads.
The bulk mode stage could last anywhere from one to four hours based on the battery and load
current which is being used. For a full battery, the bulk stage has a minimum time requirement of
one hour, which allows the lithium cells inside the battery the time required to “balance”.
For an empty battery, the bulk stage has a maximum time requirement of four hours. If your
application requires longer than four hours (such as a larger battery bank > 200 Ahr), a simple
cycling of power will reset the timers.
As the energy is restored into the battery, the DC system voltage will climb and the current from
the converter will decrease. If the total amperage draw from the converter reaches a preset point
(within the one-to-four-hour timer), the converter is designed to drop out of bulk mode.
ABSORPTION MODE
This mode is designed with 1 purpose in mind. This purpose is to provide a safe operating
voltage for all loads in the RV. This is accomplished by reducing (from bulk mode) the output
voltage to 13.6 VDC and remaining at this voltage until the power is cycled to the converter.
The absorption mode stage is the default or normal mode of operation, which has no timer
associated with it. In this mode an output of 13.6 VDC is provided to the DC circuits in the RV.
This voltage has a long-term history as the acceptable voltage for all loads in the RV, and should
not place undue stress (nor reduce the longevity) of the lights and appliances in the RV. This is
not to say that all loads will have an issue with a constant higher voltage; however, some loads
may have an issue. Please refer to the individual manufacturer’s specications for acceptable
operating voltage range of the connected load.
TROUBLE SHOOTING INSTRUCTIONS
Troubleshooting the WF-8900-AD Series Power Center
Refer to the Troubleshooting Guide for the WF-8900-AD Series Power Center (Figure 5) on
page 8.
CHECKING CONVERTER OUTPUT VOLTAGE
Before checking the WF-8900-AD Series Power Center output voltage, disconnect the battery
cables at the battery. Make sure the converter is plugged into an AC source (105-130 VAC).
Check the converter output voltage at the battery with a voltmeter. Place the meter probes on
the disconnected battery cables; place the Positive (red) meter probe on the + Positive battery
wire and place the Negative (black) meter probe on the - Negative wire on the battery cable.
Be sure you have good connections at the cables. If the voltage reads 13.6-14.6V, the converter
is functioning properly.

8
Figure 5
UL
The WF-68100-AD Series Converter-Chargers are UL-Listed, and cUL-Listed (Canadian).
FCC COMPLIANCE CLASS B
NOTE: This equipment has been tested and found to comply with the limits for a Class B digital
device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable
protection against harmful interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio frequency energy, and if not
installed and used in accordance with the instruction manual, may cause harmful interference to
radio communications. Operation of this equipment in a residential area is likely to cause harmful
interference in which case the user will be required to correct the interference at his
own expense.
GENERAL COMPLIANCE INFORMATION
Agency Listings

9
MOUNTING THE ENCLOSURE
The WF-68100-AD Series Converter-Charger enclosure should be mounted in an accessible area
such as a wall or in the side of a cabinet. Select a mounting location near the shore power and
battery (batteries), in an area where the owner is unlikely to store items as this could reduce
clearance requirements, obstruct ventilation openings and affect the performance of the
converter. The location should be selected to prevent excessive heat, water, moisture, dust and
dirt entering the unit installed. As a rule, allow a minimum of two cubic feet of clear airspace
and or any additional venting as necessary to prevent the unit from overheating. The front of the
enclosure should not be obstructed to allow free air ow for the cooling fan (Figure 6).
An 8AWG copper conductor shall be used to bond the WF-68100-AD Series Converter-Charger
to the vehicle frame.
DC CONNECTIONS
Connect a red 2 AWG wire to the POS+ lug on the distribution center’s fuse board. Make sure
this lug is torqued properly. In a similar fashion, connect a black 2 AWG wire to the NEG- lug on
the distribution center’s fuse board.
INSTALLATION INSTRUCTIONS
Installing the WF-68100-AD Series Converter-Charger
Figure 6

10
AC CONNECTIONS
The WF-68100-AD Series Converter-Chargers receive power from the power cord located to the
left of the rear panel fan. Due to the higher current required from the AC line to produce the high
DC current output, a 20 Amp power plug is provided.
The 20 Amp plug and corresponding receptacle are shown in Figure 7 below. The 20 Amp
receptacle must be wired back to the fuse box using 12AWG wire minimum.
Figure 7

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Figure 9

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WFCO extends, to the original owner, a Two-Year Limited Product Warranty. This warranty is
in effect from the date of original purchase for a period of two years. This limited warranty is
extended specically for and is limited to Recreational Vehicle application and is only valid within
the continental United States, Alaska, Hawaii and the Provinces of Canada. WFCO warrants, to
the owner, that its products are free from defects in material and workmanship under normal
use and service based on its intended use and function. This warranty is limited to the repair or
replacement, at WFCO’s discretion, of any defective parts or defective assembly. Any implied
warranties of merchantability or tness for intended use are limited in duration unless applicable
State Law provides otherwise. You may have other rights as specied by each individual state.
EXCLUSIONS AND LIMITATIONS
The OEM warranty specically does not apply to the following:
• Any WFCO product that has been repaired or altered by an unauthorized person.
• Any damage caused by misuse, faulty installation, testing, negligence, accident or any WFCO
product installed in a commercial vehicle.
• Any WFCO product, whose serial number has been defaced, altered or removed.
• Any WFCO product, whose installation has not been in accordance with the WFCO
written instructions.
• Any consequential damages arising from the loss of use of the product including but not
limited to inconvenience, loss of service, loss of revenue, loss or damage to personal property,
cost of all services performed in removing or replacing the WFCO product. Specications are
subject to change without notice or obligation.
• Any WFCO Electronics products sold through unauthorized Internet sources. (Example: eBay)
will be excluded from all warranty coverage offered by Arterra Distribution / WFCO.
CONSUMER WARRANTY CLAIM PROCEDURE
Upon determination and validation by an authorized OEM dealer that a WFCO product has a
defect, a Return Goods Authorization (RGA) number will be required before the product can be
returned. The RGA number can be requested by completing the Warranty Information
Fax Sheet and appropriate Troubleshooting Form found at www.wfcoelectronics.com. Once
these forms have been completed, email the forms along with Proof of Purchase to
[email protected] or fax the three documents to the Warranty Department at
[phone]. After receipt of the forms, an RGA number will be issued. This number shall
appear on all correspondence with warranty service. Upon validation of the warranty, WFCO shall
replace the product with a like product. The RGA number shall be placed on the outside of the
carton used to return the product for ease of identication.
Do not mark directly on the product. The product must be packaged properly to avoid further
product damage which could cause a non-warrantable condition.
CONSUMER LIMITED WARRANTY
For WFCO Electronic Products

13
WARRANTY ASSISTANCE
The consumer may contact the selling Dealer or OEM for warranty assistance. The consumer may
also contact Arterra Distribution, exclusive distributor to WFCO Products at:
[phone] or Fax [phone].

14
ARTERRA DISTRIBUTION
[phone]
wfcoelectronics.com
WARRANTY
[email protected]
Fax [phone]
Distributed by Arterra in the U.S.A. and Canada
Power PROs Technical Support
[phone]