WFCO WF-984S User manual

OPERATOR’S MANUAL
WF-8900-AD-REP SERIES
CONVERTER REPLACEMENT KIT
ARTERRA DISTRIBUTION
[phone]
wfcoelectronics.com
WARRANTY
[email protected]
Fax [phone]
Distributed by Arterra in the U.S.A. and Canada

2
SAFETY INFORMATION ....................................................................................................... 3
KIT FEATUES ........................................................................................................................... 3
PERFORMANCE FEATURES.................................................................................................. 4
INSTALLATION INSTRUCTIONS
Tools Needed ................................................................................................................... 4
Step-by-Step Instructions .............................................................................................. 4
DC Fuse Board ................................................................................................................ 5
TROUBLESHOOTING INSTRUCTIONS............................................................................... 6
GENERAL INFORMATION
Reverse Battery Protection .............................................................................................. 6
Automatic Cooling Fan ................................................................................................... 7
Over-Temperature Protection ......................................................................................... 7
Electronic Current Limiting ............................................................................................. 7
Short-Circuit Protection ................................................................................................... 7
CIRCUIT PROTECTION
DC Fuses ........................................................................................................................... 7
OPERATIONAL FEATURES
Auto Detect ...................................................................................................................... 8
Three-Stage Smart Charging .......................................................................................... 8
Two-Stage Smart Charging ........................................................................................... 10
Converter Output Voltage ............................................................................................ 12
Reverse Polarity Fuses ................................................................................................... 12
Troubleshooting Flow Chart ......................................................................................... 13
GENERAL COMPLIANCE INFORMATION
Agency Listings .............................................................................................................. 13
SPECIFICATIONS ................................................................................................................. 14
WARRANTY INFORMATION .............................................................................................. 15
TABLE OF CONTENTS

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GENERAL INFORMATION
WF-8900-AD-REP Kit Features
The WF-8900-AD-REP Converter Replacement Kit allows easy upgrade of existing power centers. Technicians
can easily remove the lower section of certain power center brands and slide in the WF-8900-AD-REP unit.
This exchange upgrades the old single stage charger to a high performance three-stage charging
powerhouse.
The WF-8900-AD-REP Kit contains all the necessary parts needed for the conversion:
• Metal mounting frame with preinstalled WF-9800-AD Series deck mount converter/charger
• Nine-circuit fuse panel with two preinstalled reverse polarity fuses
• All required mounting fasteners

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OPERATIONAL FEATURES
WF-8900-AD-REP Performance Features
The WF-8900-AD-REP Converter Replacement Kit provides all WFCO’s performance standards:
• Quiet Operation
• Filtered Power
• Overload Protection
• Short Circuit Protection
• FCC Class B Approval
INSTALLATION INSTRUCTIONS
INSTALLATION INSTRUCTIONS
Installing the WF-8900-AD-REP Kit
TOOLS NEEDED FOR ASSEMBLY
• Safety Glasses
• Large and Small Straight Blade Screwdriver
• #2 Phillips Screwdriver
• #2 Square Drive Screwdriver
• Pliers
• 1/4” Nutdriver
• 5/16” Nutdriver
STEP-BY-STEP INSTALLATION
Before beginning installation, make sure no AC power is coming into the RV from either the
Shore Power cord or an on-board generator. Remove and set aside the Reverse Polarity Fuses
located on the fuse board to disconnect the converter section from the rest of the RV’s DC power.
In order to install the WF-8900-AD-REP Kit, you must rst remove the existing
converter section in your power center. This kit can be used on several different products. Your
power center may differ slightly in the removal process.
REMOVING THE ORIGINAL CONVERTER SECTION
Removal of the original power center is divided into 3 segments:
• Removing the AC (110 volt) side of the converter
• Removing the DC (12 volt) side of the converter
• Removing the converter MBA (Main Board Assembly)

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REMOVING THE AC (110 VOLT) SIDE OF THE CONVERTER
1. Drop the front door down and turn off 30amp main breaker.
2. Remove all screws holding the front door assembly on.
3. Remove two screws holding the metal plate that covers the AC breakers.
4. Remove the converter neutral wire (white wire) from the neutral bus bar.
5. Remove the converter ground wire (green wire) from the ground bus bar.
Note: some converters may not have ground wire attached to the bus bar.
6. Remove the converter hot wire (black wire) from the breaker provided for the converter.
Note: sometimes removing the breaker from the stab bar may make this step easier.
Removing the DC (12 volt) side of the converter:
7. Record the fuse locations and wire locations off the old fuse board.
8. Remove all the output circuit wires from the fuse board.
9. Remove the two screws that old the fuse board to the converter mounting bracket.
10. Turn the fuse board over to the back side and remove the red wire, white wire and blue wire
from the fuse board.
REMOVING THE CONVERTER MBA
11. Remove the (four) screws holding the converter (MBA) frame to the housing.
12. Slide the converter MBA and frame out of the housing.
Note: The new WF-8900-AD-REP comes with a new fuse board and hardware package.
INSTALLATION OF THE WF-8900-AD-REP IS DIVIDED INTO THREE SEGMENTS
• Installing new converter (MBA) Into housing.
• Installing the DC (12 volt) side of the converter
• Installing the AC (110 volt) side of the converter
INSTALLING NEW CONVERTER (MBA) INTO HOUSING
1. Position the new converter and frame in front of housing and remove the two screws hold the
converter to the frame (this makes routing the wires easier).
2. Carefully install the frame and converter into the housing and route wires from the converter
through the holes in the frame and the housing.
3. Once all wires are routed correctly replace the two screws that hold the converter to
the frame.
4. Attach the fame to the housing using the (four) screws provided.
Figure 1
THE WF-8900-AD-REP DC FUSE BOARD

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INSTALLING THE DC (12 VOLT) SIDE OF THE CONVERTER. REFER TO FIGURE 1 ABOVE
5. Route the red wire from the converter up behind the mounting bracket for the fuse board
and connect it to the lug on the fuse board marked CONV POS.
6. Route the white wire from the converter to the fuse board and connect it to the lug on the
fuse board marked BATT NEG-.
7. Connect your wire coming from the battery positive to the lug on the fuse board marked
BATTERY POS+.
8. Connect your wire coming from the battery negative to the lug on the fuse board marked
BATT NEG-. NOTE: In some applications where the items in the RV are not grounded to
frame you may have to run an 8 AWG wire from the BATT NEG- lug on the fuse board out the
back of the housing and connect it to an additional bus bar (customer will have to purchase).
Then connect the wire from the battery negative and any negatives from the DC items to this
bus bar.
9. Attach the fuse board to the mounting bracket using the two screws provided.
10. Make sure you have the two 30-amp reverse polarity fuses in place and connect all the DC
output wire (as recorded) to the fuse board along with the correct fuse locations.
INSTALLING THE AC (110 VOLT) SIDE OF THE CONVERTER
11. Connect the neutral (white wire) from the converter to the neutral bus bar.
12. Connect the converter hot wire (black wire) from the converter to the breaker for the converter.
13. Connect the ground wire (green wire) from the converter to the ground bus bar.
14. Replace AC cover plate using the two screws provided.
15. Replace the door assembly using the screws provided.
16. Turn all breaker on and apply 110volt power to the RV. Test for operation.
TROUBLESHOOTING INSTRUCTIONS
Troubleshooting the WF-8900-AD-REP Series
Refer to the WF-9800-AD Series Troubleshooting Guide for the WF-9800-AD Series Deck Mount
found on page 11 of this manual.
SAFETY & PROTECTION FEATURES
WF-8900-AD Series Converter-Charger Features
REVERSE BATTERY HOOKUP PROTECTION
The WF-9800-AD Series Converter-Chargers will charge the 12-volt house battery if installed.
When a battery is installed, two 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 2 below). 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. A battery does not have to be installed for WF-9800-AD Series
Converter-Charger’s operation.

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AUTOMATIC COOLING FAN
The cooling fan in the WF-9800-AD Series Converter-Chargers is incremental 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-9800-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-9800-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.
DC FUSES (12 VOLTS)
The DC fuse receptacle on the rear panel of the WF-9800-AD Series Converter-Charger has
space for one or two Reverse Battery Protection fuses (see Figure 2 above). These fuses should
be replaced with ATC or ATO automotive type fuses, such as Littelfuse type 257 or Bussmann
type ATC. Each converter model requires a different Amperage value fuse as follows:
• WF-9835-AD – (1) 40A
• WF-9845-AD – (2) 30A
• WF-9855-AD – (2) 35A
Figure 2

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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
The three-stage “smart” charger continuously measures the battery voltage output and regulates
the amount of charge using three modes of operation: Absorption, Bulk, and Float.
3-STAGE CHARGING
WFCO converters of every style have become the favored brand for power conversion and
electric distribution in the RV industry. They provide RV owners wth an efcient and cost-effective
method to use an AC power source and provide power to DC components inside the RV, while
charging accessory batteries at the same time.
SMART ENGINEERING: THREE STAGE CHARGING IS BETTER
WFCO’s automatic three-stage converters handle every charging need for the RV while extending
the battery’s life. Well-maintained batteries should never need more than two-stage (Normal and
Trickle) charging. Our third stage (Bulk) is provided for the rare times a battery needs extra power
for charging.
RVs are frequently sold with at least one 12 VDC accessory battery installed. This battery is
normally a deep-cycle battery that could sustain a slower drain of power. RV owners nd this
useful when powering loads such as lights, radios, and refrigerators without being
connected to AC power or running the motorhome engine. As soon as the RV is connected to
AC power, the converter begins charging the battery as needed, while, at the same time, provid-
ing 12 VDC power to loads such as lights, radios, and refrigerators.
When the RV is connected to AC power, users frequently use the lights, refrigerators, fans, and
other electronics as they would in their home. RV users also expect the battery to be fully charged
when they want to disconnect from power and move the RV, or when they are dry camping and
turn off their generator.
OPERATIONAL FEATURES

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Figure 3
ABSORPTION MODE
This is the default, or normal operation, providing an output of 13.6 volts DC. Because RVs today
are designed with converters sized to provide ample DC output power for all DC loads in normal
usage, an RV will rarely require anything other than Absorption Mode.
When a WFCO converter is connected to a battery in Absorption Mode, power is available
for charging that battery whenever the converter output is greater than the voltage level of
the battery.
If the battery is at or near fully charged, the current draw from the converter to the battery may
be very small. On the other hand, if the battery were to be fully discharged, the current draw from
the converter to the battery may be quite high.
Testing has shown that a completely discharged battery (11.9 VDC) connected to a WFCO
converter in Absorption Mode with an output of 13.6 VDC and having a 20 Amp lighting load
connected to the converter will charge the battery to its fully charged level of 12.7 VDC in fewer
than three hours.
Adding more DC loads will lessen the amount of current available and will lengthen the time
required to charge the battery. Batteries with damaged cells will also require additional time to
charge and may never reach a full charge voltage.
Because of the relationship between voltage and amperage, once the converter reaches its
maximum rated operating current level, any increase in the DC load will start to decrease the
voltage output level. When the output from the converter reaches a preset level, the converter
will go into Bulk Mode.
BULK MODE
This is designed to charge a signicantly discharged battery in a little less time than Absorption
Mode. The microprocessor in WFCO converters continuously monitors the DC line voltage.
When the microprocessor detects the preset voltage level, it will boost the converter voltage to
14.4 VDC. The increased voltage will help the battery charge faster, while still providing power to
the DC appliances in the RV.
In Bulk Mode, it may not be possible to observe the 14.4 VDC output because of the voltage-
current relationship. To measure the 14.4 VDC, reduce some DC loads while monitoring the
voltage at the converter output. As the DC loads are removed, the voltage will begin to climb
until 14.4 VDC (nominal) is shown on the meter.

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As the battery continues to charge, the current drawn by the battery will gradually decrease.
WFCO converters are designed to drop out of Bulk Mode when the total amperage draw from
the converter reaches a preset point, indicating the battery is charged. If the amperage draw
stays above the preset point, the converter will stay in Bulk Mode for a maximum of four hours.
These features have been implemented to protect and extend the life of the battery.
FLOAT MODE
This is the third stage of converter operation. This mode is designed to provide a trickle charge
to the battery. If the converter observes no signicant variations in current draw for approximately
44 continuous hours, it will drop the output of the converter from 13.6 VDC to 13.2 VDC. This
lower voltage will keep the battery charged while the RV is not in use. This also helps 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 Float Mode and return to the default, or normal, Absorption Mode.
Note: The converter, while in Float Mode, will continue to supply a trickle charge to the battery.
If the RV is in storage for thirty (30) days or more, be sure to check the battery and its uid levels.
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 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 1 to 4 hours based on the battery and load cur-
rent which is being used. For a full battery, the bulk stage has a minimum time requirement of 1
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 4 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.

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CHECKING CONVERTER OUTPUT VOLTAGE
Before checking the WF-9800-AD Series Converter-Charger output voltage, disconnect the bat-
tery cables at the battery. Make sure the converter is plugged into an AC source (105-130 Volts).
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
(Figure 5).
Be sure you have good connections at the cables. If the voltage reads 13.6 - 14.4V, the converter
is functioning properly.
If the converter output voltage at the battery reads 0.0 VDC, or if the battery is not charging,
check for an open inline fuse in the battery wire circuit. One may have been installed by the RV
manufacturer. Also check for loose wiring connections.
CHECKING FOR REVERSE BATTERY HOOKUP (REVERSE POLARITY FUSES)
If there is no DC output coming from the WF-9800-AD Series Converter-Charger output lugs, rst
check the reverse polarity fuses on the rear panel. Then, visually inspect the fuses for any breaks
in the fuse element. If no breaks are found, use a continuity tester to check for continuity. If the
reverse polarity fuses are blown, it means the RV battery was accidentally connected in reverse,
either at the battery or at the converter. Investigate the connections and reconnect the cables
properly. Replace the fuse with the same type and amperage rating as the original.
IMPORTANT: These fuses protect the converter from damage if the RV battery is accidentally
connected in reverse. A reversed battery connection, even if for only a second, will cause these
fuses to blow.
If the above checks have been made but the converter output still reads 0.0 VDC, the converter is
not functioning properly.
Figure 5

13
Figure 6
UL
The WF-9800-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.
AC REVERSE POLARITY (AUDIBLE ALARM)
This power center is equipped with an AC REVERSE POLARITY PROTECTION feature. Should
the incoming AC neutral wire and lead wire be connected backwards at the power center, an
alarm located in the power center enclosure will sound. This alarm will continue to sound until
the AC wires are connected correctly.
GENERAL COMPLIANCE INFORMATION
Agency Listings

14
Figure 7

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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 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.
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].
CONSUMER LIMITED WARRANTY
for WFCO Electronic Products

16
16
WF-8900-AD-REP DIMENSIONAL DRAWING
Figure 8

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17

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]