WFCO WF-9800-AD Deck Mount Converter Charger User Manual
- June 4, 2024
- WFCO
Table of Contents
WFCO WF-9800-AD Deck Mount Converter Charger
SAFETY AND PROTECTION FEATURES
WF-9800-AD Series Converter-Charger Safety Features
REVERSE BATTERY HOOKUP PROTECTION
The WF-9800-AD Series Converter-Charger’s will charge the 12-volt house
battery if installed. A battery does not have to be installed for WF-9800-AD
Series Converter-Chargers operation. 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 1 on the next 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. Automatic Cooling Fan The cooling fan in the WF-9800-AD
Series Converter-Chargers is controlled by the current (Amperage) load
attached to the converter, NOT by temperature. 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 that 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 qualified 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 1 (one) or 2 (two) 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. 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 WF-9865-AD – (2)
- 40A WF-9875-AD – (2) 40A
OPERATIONAL FEATURES
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 (profile) 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 BATTERY 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 reaches its maximum (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 five Amps, or until
the timer reaches four hours (whichever happens first). 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.
FLOAT MODE
The third mode of charging is what is called the “float” charge. This mode is
designed to pro-vide a “trickle charge” to the battery after the system
observes no significant variations in current draw over a long period of time.
When in “float” 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.
Note : For a detailed explanation of the charging modes, please refer to our publication “Theory of Operation”, document #AD-TD-0001-0.
LITHIUM BATTERY 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.
CONVERTER MODES OF OPERATION
Understanding output voltages of a two-stage converter.
BULK MODE
This mode is designed with 2 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 flow as required by the loads.
The bulk mode stage could last anywhere from 1 to 4 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 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 4 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 1-to-4 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 specifications for acceptable operating voltage range of the
connected load.
CHECKING CONVERTER OUTPUT VOLTAGE
Before checking the WF-9800-AD Series Converter-Charger output voltage, disconnect the battery cables at the battery. Make sure the converter is plugged into a live 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 4). Be sure you have good connections at the cables. If the voltage reads 13.6 – 14.6 V, 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, first 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.
GENERAL COMPLIANCE INFORMATION
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.
INSTALLATION INSTRUCTIONS
MOUNTING THE ENCLOSURE
The WF-9800-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 clear-ance requirements,
obstruct ventilation openings and affect the performance of the
converter (Figure 6).
The location should be selected to prevent excessive heat, water, moisture,
dust and dirt entering the unit installed. As a rule, allow 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 ob-structed to
allow free air flow for the cooling fan (Figure 6).
An 8AWG copper conductor shall be used to bond the WF-9800-AD Series
Converter-Charger to the vehicle frame.
DC CONNECTIONS
Connect a Red 8 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 8 AWG wire to the NEG- lug on the distribution center’s fuse board. A
battery IS NOT required for converter operation. The battery works in
conjunction with the converter to supply DC power to the RV. A battery is
typically only necessary if you do a lot of dry camping or have slide-outs
and/or a leveling system. The batteries can be either of the Lead-Acid
(Flooded, Deep Cycle & AGM) or lithium type. The Amp hour (Ah) rating should
be shown on the battery; for example, 120Ah. The higher the Amp hour rating,
the longer the battery will be able to deliver power when the converter is not
plugged in.
When installing batteries, the batteries MUST be the same brand and type
(preferably the same age as well). Adding more batteries will provide longer
use of DC appliances when not on shore power. And, due to the additional
battery load, the battery charging time will also increase.
NOTE : The converter will not work without AC input. You may notice that, when a battery is connected or reconnected to the converter’s output, the onboard fan may energize for a few seconds. This is normal and is the converter’s circuitry recognizing the battery voltage. You will notice the same occurrence when the converter is initially energized on Shore power.
AC CONNECTIONS
The WF-9800-AD Series Converter-Chargers receive power from the power cord on
the opposite end of the enclosure from the DC lugs. The WF-9835-AD, WF-9845-AD
and WF-9855-AD have a standard 15 Amp plug. The WF-9865-AD and WF-9875-AD have
a 20 Amp plug due to the higher current required from the AC line to produce
the high DC current output. The 20 Amp plug and corresponding receptacle is
shown in Figure 7 below. The 20 Amp receptacle must be wired back to the fuse
box using 12AWG wire minimum.
CONSUMER LIMITED WARRANTY
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 specifically 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 fitness for intended use are limited in duration unless applicable State Law provides otherwise. You may have other rights as specified by each individual state.
EXCLUSIONS AND LIMITATIONS
The OEM warranty specifically 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 to 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. Specifications 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
warranty@wfcoelectronics.com or fax the
three documents to the Warranty Department at
574-294-8698. 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
identification. 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: 574-294-8997 or Fax
574-294-8698.
ARTERRA DISTRIBUTION 877-294-8997 wfcoelectronics.com
WARRANTY warranty@wfcoelectronics.com Fax 574-294-8698 Power PROs Technical Support 877-294-8997