Wagan 2403 User Manual

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Item no. 2403

8000W Power Inverter

By Wagan Tech

Thank you for purchasing this 8000 Watt DC to AC Power Inverter by

Wagan Tech. With minimal care and proper treatment it will provide years

of reliable service. Carefully read, understand and comply with all

instructions before use. Keep this manual for future reference.

CONTENTS

1. INTRODUCTION

1.1. About This Inverter

1.2. General Instructions

1.3. Load Considerations

2. CONTROLS, INDICATORS AND CONNECTIONS

2.1. Front Panel

2.2. Rear Panel

3. OUTPUT WAVEFORM

4. PLANNING THE INVERTER SYSTEM

4.1. Determining The Maximum Appliance Wattage

4.2. Configuring The Battery Bank

4.3. Derating The Battery Bank

4.4. Fusing Requirements 435C

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USER’S MANUAL — Please read before using this equipment.

1. INTRODUCTION

1.1 About this Inverter.

This power inverter converts 12 volts, direct current (12VDC) to 115 volts

alternating household current (115VAC). It easily powe r s TV/VCR

combinations, microwave ovens, refrigerators, even air conditioners! It also

operates at highest efficiency (up to 90%) which results in longer running time

and extended battery life compared to other inverters with this power.

This inverter has the highest surge capability in its class. Superior surge

capability allows the inverter to start the most difficult motorized loads.

Advanced, microprocessor-controlled circuits run cooler and, therefore, are more

reliable than competing units.

1.2 General Instructions:

• Keep the Inverter away from any direct heat source or combustible

materials.

• Keep well ventilated – this device generates heat.

• Keep the inverter away from combustible gases.

• Do not operate any equipment over 8000 Watts.

• This inverter will only operate from a 12- Volt DC power source.

• Do not attempt to connect the inverter to any other power source, including

any AC power source.

• Incorrect battery polarity will damage the inverter and void the warranty.

• Keep this inverter in a dry environment.

• Do not open the inverter; there are no user serviceable parts inside.

8000W Power Inverter

By Wagan Tech

Appliance power is rated in watts. This information is usually stamped or printed

on most appliances and equipment. In some cases, a tool will be rated in amperes.

To convert from amps to watts, multiply: AMPS X

WATTS. This formula yields an approximation of the continuous wattage load of

the appliance.

The start up load of an appliance is a major factor of whether this inverter can

power it. Start-up load is momentary. With many devices, it is approximately

twice the continuous load. However, with some devices start-up load can be as

high as eight times the continuous load. To determine if an appliance or tool will

operate with this inverter, run a test. This inverter is designed to automatically

shut down in the event of an output overload, so there is no danger of damaging

either the inverter or the equipment.

This inverter may not properly operate some devices with either speed control

features or dimmer controls. Some appliance GFCI power cords will not operate

properly while powered by this inverter. Again, the only way to be sure of proper

operation, is to try it.

If an appliance within the 8000 watt range will not operate properly, it is likely

that the inverter system does not have the required output to operate that

appliance.

SAFETY WARNING.

THE INVERTER OUTPUT CAN BE LETHAL. IMPROPER USE OF THIS

INVERTER MAY RESULT IN PROPERTY DAMAGE, PERSONAL INJURY

OR LOSS OF LIFE.

5 (AC voltage)

1.3 Load Considerations

When a motorized appliance motor starts, it requires an initial surge of power.

This surge of power is called the "starting load" or "peak load". Once started, the

appliance requires less power to continue to operate. This is known as the

"continuous load". It is important to know the starting loads and the continuous

loads of the appliances that are to be

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2. CONTROLS, INDICATORS AND CONNECTIONS

2.1 Front Panel

The Front Panel view shows the inverter’s On/OFF Switch, indicators, AC outlets

and direct wiring high current terminals.

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a. ON/OFF Switch.

This switch controls ON/OFF operation of the inverter.

b. OVER HEAT INDICATOR

The Over Temperature LED will turn RED and the inverter will automatically

shut down if the inverter shuts down because of inadequate ventilation or

excessive load. If this occurs, turn OFF the inverter and check that the

ventilation openings are not blocked. Then check that the co n tinuous power

requirement of the appliance load does not exceed 8000 watts. After the shut

down condition is removed, turn on the inverter. When the inverter cools to a safe

temperature, it will automatically restart.

8000W Power Inverter

By Wagan Tech

diagnosis if there are DC power supply problems.

DC voltage reading is the measurement of the voltage between the DC input

terminals of the inverter, not the actual battery voltage. During high wattage

applications the display may show a lower voltage level than the battery because

of the voltage drop that occurs between the input cables and the battery. Th is

voltage drop should not be excessive as this will seriously reduce run time. This

inverter will operate with input voltage ranging from 1 1 to 15 Volts of direct

current (DC). If the inverter input voltage level falls below 10.5 Volts DC, an

audible alarm will sound. Should the voltage drop below 10 Volts DC, the

inverter will automatically shut down.

During charging from a generator, solar panel, or AC powered charger, the

battery voltage will be higher than when there is no load on the batteies. This

inverter will shutdown if the input voltage is 15 Volts. It will shut down

automatically if this occurs, however, in some rare cases voltages greater than 15

may cause damage to the inverter. Damage caused by excessive voltage input is

not covered under warranty.

The DC Current Meter indicates the current drawn by the inverter with the present

DC load operating. The current displayed is the sum of currents supplied to all the

DC input terminals. The meter should show minimal current drawn when the

inverter is operating and all AC loads are turned off.

e. Four 115V AC Outlets.

Each outlet will supply l5A (1600 watts) 115V AC maximum, for powering

appliances. Exceeding l5A of continuous power from an outlet may cause damage

to the inverter and cause possible injury.

c. OVER LOAD INDICATOR.

This indicator turns RED as the inverter shuts down. Immediately turn off some

appliances if this occurs. The inverter will automatically restart.

d. BAR GRAPH METERS.

The inverter is equipped with digital bar meters that display DC input voltage and

DC current drawn to indicate system operation. These meters are there to assist

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f. High Wattage AC Outlet

There are three insulated terminals on the front panel of the inverter. These

terminals are for connecting 115 Volt AC devices that require more than 15 amps

to operate. Other uses are for connection to distributed wiring that has multiple

AC outlets. Any wiring that is directly connected must be 6 gage or larger.

Terminal connections from left to right are:

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LEFT MIDDLE RIGHT

GROUND NEUTRAL HOT

g. Ground Terminal.

USER’S MANUAL — Please read before using this equipment.

8000W Power Inverter

By Wagan Tech

from accidental short circuits. Cable “boot” insulators are supplied that will cover

the cable and terminal. If any positive (+) DC terminals are not used they should

also be kept covered. All Positive DC terminals are connected together inside the

inverter. All Negative DC terminals are connected together inside the inverter and

connected to the chassis. It does not matter which Positive DC terminals are used.

Similarly any negative DC terminal can be used.

This connection is for connecting to a 6 gage insulated ground wire. Do not

directly connect this ground connection to the Negative DC terminal. This is

described in the installation procedure.

2.2 Rear Panel

a. High-Speed Cooling Fans/ Ventilation Windows

The fans automatically operate when the internal temperature of the inverter

requires

b. Four Positive (+) DC Input Terminals, Four Negative DC (-) Input Terminals.

All Negative (-) and Positive (+) DC terminals should be kept insulated to

cooling. Always allow free air flow – do not bl ock the vents.

protect

Multiple DC terminal sets allow one to four sets of battery cables to be connected

to the inverter. This allows multiple, more readably available flexible cables to be

attached to the inverter.

3.0 POWER INVERTER OUTPUT WAVEFORM

This inverter’s AC output is a Modified Sine Wave (MSW) 115 volts AC. The

comparison of Modified Sine Wave and household sine wave is shown below.

This modified sine wave has a root mean square (RMS) voltage of 115 Volts.

Most ordinary AC voltmeters are calibrated to read “average” voltage and assume

that the AC waveform will be a pure sine wave. These meters will not correctly

read MSW voltage, and will display about 20 to 30 volts too low. Any multi-

meter identified as "TRUE RMS" will accurately read MSW correctly.

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USER’S MANUAL — Please read before using this equipment.

5. PLANNING THE INVERTER SYSTEM

Larger wattage inverters require planning before installation. There are several

steps to the planning process. The user must determine the following:

1. Maximum inverter wattage required

2. Operating time (run time) needed between batte ry recharges

3. Battery bank capacity in amp-hours

4. Charger requirement to recharge batteries within a reasonable time.

5.1 Determining The Maximum Appliance Wattage

Maximum Appliance Wattage is the first factor in planning battery and charging

systems.

Some background:

Large microwave oven specifications list cooking power (watts) and appliance

power. Appliance power is the AC load the inverter has to supply.

Most other electrical tools, appliances and audio/video equipment have labels that

list the unit's power requirements in watts. If the tool or device is rated in amps,

multiply the amps by 115 (115-VAC) to determine the watts. For example, a

power tool rated at 4-amps will draw 460 watts.

Determine the wattage of each appliance you need to simultaneously operate. Add

all of the appliance wattages to obtain an estimated “total watts” number.

Remember to consider the start-up surge that motorized appliances will cause. Do

not exceed the surge rating of the inverter.

At 8000 watts continuous output this inverter requires a DC pow er supply (battery

bank) that can continuously supply 800 amps at 12VDC for the duration of the

run time.

5.2 Configuring the Battery Bank

To determine the minimum battery ampere-hour rating that you will need to

operate appliances from the inverter, and any DC appliances powered by the

battery bank. Follow these steps:

1. List the maximum wattage that the inverter has to provide (as above).

8000W Power Inverter

By Wagan Tech

2. Estimate the number of hours the appliances will be in use between battery

recharges. This will vary depending on appliances. For example, a typical home-

use coffeemaker draws 500 watts during its brew time of 5 minutes, it maintains

he temperature of the pot at about 100 watts. Typical use of a microwave oven is

only for a few minutes. Some longer operating time appliances are lamps, TV's,

computers and refrigerator/freezers.

3. Determine the total watt-hours of energy needed. This is done by multiplying

the average power consumption in watts by the num ber of hou rs of r un time. For

example: 1500 watts for 10 hours = 15,000 watt hours.

To get an estimate of the maximum current (in amps) that a battery bank must be

capable of delivering to the inverter, divide the load watts by ten. For example a

1500 watt appliance load will need 150 amps at 12 Volts DC.

Using the 1500 watts (or 150 Amps) for 10 hours example as above, then 150

amps is needed for 10 hours. This provides us wit h the basic amp-hours (AH) of

battery that is required. Ten hours at 150 amps equals 1500 Amp Hours (AH).

This answer is just a beginning because there are other factors that determine

actual run time. These include:

• AC applian ce lo ad and time in use (basic AH)

• Cable gage and length (cable losses)

• Charge level of the batteries (between use, chargers have to be able

• to fully ch arg e the batteries)

• Temperature of the batteries (colder batteries provide fewer amps)

• Age and con dition of the batteries (older batteries lose capacity)

• Compliance with turning off unn ecessary AC loads.

• Compliance with turning off unn ecessary DC loads.

5.3 Derating the Battery Bank

Most lead-acid batteries have a rating expressed in amp-hours (AH). The most

common rating of AH is “at the 20 hour rate”. For example; if a 20AH battery is

discharged at a 1 amp rate, is will take 20 hours to discharge that battery. The

terms “charged” and “discharged” relate to actual battery voltage. This means that

the output voltage of a nominal 12 volt battery starts at 13.2 volts (fully charged)

then drops to 10.6 volts (discharged). If the load on the battery causes the battery

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to discharge faster than the 20 hour rate, the capacity (AH) of the battery is

measurably reduced (derated). Derating is a major run time factor. The curve

below can help to determine what the battery bank can deliver under load. The

results are used to estimate how much additional battery capacity is needed to

achieve the desired run time.

The left vertical numbers of the curve represents percentage of the battery

capacity at the 20 hour rate. In this example, the user needs a one hour run time. If

the example battery is 220AH (20hr rate), and the load is 220 amps that is 100

percent (horizontal number) of the AH (20hr rate). Starting at the 100 percent

horizontal point and looking up to the curve the results are that only 56 the

percent of the battery capacity is available. This means that a higher battery

capacity is required to get the desired run time, one hour. The curve also shows

that a load of 200 percent of the 20 hour rate yields only 31 percent of the battery

capacity. The installer must carefully plan the capacity of battery bank or the run

time may be seriously affected. To the inexperienced installer, several trial

battery capacities may be required to make sure the large enough battery capacity

is available to achieve the desired run time.

The curve can be applied to any lead acid battery under load providing that it h a s

an AH rating at the 20 hour rate.

Derating Curve Lead Acid Batteries

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Continuing with the example above: The 150 amp load will need to run for 10

hours, so we begin configuration with a 1500 AH battery. If the v ertical is 1500

and the horizontal is 150 amps the percentage of load on the battery is 10 percent.

The curve shows that the 1500 AH is derated to 90 % of maximum. This means

that the battery will have to be 16500 AH for the full 10 hour run time. It is

important to add some extra battery capacity, to compensate for battery age.

CONFIGURATING THE BATTERY BANK

Six volt, 220 AH deep cycle “golf cart” batteries were selected for these

illustrations because they are generally readily available and relatively

inexpensive. With regular recharging they have a relatively long life. These

batteries are “flooded” and vented types; they freely vent hydrogen and oxygen

while under charging and heavy discharge. They must be vented to outside air to

prevent accumulation of explosive gases.

If the batteries are to share a compartment with the inverter, then use sealed lead-

acid batteries that are available in gel cell and AGM varieties. Both sealed battery

types will not spill liquid electrolyte (acid) when overturned or punctured.

Battery Bank diagram

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5.4 Fusing requirements

NOTE: It is important that for this 8000 watt inverter has main battery fuses

connected to the positive (+) battery cable(s) as close as possible to the connected

battery bank’s positive terminal. The fuse amperage rating must be sized to allow

simultaneous operation of all the AC appliances to be powered, allowing for the

momentary high start-up current requirements of inductive loads. Use the

recommended fuse block (fuse holder) and fuse, or an electrical equivalent. ANL

type fuses and fuse holders are readily available from marine supply dealers. The

fuse and fuse holders may be connected in parallel to provide the required

protection. There are larger capacity fuses and fuse holders available. Make sure

that if the inverter is operating at 8000 watts that the battery is fused at greater

than 800 amps.

The fuses are very important to protect equipment, batteries and personnel. The

fuses protect against battery explosion if the cables that connect to the inverter

accidentally short. READ AND COMPLY WITH THE WARNING BELOW.

WARNING EXPLODING BATTERIES CAN SPRAY MOLTEN LEAD, HOT SULFURIC ACID AND OTHER METAL AND PLASTIC FRAGMENTS. BATTERIES THAT ARE CHARGING OR UNDER HIGH DISCHARGE RATES PRODUCE EXPLOSIVE HYDROGEN GAS INTO THE SURROUNDING AREA. BE SAFE - FUSE THE BATTERY BANK AND MAKE SURE THE BATTERIES ARE PROPERLY VENTILATED.

DC Cable Gage

Minimize cable losses by using the thickest wire available, and the shortest

practical length. If the inverter and the battery are positioned within four feet of

each other, a minimum of 0 gage (zero gage) insulated copper wire should be

used to make the connections. If the distance is longer than 4 feet, heavier wire

will be required.

Because multiple battery cables are used with this inverter, keep cable gages and

lengths the same. This will ensure that cable losses will be evenly distributed. Use

the following table as a guide to the number of cable connections required. Be

sure to include any surge wattage in determining the cable configurations.

Remember that terminals also have current carrying

limits.

8000W Power Inverter

By Wagan Tech

Total AC Watts Negative cables (-) Positive Cables(+)

2500 or lower One One

2500 or more but

less than 5000

5000 to 8000 Four Four

6. CONNECTING THE INVERTER

6.1 General information

Loose connections will result in a severe voltage drop that can cause damage to

the conductors and insulation and cause sparking.

Reverse polarity connection will blow the fuses in the inverter and can cause

permanent damage to the inverter.

Damage caused by reverse polarity will void the warranty.

6.2 Procedure

1 Make sure the cables are the proper gage and have the fuse holders as close to

the battery bank’s Pos (+) terminal.

2. Install the fuses in the Pos (+) cable.

3. Make sure the ON/OFF switch located on the front panel of the inverter is in

the OFF (0) position. Disconnect any remote switch from the connector on the

front panel.

4. Locate the Ground Lug Terminal at the rear of the inverter. Connect an

insulated 6 gage copper wire to the terminal. The other end of the ground wire is

connected to a “proper” grounding point. Use the shortest practical length of wire.

Connect this wire to the chassis of your vehicle or to the grounding system in

your boat. In a city, the ground wire can connect to a metal cold water pipe that

goes underground. In remote locations, the ground wire can be connected to an

“earth ground”. This can be an attachment to a six foot long copper clad metal rod

driven into the ground. In the unlikely event of a short circuit, o p erating the

inverter without proper grounding can r esult in electrical shock. At the factory,

the negative DC terminals are also electrically connected to the ground terminal.

Two Two

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5. Locate the cable/terminal insulating boots. Slide the boot

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an example of what is necessary to recharge a battery bank that has 16500 AH of

capacity (as in the example above) and has been discha rged to 10.5 volts

(discharged). The charger has to replace 2145 AH (1650x 1.3 AH) in 14 hours. So

the charger must charge at a rate of 153 Amps for 14 hours. As this charge current

is distributed among the batteries in the battery bank, the current received by an

individual battery is within its charge rating. Be sure that the battery is well

vented as the area will likely have accumulations of an explosive mixture of

hydrogen and oxygen. Follow all recommendations for use that are contained in

the battery charger manual. If commercial automatic battery chargers do not have

the capacity to fully recharge the battery bank within the required time,

investigate using more than one automatic charger. Seek an expert to avoid

charging too quickly and risking overheating the batteries.

8000W Power Inverter

By Wagan Tech

reception.

• First, make sure that the television antenna produces a clear signal under

normal operating conditions (i.e., at home plugged into a standard

11O/120V AC wall outlet). Also, ensure that the antenna cable is

properly shielded and of good quality.

• Change the positions of the antenna cables and television power cord.

• Isolate the television, its power cord and antenna cables from the inerter

by running an extension cord from the inverter to the television set.

• Coil the television power cord or install a clamp-on ferrite choke

(available from electronic parts suppliers).

WARNING

THERE IS DANGER OF EXPLOSION. DO NOT CONNECT OR

DISCONNECT CHARGER CABLES DIRECTLY AFTER BATTERY

DISCHARGE OR RECHARGE –MAKE SURE THAT THE BATTERY BANK

AREA IS WELL VENTED BEFORE ATTACHING OR REMOVING CABLES.

If the flooded lead-acid batteries are used, as examples given in this document, be

sure to make periodic checks of battery electrolyte levels. Follow battery

manufacturer’s instructions in keeping the electrolyte at the proper level. Be sure

to use pure distilled water when replacing evaporated electrolyte liquid.

7.3 Aboard A Vessel Or Vehicle

Manufacturer-supplied, engine-driven alternators can usually be replaced with

one that can continuously deliver higher amperage. This should be done at the

outset. Keep the batteries charging when the vessel or vehicle engine is operating.

In the case of a vessel, make sure that shore power is used to recharge the

batteries whenever possible.

8. OPERATING ISSUES TV AND AUDIO

Although all inverters are shielded and filtered to minimize signal interference,

some interference with your television picture may be unavoidable, especially

with weak signals. However, here are some suggestions that may improve

Note: Some inexpensive audio systems may have a slight "buzzing" sound when

operated with the inverter. This is caused by insufficient filtering in the audio

system. The only solution to this problem is to get a sound system with a higher

quality power supply.

9. TROUBLESHOOTING

PROBLEM: No Output Voltage

Reason Solution

Poor contact with battery

terminals.

Blown DC battery fuse(s). Turn off inverter. Replace

PROBLEM: Inverter is Shut Down

Reason Solution

Battery voltage below 10

Volts

Inverter is too hot (thermal

shut down mode).

Shut down inverter and

disconnect. Clean terminals

thoroughly and reconnect

fuse(s) with same type and rating

Recharge or replace battery.

Allow inverter to cool.

Check for adequate ventilation.

Reduce the load on the inverter

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to rated continuous power

output.

Unit may be defective. See warranty and call customer

service.

PROBLEM: Low Battery Alarm on all the Time

Reason Solution

Input voltage below 10.5 Volts Keep input voltage above 10.5 Volts

to maintain regulation.

Poor or weak battery condition. Recharge or replace battery.

Inadequate power being

delivered to the inverter or

excessive voltage drop.

PROBLEM: TV does not Work

Reason Solution

TV does not turn on. Contact TV manufacturer to find out

Use lower gage (heavier) cable.

Keep cable length as short as

possible.

if the TV is compatible with a

modified sine wave.

8000W Power Inverter

By Wagan Tech

10. SPECIFICATIONS

Name Description

Input 12V (10-15V) DC

Output 115V AC

Output waveform Modified Sine Wave (MSW)

Continuous power 8000 Watt

Surge power 16000 Watt

Efficiency Approx. 90 %

Power Switch ON/OFF Control

No load current

Switch ON

Switch OFF

Battery low alarm 10.5 ± 0.5 V DC

Battery low

shutdown

AC output socket 4 North American Standard 15 amps

AC output terminals Direct wiring up to 68 amps @ 115VAC

Dimensions 22.5 x 11 x 8.5 in. (570 x 280 x 215 mm)

Net Weight 42.6 lb (19.2 kg)

NOTE

All specifications are typical at nominal line, half load, and 77deg F 25 deg C unless otherwise

noted. Specifications are subject to change without notice.

11. DISPOSAL / RECYCLING OF INVERTER

Electronic products are known to contain materials that are toxic if improperly

disposed. Contact local authorities for disposal and recycling information.

<2.5 ADC

<0.3 ADC

10 ± 0.5 V DC

(use 6 gage wire)

(L x W x H)

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USER’S MANUAL — Please read before using this equipment.

12. WARRANTY – REGISTRATION FORM

WAGAN Corp. Limited Warranty Registration Form

All WAGAN Corporation products are warranted to the origin al purchaser of this product.

Warranty Duration: This product is warranted to the original purchaser for a period of one (1) Year from the

original purchase date, to be free of defects in material and workmanship . WAGAN Corporation disclaims any

liability for con

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Wagan 2403 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual