Wagan 2403 AC Inverter User manual

Item No. 2403
User’s Manual
AC Inverter™8,000 Watt
DC to AC Power Inverter
Please visit our website for the latest information on this product.

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Thank you for purchasing this 8,000 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.
ABOUT THIS INVERTER
This power inverter converts 12 volts, direct current (12V DC) to 115 volts alternating household
current (115V AC). It easily powers 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.
GENERAL INSTRUCTIONS
• Keep the inverter away from any direct heat source or combustible materials or gases.
• Keep well ventilated–this device generates heat.
• Do not operate any equipment over 8,000 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.

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SPECIFICATIONS
Name Description
Input 12V (10V-15V) DC
115 V A C
Modified Sine Wave (MSW)
8,000W
16,000W
Approximately 90%
ON/OFF Control
10.5V ± 0.5V DC
10V ± 0.5V DC
4 North American Standard 15A
Direct wiring up to 68A @ 115V AC
22.5 x 11 x 8.5 in. (570 x 280 x 215 mm)
42.6 lb (19.2 kg)
< 2.5A DC
< 0.3A DC
Output
Output waveform
Continuous power
Surge power
Efficiency
Power switch
Battery low alarm
Battery low shutdown
AC output socket
AC output terminals
Dimensions (L x W x H)
Net weight
No load current
Switch ON
Switch OFF

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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 powered by the inverter.
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 115 (AC voltage) = 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 8,000 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.

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FRONT PANEL
The Front Panel view shows the inverter’s On/OFF Switch, indicators, AC outlets and direct wiring
high current terminals.
1. ON/OFF Switch
This switch controls ON/OFF operation of the inverter.
2. 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
continuous power requirement of the appliance load does not exceed 8,000 watts. After the shut
down condition is removed, turn on the inverter. When the inverter cools to a safe temperature, it
will automatically restart.
3. 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.
4. 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 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

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lower voltage level than the battery because of the voltage drop that occurs between the input
cables and the battery. This voltage drop should not be excessive as this will seriously reduce
run time. This inverter will operate with input voltage ranging from 11 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.
5. Ground Terminal
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.
6. Four 115V AC Outlets
Each outlet will supply 15A (1,600 watts) 115V AC maximum, for powering appliances.
Exceeding 15A of continuous power from an outlet may cause damage to the inverter and cause
possible injury.
LEFT
GROUND
MIDDLE
NEUTRAL
RIGHT
HOT
7. AC Output Terminals
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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1. High-Speed Cooling Fans/ Ventilation Windows
The fans automatically operate when the internal temperature of the inverter requires cooling.
Always allow free air flow – do not block the vents.
2. Four Positive (+) DC Input Terminals, Four Negative DC (-) Input Terminals
All Negative (-) and Positive (+) DC terminals should be kept insulated to protect 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.
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.
REAR PANEL

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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.
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 battery recharges
3. Battery bank capacity in amp-hours
4. Charger requirement to recharge batteries within a reasonable time.

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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 (115V
AC) 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 8,000 watts continuous output this inverter requires a DC power supply (battery bank) that can
continuously supply 800 amps at 12V DC for the duration of the run time.
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).
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 number of hours of run time. For example: 1,500 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 1,500 watt appliance load
will need 150 amps at 12 volts DC.
Using the 1,500 watts (or 150 amps) for 10 hours example as above, then 150 amps is needed
for 10 hours. This provides us with the basic amp-hours (AH) of battery that is required. Ten hours

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at 150 amps equals 1,500 amp-hours (AH). This answer is just a beginning because there are
other factors that determine actual run time. These include:
• AC appliance load 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 charge
the batteries)
• Temperature of the batteries (colder batteries provide fewer amps)
• Age and condition of the batteries (older batteries lose capacity)
• Compliance with turning off unnecessary AC loads.
• Compliance with turning off unnecessary DC loads.
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 20 AH 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
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 220 AH (20
hour rate), and the load is 220 amps that is 100 percent (horizontal number) of the AH (20 hour
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 has an AH rating
at the 20 hour rate.

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Derating Curve Lead Acid Batteries
Continuing with the example above: The 150 amp load will need to run for 10 hours, so we begin
configuration with a 1,500 AH battery. If the vertical 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 percent of maximum. This means that the battery will have to be 1,650 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.

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Fusing Requirements
NOTE: It is important that for this 8,000 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 8,000 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.
Battery Bank Diagram

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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.
Total AC Watts Negative Cables (-) Positive Cables (+)
2,500W or lower One One
5,000W to 8,000W Four Four
2,500W or more but
less than 5,000W
Two Two
CONNECTING THE INVERTER
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.
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, operating the inverter without proper grounding can

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result in electrical shock. At the factory, the negative DC terminals are also electrically connected
to the ground terminal.
5. Locate the cable/terminal insulating boots. Slide the boot on the cable before stripping the
insulator and installing the ring connector.
NOTE: Ring connectors are required to fasten cables to the inverter’s Positive and Negative DC
terminals. The cable ends need to be stripped of insulation for approximately three-quarters of
an inch before the ring terminals are attached. Be sure that the cable connector covers are on the
cable so they can be reinstalled after the cables are connected.
6. Use a hex head wrench to loosen and remove the retaining nut on the terminal. Insert the
Negative cable ring terminal on the threaded bolt of the terminal. Replace the retaining nut and
tighten using the wrench. Make sure you have a good, secure connection.
7. Recheck and make sure the DC cable fuses are installed in the fuse holders.
CHARGING THE BATTERY BANK
General Information
It is not the purpose of this Inverter User’s guide to provide detailed information regarding battery
charging systems. However, the user should try to augment any charging system with either
wind power or solar power. These can continue to operate during power outages and they also
recharge time.
Regular Loss Of Commercial Power
It is not the purpose of this Inverter User’s guide to provide detailed information regarding battery
charging systems. However, the user should try to augment any charging system with either
wind power or solar power. These can continue to operate during power outages and they also
recharge time.
If the inverter system is used during commercial power outages that occur daily, configure
the charger system to replace energy during the time that commercial power is available.
Replacement of battery energy always requires more than was taken from the battery typically
130 percent. In the example used earlier in this document, the AC load ran for 10 hours. If
commercial power is available, there are approximately 14 hours left in the day to do the
recharging. The following is an example of what is necessary to recharge a battery bank that
has 1,650 AH of capacity (as in the example above) and has been discharged to 10.5 volts
(discharged). The charger has to replace 2,145 AH (1,650 x 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.

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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.
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.
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 reception.
• First, make sure that the television antenna produces a clear signal under normal operating
conditions (i.e., at home plugged into a standard 110V/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).
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.

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TROUBLESHOOTING
PROBLEM: No Output Voltage
PROBLEM: Inverter Is Shut Down
Reason Solution
Poor contact with battery terminals. Shut down inverter and disconnect. Clean
terminals thoroughly and reconnect.
Turn off inverter. Replace fuse(s) with same
type and rating.
Blown DC battery fuse(s)
Reason Solution
Battery voltage below 10 volts. Recharge or replace battery.
Allow inverter to cool. Check for adequate
ventilation. Reduce the load on the inverter to
rated continuous power output.
See warranty and call customer service.
Inverter is too hot (thermal shut
down mode).
Unit may be defective.

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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.
Recharge or replace battery.
Use lower gage (heavier) cable. Keep cable
length as short as possible.
Poor or weak battery condition.
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 if the TV
is compatible with a modified sine wave.

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The WAGAN Corporation warranty is limited to products sold
only in the United States.
Warranty Duration:
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 consequential
damages. In no event will WAGAN Corporation be responsible for any
amount of damages beyond the amount paid for the product at retail.
Warranty Performance:
During the warranty period, a product with a defect will be replaced with
a comparable model when the product is returned to WAGAN Corporation
with an original store receipt. WAGAN Corporation will, at its discretion,
replace or repair the defective part. The replacement product will be
warranted for the balance of the original warranty period. This warranty
does not extend to any units which have been used in violation of written
instructions furnished.
Warranty Disclaimers:
This warranty is in lieu of all warranties expressed or implied and no
representative or person is authorized to assume any other liability
in connection with the sale of our products. There shall be no claims for
defects or failure of performance or product failure under any theory of tort,
contract or commercial law including,but not limited to negligence, gross
negligence, strict liability, breach of warranty, and breach of contract.
Returns:
Please contact customer service by phone, email, or visiting our website
under "Customer Care" page for instructions on how to process a warranty
claim. WAGAN Corporation is not responsible for any shipping charges
incurred in returning the item(s) back to the company for repair or
replacement, nor is WAGAN responsible for any item(s) returned without an
official Return Authorization number (RA#).
Register your product online at http://tinyurl.com/wagan-registration to be
added to our email list. You will receive previews on our upcoming products,
promotions, and events.
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WAGAN Corp. Limited Warranty

www.wagan.com

31088 San Clemente Street
Hayward, CA 94544, U.S.A.
Tel: + 1.510.471.9221
U.S. & Canada Toll Free: 1.800.231.5806
[e-mail]
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