Wagan 2403 User manual

8000W Power Inverter
By Wagan Tech
www.wagan.com
2
Item no. 2403
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 Th e Battery Bank
4.3. Derating The Battery Bank
4.4. Fusing Requ irements 435C

USER’S MANUAL — Please read before using this equipment.
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8000W Power Inverter
By Wagan Tech
1. INTRODUCTION
1.1 About this Inverter.
This power inverter conv erts 12 vo lts, direct curr ent (12VDC) to 115 volts
alternating household cu rrent (115 VAC). It easily powers TV/V CR
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 cap ability in its class. Sup erior surge
capability allows the inverter to start the most difficult motorized load s.
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 sou rce.
•Do not attempt to connect the inverter to any other power source, including
any AC pow er 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.
1.3 Load Considerations
When a motorized app liance motor starts, it requires an in itial surge o f 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 continuo us
loads of the applian ces that are to be
powered by the inverter.
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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
11 5 (AC voltage) =
WATTS. This formula yields an approximation of the continuous wattage load of
the applian ce.
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 d evices, it is approximately
twice the continuous load. Howev er, with some devices start-up load can be as
high as eight times the continu ous load. To determine if an appliance or tool will
operate with this inverter, run a test. This inverter is de signed 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 op erate
properly while powered by this inverter. Ag ain, 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.
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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© 2007 Wagan Corporation.
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a. ON/OFF Switch.
This switch controls ON/OFF operation of the inverter.
b. OVER HEAT INDICATOR
The Over Temperatur e LED will turn RED and the inverter will automatically
shut down if the in verter shuts do wn because o f inadequate ventilation or
excessive load . If this occurs, turn OFF the inverter and check that the
ventilation openings are not block ed. Then check that the con tinuous power
requirement of the appliance load does not exceed 8000 watts. After the shut
down cond ition is removed , turn on the inv erter. When the in verter cools to a safe
temperature, it will automatically restart.
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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diagnosis if there are DC power supply problems.
DC voltage reading is the measurement of the voltag e 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 vo ltage drop that occu rs between th e input cables and the battery. This
voltage dro p should not be excessive as this will seriously red uce run time. This
inverter will op erate with input voltage rangin g from 11 to 15 Vo lts of direct
current (DC). If the inv erter input voltage lev el falls below 1 0.5 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 voltag e will be higher than when there is no load on the batteies. This
inverter will shutdo wn if the input vo ltage 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 curren t drawn by the inverter with the present
DC load operating. The current disp layed is the sum of currents supp lied to all the
DC input terminals. The meter should show minimal current drawn when the
inverter is op erating 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.
f. High Wattage AC Outlet
There are three insulated terminals on the front p anel of the inverter. These
terminals are fo r connecting 1 15 Volt AC devices that require more than 15 amps
to operate. Other uses are for connection to distribu ted wiring that h as multiple
AC outlets. Any wiring that is directly connected must be 6 gage or larger.
Terminal connections fro m left to right are:

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LEFT MIDDLE RIGHT
GROUND NEUTRAL HOT
g. Ground Terminal.
This conn ection is for connecting to a 6 gage insulated ground wire. Do not
directly connect this ground connection to the Negativ e DC terminal. This is
described in the installation procedure.
2.2 Rear Panel
a. High-Speed Cooling Fans/ Ventilation Windows
The fans automatical ly operate when the internal temperature of the inverter
requires
cooling. Always allow free air flow – do not block the vents.
b. Four Positive (+) DC Input Terminals, Four Negative DC (-) Input
Terminals.
All Negative (-) and Po sitive (+) DC terminals should be kept in sulated to
protect
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from accidental short circuits. Cable “boot” insulators are supplied that will cover
the cable and terminal. If an y positive (+) DC terminals are not used they should
also be kept covered. All Positive DC terminals are connected together inside the
inverter. All Negativ e 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 ne gative DC terminal can be u sed.
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 no t correctly
read MSW vo ltage, and will display ab out 20 to 30 volts too low. Any multi-
meter identified as "TRUE RMS" will accurately read MSW correctly.

USER’S MANUAL — Please read before using this equipment.
© 2007 Wagan Corporation.
All Rights Reserved.
Wagan and Wagan.com are trademarks used by Wagan Corporation.
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5. PLANNING THE INVERTER SYSTEM 2. Estimate the number of h ours the ap pliances will b e in use b etween 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.
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) n eeded between batter y rech arges
3. Determine the total watt-hours o f energy n eeded. This is don e by multiplying
the average power consumption in watts by the number of hours of run time. For
example: 1500 watts for 10 hours = 15,000 watt hours.
3. Battery b ank capacity in amp-hours
4. Charger requirement to rech arge batteries within a reasonab le time.
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.
5.1 Determining The Maximum Appliance Wattage
Using the 1500 watts (or 150 A mps) for 10 hours example as abov e, then 15 0
amps is needed for 10 hours. This provides us with the basic amp-hours (AH) of
battery th at 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:
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 11 5 (115-VAC) to determine the watts. For example, a
power tool rated at 4-amps will draw 460 watts.
•AC appliance load and time in u se (basic AH)
•Cable gage and length (cable losses)
•Charge level of the batteries (between use, chargers have to be able
Determine the wattage o f each ap pliance you need to simultaneously operate. Add
all of the appliance wattages to obtain an estimated “total watts” number.
Remember to co nsider the start-up surge that motorized appliances will cause. Do
not exceed the surge rating of the inverter.
•to fully charge the batteries)
•Temperature of the batteries (colder batteries provide fewer amps)
•Age and condition of the batteries (older b atteries lose cap acity)
•Compliance with turning off un necessary AC loads.
•Compliance with turning off un necessary DC loads.
At 8000 watts continuo us output this inverter requires a DC po wer supp ly (battery
bank) th at can con tinuously supply 800 amps at 12VDC fo r the dur ation of th e
run time. 5.3 Derating the Battery Bank
5.2 Configuring the Battery Bank
Most lead-acid batteries have a rating expressed in amp-hours (AH). The most
common ratin g of AH is “at the 20 hour rate”. Fo r example; if a 2 0AH 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 determine the minimum battery a mpere-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).

USER’S MANUAL — Please read before using this equipment.
© 2007 Wagan Corporation.
All Rights Reserved.
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11
to discha rge faster than the 20 hour rate, the capacity (AH) of the b attery 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 th e load is 220 amps that is 1 00
percent (ho rizontal number) of the AH (20hr rate). Starting at the 100 percent
horizontal point and loo king up to the curv e the resu lts 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 o f the battery
capacity. The installer must carefully plan the capacity of battery bank or the run
time may b e 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 curv e can be applied to any lead acid battery u nder load providing that it h as
an AH rating at the 20 hour rate.
Derating Curve Lead Acid Batteries
L
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Continuing with the example above: The 150 amp load will n eed to run for 10
hours, so we begin configuration with a 1500 AH battery. If the v ertical is 15 00
and the horizontal is 150 amps th e percentage of load on the ba ttery is 10 p ercent.
The curve shows that the 1500 AH is derated to 90 % of maximum. This means
that the battery will h ave to be 16500 AH for the fu ll 10 hou r run ti me. 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” ba tteries were selected for th ese
illustrations because they are gen erally readily availab le 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 electro lyte (acid) when overturned or punctured.
Battery Bank diagram

USER’S MANUAL — Please read before using this equipment.
© 2007 Wagan Corporation.
All Rights Reserved.
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8000W Power Inverter
By Wagan Tech
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5.4 Fusing requirements
Total AC Watts Negative cables (-) Positive Cables(+)
2500 or lower One One
2500 or more but
less than 5000
Two Two
5000 to 8000 Four Four
NOTE: It is importan t that for this 8000 watt inverter has main battery fuses
connected to the positive (+) battery cable(s) as close as possible to the co nnected
battery bank’s positive terminal. Th e fuse amperag e rating must b e sized to allow
simultaneous op eration of all the AC ap pliances to b e powered, allowing for the
momentary h igh start-up curren t 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 conn ected in parallel to prov ide the requ ired
protection. There are larger capacity fuses and fuse holders available. Make sure
that if the inverter is operating at 8000 watts that the b attery is fused at greater
than 800 amps.
6. CONNECTING THE INVERTER
6.1 General information
Loose conn ections will result in a severe voltage drop that can cause damage to
the condu ctors and in sulation and cause sparking.
Reverse polarity co nnection will b low the fuses in the inverter and can cause
permanent damage to the inverter.
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.
Damage caused by reverse polarity will void th e warranty.
6.2 Procedure
WARNING
1 Make sure the cables are the proper gage and have the fuse holders as close to
the battery bank’s Pos (+) terminal.
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.
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. D isconnect any r emote switch from the connector on th e
front panel.
DC Cable Gage
4. Locate the Ground Lug Terminal at the rear of the inverter. Connect an
insulated 6 gage copper wire to the terminal. The other en d of the g round wire is
connected to a “proper” grounding po int. Use the shortest practical length of wire.
Connect this wire to the chassis of your vehicle or to the grounding system in
your boa t. In a city, the ground wire can conn ect 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 in to the grou nd. In the unlik ely event o f a sh ort circuit, op erating the
inverter witho ut proper grounding can result in electrical sho ck. At the factory,
the negative DC terminals are also electrically connected to the ground terminal.
Minimize cable losses by using the thickest wire available, and the shortest
practical length . If the inverter and the battery are positioned with in four feet of
each other, a minimum of 0 gage (zero gage) insulated copper wire should be
used to make the connections. If the distan ce is lon ger than 4 feet, heavier wire
will be requ ired.
Because multiple battery cables are used with this inverter, keep cable gages and
lengths the same. This will ensure that cable losses will be even ly distributed. Use
the following table as a guide to the number of cable connection s required. Be
sure to include any surge wattage in determining the cab le configurations.
Remember that terminals also have current carrying
limits.

USER’S MANUAL — Please read before using this equipment.
© 2007 Wagan Corporation.
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5. Locate the cable/terminal insulating boots. Slide the b oot

USER’S MANUAL — Please read before using this equipment.
© 2007 Wagan Corporation.
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17
8000W Power Inverter
By Wagan Tech
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 discharged 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 charg e rating. Be sure that the b attery 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 b attery chargers do not h ave
the capacity to fully rech arge the battery bank within the required time,
investigate u sing more than one auto matic charger. Seek an expert to avoid
charging too quickly and risking overheating the batteries.
WARNING
THERE IS DAN GER OF EXPLOSION. DO NO T 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 ch ecks 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 liqu id.
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 sign al interference,
some interference with your television picture may be unavo idable, especially
with weak signals. However, here are some suggestions that may improve
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18
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, en sure that the antenna cab le 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 an tenna cables from the inerter
by running an extension cord from the inverter to the television set.
•Coil the television po wer 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 th e inverter. This is caused by insufficient filtering in the audio
system. The only solution to this p roblem is to get a sound syste m with a high er
quality power supply.
9. TROUBLESHOOTING
PROBLEM: No Output Voltage
Reason Solution
Poor contact with battery
terminals.
Shut down inverter an d
disconnect. Clean terminals
thoroughly and r econnect
Blown DC battery fuse(s). Turn off inverter. Replace
fuse(s) with same type and rating
PROBLEM: Inverter is Shut Down
Reason Solution
Battery voltage below 10
Volts
Recharge or replace battery.
Inverter is too hot (thermal
shut down mode).
Allow inverter to cool.
Check for adequate v entilation.
Reduce the load on the inverter

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© 2007 Wagan Corporation.
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19
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 voltag e below 10.5 Volts Keep input vo ltage above 10.5 Volts
to maintain regu lation.
Poor or weak battery condition. Recharge or replace battery.
Inadequate power being
delivered to the inverter or
excessive voltage drop.
Use lower gage (heavier) cable.
Keep cable length as short as
possible.
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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10.SPECIFICATIONS
Name Description
Input 12V (10- 15V) DC
Output 115V AC
Output waveform Modified Sine Wave (MSW)
Continuous power 8000 Watt
Surge po wer 16000 W att
Efficiency Approx. 90 %
Power Switch ON/OFF Control
No lo ad curr ent
Switch ON
Switch OFF
<2.5 AD C
<0.3 AD C
Battery low alarm 10.5 ± 0.5 V DC
Battery low
shutdown
10 ± 0.5 V DC
AC output socket 4 North American Standard 15 amps
AC output terminals Direct wiring up to 68 amps @ 115VAC
(use 6 gage wire)
Dimensions 22.5 x 11 x 8.5 in. (570 x 280 x 215 mm)
(L x W x H)
Net Weigh t 42.6 lb (1 9.2 kg)
NOTE
All specifications are typical at no minal 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.

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12. WARRANTY – REGISTRATION FORM
WAGAN Corp. Limited Warranty Registration Form
All WAGAN Corporation products are warranted to the original pu rchaser of this product.
Warranty Duration: This product is warranted to th e original purchaser for a period of one (1) Year from the
original purchase date, to be free of defects in material and wo rkmanship. WAGAN Corporation dis claims any
liability for con