Wagan 2403 User's Manual
Contents
1. 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 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 WAGAN TECH www wagan com USER S MANUAL Please read before using this2. appliances Exceeding 15A 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 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 WAGAN TECH www wagan com USER S MANUAL Please read before using this equipment LEFT MIDDLE GROUND RIGHT NEUTRAL HOT g 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 2 2 Rear Panel a Ventilation window b Battery terminals a 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 b Four Positive DC Input Terminals Four Negative DC Input Terminals All Negative and Positive DC terminals should be kept insulated to protect 2007 Wagan Corporation All Rights Reserved Wagan and Wagan com are trademarks used by Wagan Corporation 8000W Power Inverter By W
3. 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 2007 Wagan Corporation All Rights Reserved Wagan and Wagan com are trademarks used by Wagan Corporation 8000W Power Inverter By Wagan Tech Total AC Watts Negative cables Positive Cables 2500 or lower One One 2500 or more but Two Two 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
4. equipment a ON OFF switch d Bar Graph Meters b Over Heat Indicator gt e AC Outlet 900 oc 000000000 00000000000 9000 OOO 2000000000 000 ON 00000000000 00000000000 7 ee c Over Load Indicator gao g Ground Terminal e f High wattage AC Outlet 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 continuous 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 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 2007 Wagan Corporation All Rights Reserved Wagan and Wagan com are trademarks used by Wagan Corporation 8000W Power Inverter By Wagan Tech diagnosis if there are DC power supply problems D
5. reconnect Turn off inverter Replace fuse s with same type and rating Blown DC battery fuse s PROBLEM Inverter is Shut Down Reason Solution Battery voltage below 10 Recharge or replace battery Volts Allow inverter to cool Check for adequate ventilation Reduce the load on the inverter Inverter is too hot thermal shut down mode WAGAN TECH www wagan com 8000W Power Inverter By Wagan Tech USER S MANUAL Please read before using this equipment PROBLEM Low Battery Alarm on all the Time 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 Dimensions 22 5 x 11 x 8 5 in 570 x 280 x 215 mm modified sine wave Lx WxH Net Weight 42 6 lb 19 2 kg NOTE 19 2007 Wagan Corporation All Rights Reserved Wagan and Wagan com are trademarks used by Wagan Corporation to rated continuous power 10 SPECIFICATIONS output Unit may be defective See warranty and call customer Nam Description service Input 12V 10 15V DC Output 115V AC Output waveform Modified Sine Wave MSW shutdown Reason Solution Continuous power 8000 Watt Input voltage below 10 5 Volts Keep input voltage above 10 5 Volts Surge power 16000 Watt to maintain regulation Efficiency Approx 90 Poor or weak batte
6. 8000W Power Inverter By Wagan Tech Item no 2403 Thank you for purchasing this 8000 Watt DC to AC Power Inverter by pA WAGAN Wagan Tech With minimal care and proper treatment it will provide years TEC H of reliable service Carefully read understand and comply with all instructions before use Keep this manual for future reference NCinverter CONTENTS ADDOWATT provocan About This Inverter DC to AC Power Inverter 1 2 General Instructions 1 3 Load Considerations 2 CONTROLS INDICATORS AND CONNECTIONS 2l Front Panel 22 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 WAGAN TEC H www wagan com 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 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 r
7. C 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 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 e Four 115V AC Outlets Each outlet will supply 15A 1600 watts 115V AC maximum for powering
8. 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 result in electrical shock At the factory the negative DC terminals are also electrically connected to the ground terminal WAGAN i TECH www wagan com 15 USER S MANUAL Please read before using this equipment 5 Locate the cable terminal insulating boots Slide the boot 2007 Wagan Corporation All Rights Reserved Wagan and Wagan com are trademarks used by Wagan Corporation 8000W Power Inverter By Wagan Tech WAGAN TECH www wagan com 16 USER S MANUAL Please read before using this equipment 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 th
9. agan 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 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 MODIFIED CINE WAVE ASSO b iviveny TT meme Wi te vr SINE WAVE 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 WAGAN TECH www wagan com USER S MANUAL Please read before using this equipment 5 PLANNING THE INVERTER SYSTEM Larger watta
10. e 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 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 whenev
11. ed by Wagan Corporation
12. eeded 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 has an AH rating at the 20 hour rate Derating Curve Lead Acid Batteries 2007 Wagan Corporation All Rights Reserved Wagan and Wagan com are trademarks used by Wagan Corporation 8000W Power Inverter By Wagan Tech 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 vertical is 1500 and the horizontal is 150 amps the
13. er 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 2007 Wagan Corporation All Rights Reserved Wagan and Wagan com are trademarks used by Wagan Corporation 8000W Power Inverter By Wagan Tech reception e First make sure that the television antenna produces a clear signal under normal operating conditions i e at home plugged into a standard 110 120V AC wall outlet Also ensure that the antenna cable is properly shielded and of good quality e Change the positions of the antenna cables and television power cord e Isolate the television its power cord and antenna cables from the inerter by running an extension cord from the inverter to the television set e 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 9 TROUBLESHOOTING PROBLEM No Output Voltage Reason Solution Poor contact with battery Shut down inverter and terminals disconnect Clean terminals thoroughly and
14. ge 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 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 power 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 ho
15. his 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 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 WAGAN i TECH www wagan com USER S MANUAL Please read before using this equipment 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 n
16. 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 INVERTER GROUND WAGAN j TECH www wagan com USER S MANUAL Please read before using this equipment 5 4 Fusing requirements NOTE It is important that for this 83000 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 po
17. ry condition Recharge or replace battery Power Switch ON OFF Control Inadequate power being Use lower gage heavier cable No load current delivered to the inverter or Keep cable length as short as Switch ON lt 2 5 ADC excessive voltage drop possible Switch OFF lt 0 3 ADC Battery low alarm 10 5 0 5 V DC Battery low 10 0 5 VDC AC output socket 4 North American Standard 15 amps AC output terminals Direct wiring up to 68 amps 115VAC use 6 gage wire 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 WAGAN TECH www wagan com 20 21 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 original 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 2007 Wagan Corporation All Rights Reserved Wagan and Wagan com are trademarks us
18. un cooler and therefore are more reliable than competing units 1 2 General Instructions e 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 e Keep this inverter in a dry environment e Do not open the inverter there are no user serviceable parts inside 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 powered by the inverter 2007 Wagan Corporation All Rights Reserved Wagan and Wagan com are trademarks used by Wagan Corporation 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 11 5 AC voltage
19. ur 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 2007 Wagan Corporation All Rights Reserved Wagan and Wagan com are trademarks used by Wagan Corporation 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 number of hours of run 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 with the basic amp hours AH of battery that is required Ten hours at 150 amps equals 1500 Amp Hours AH T
20. wered 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
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