Dual Electronics Corporation XPR522 Operating instructions

DualElectronicsCorp.
TollFree:1-866-382-5476
www.dualav.com
©2013DualElectronicsCorp.
NSA0513-V01
INSTALLATION / OWNER'S MANUAL
Mobile Power Amplifiers
XPR SERIES
XPR522
XPR540

2
Preparation
Please read entire manual before installation. Due to the technical nature of amplifiers,
it is highly recommended that your DUAL amplifier is installed by a professional installer
or an authorized dealer.
Before You Start
•Disconnectnegativebatteryterminal.(consultaqualifiedtechnicianforinstructions)
•Avoidinstallingtheamplifierwhereitwouldbesubjecttohightemperatures,suchas
fromdirectsunlight,orwhereitwouldbesubjecttodust,dirtorexcessivevibration.
•Useextremecautionwhendrillingholestoavoiddamagingfuellinesorexisting
vehiclewiring.
•Allamplifierinstallationsrequirepower,signalandspeakerwires(notincluded).
•Anamplifierinstallationkit(soldseparately)ishighlyrecommendedtofacilitatethe
installation. Consult your dealer for recommendations.
Mounting Location
•Chooseamountinglocationfortheamplifier.Suggestedlocationsincludeunderaseat
orinthetrunk.
•Theamplifiercanbemountedhorizontal(recommended)orvertical.Foroptimum
performance,makesuretoprovideatleast1"ofspacetoaroundallsides.Donot
mounttheamplifierundercarpetsorwhereairflowisrestricted.
•Donotinstalltheamplifierwhereitmaybeexposedtomoisture.
•Theoptimummountinglocationvariesbetweenvehicles.Remembertotestall
amplifier functions before completing the final mounting procedure.
TYPICAL MOUNTING METHOD
11
Troubleshooting
Problem Cause Action
Unit will not turn on
(no power LED indicator)
+12Vwirenotconnectedorincorrectvoltage
REMwirenotconnectedorincorrectvoltage
Checkconnectionsforpropervoltage
(11~16VDC)
GNDwirenotconnected Checkconnectiontoground
Fuse(s)blown Replacefuse(s)
Unit has power - LED is
blue (but no sound)
Speakerwiresnotconnected Checkconnectionsatspeakers
Volumeturnedallthewaydown Increasevolumelevelatheadunit
Oneormorespeakerwirestouchingeach
other or touching chassis ground
Insulateallbarespeakerwiresfromeach
other and chassis ground
Speaker(s)defectiveordamaged Check/replacespeaker(s)
Inputsignalnotconnected Checkhighorlowlevelinputsforproper
connection
Unit blows fuse(s)
Incorrectfuserating Usefuse(s)withcorrectrating
+12Vwiretouchingchassisground Checkforpinchedwire
Speaker(s)defectiveordamaged Check/replacespeaker(s)
Engine noise
Bad ground connection Makesureamplifierisgroundedtoclean
bare metal
SignalgroundlooporRFI(radiofrequency
interference)
Re-routeRCAcablesfromexistinghigh
currentwiring
LED illuminates red
(protect mode)
Oneormorespeakerwirestouchingeach
other or touching chassis ground
Insulateallbarespeakerwiresfromeach
other and chassis ground
Speaker(s)defectiveor
damagedinternally(shorted) Check/replacespeaker(s)
Speakerloadlessthan2ohms(stereo)
Speakerloadlessthan4ohms(bridged)
Adjustspeakerload-amplifierwillnot
operateatlessthan4ohmswhenbridged
Distorted audio output Incorrectinputsignaltypeor
inputleveltoohigh
Checkconnectionsandreduce/adjustinput
level
Low audio output Incorrectinputsignaltypeor
inputleveltoolow
Checkconnectionsandincrease/adjust
inputlevel
Weak bass Speaker(s)arewiredoutofphase Check(+)and(-)speakerconnections
(Observecorrectpolarity)

10
Specifications
XPR522
Power Output:
150 Watts x 2 channels @ 4 ohms
300 Watts x 2 channels @ 2 ohms
600 Watts x 1 channel @ 4 ohms (bridged)
Peak Music Power Output: 600 Watts @ 4 ohms
Signal to noise ratio: 75dBA (reference: 1 watt into 4 ohms)
Frequency response: 20Hz ~ 20kHz
Amplifier dimensions: 2.76" x 9.09" x 10.55"
Typical installation dimensions: 3.75" (D) x 10.25" (W) x 11.50" (H)
XPR540
Power Output:
150 Watts x 4 channels @ 4 ohms
300 Watts x 4 channels @ 2 ohms
600 Watts x 2 channels @ 4 ohms (bridged)
Peak Music Power Output: 1200 Watts @ 4 ohms
Signal to noise ratio: 75dBA (reference: 1 watt into 4 ohms)
Frequency response: 20Hz ~ 20kHz
Amplifier dimensions: 2.76" x 13.82" x 10.55"
Typical installation dimensions: 3.75" (D) x 15" (W) x 11.50" (H)
Note: Besuretofollowspecificinstructionsincludedwithyouramplifierinstallation
kit(notincludedwiththisamplifier).Theinformationbelowshouldbeusedageneral
guideline only.
Power Wire (BAT+)
•Disconnectnegativebatteryterminalbeforeproceeding.Consultaqualified
technician for instructions if you are unsure.
•Planwireroutingbeforecuttinganywirestolength.Beginbyroutingthepower
+12Vwirefromthebatterytotheamplifierlocation.Useagrommetwhenrunning
wiresthroughthefirewallormetalopenings.Avoidrunningthepowerwirenear
existingvehiclewiringtopreventinducednoisefromenteringtheaudiosystem.
•Useextremecautionwhendrillingholestoavoiddamagingfuellinesorexisting
vehiclewiring.
•The+12VwireMUSTbefusedwithin18"ofthebatteryforprotectionofthevehicle’s
electrical system.
Ground Wire (GND)
•Theamplifiergroundwireshouldbeasshortaspossible.Chooseacleanunpainted
sectionofmetalorthevehiclechassiswhenattachingthegroundconnection.Be
sure to clean the area of any dirt or grease.
Remote Turn-on Wire (REM)
•Theremoteturn-onwireconnectstotheheadunit'samplifierturn-onleadorpower
antenna output.
Speaker Wires
•Chooseadequategaugespeakerwiredependingonyourexactamplifier/speaker
combination.Besuretoobservepolaritywhenconnecting.
•Donotgroundanyspeakerwiresorconnectanyspeakerwirestogether.
Input Signal
•Theamplifier'sinputsignalconnectstotheheadunit'slowlevel(RCA)orhighlevel
(speakerwire)outputs.
•Lowlevelinputsignaldeliverthebestperformance.Ifunavailable,usethehigh
levelinputs-wheninterfacingwithfactoryheadunitforinstance.
CAUTION
•Donotusebothlowandhighlevelinputsatthesametime-connectonlyoneor 
the other.
•Neverrunanywiresunderneathoroutsidethevehicle.
3
Connection Descriptions

4
Audio Inputs and Controls
XPR522
RCALineInputs
SpeakerInputs
Gain
CrossoverMode
1
2
3
CrossoverFrequencyControl
Bass Boost
InputMode
253 64
12 7 3 4 5 6
4
5
6
7
1
XPR522
XPR540
XPR522
9
Limited One-Year Warranty
Thiswarrantygivesyouspecificlegal
rights.Youmayalsohaveotherrights
whichvaryfromstatetostate.
DualElectronicsCorp.warrantsthis
product to the original purchaser to be free
fromdefectsinmaterialandworkmanship
for a period of one year from the date of
the original purchase.
DualElectronicsCorp.agrees,atour
option,duringthewarrantyperiod,
to repair any defect in material or
workmanshiportofurnishanequal
new,renewedorcomparableproduct
(whicheverisdeemednecessary)in
exchangewithoutcharges,subjectto
verificationofthedefectormalfunctionand
proofofthedateofpurchase.Subsequent
replacementproductsarewarrantedfor
thebalanceoftheoriginalwarrantyperiod.
Who is covered?Thiswarrantyisextended
to the original retail purchaser for products
purchased from an authorized Dual dealer
andusedintheU.S.A.
What is covered?Thiswarrantycoversall
defectsinmaterialandworkmanshipin
thisproduct.Thefollowingarenotcovered:
software,installation/removalcosts,
damage resulting from accident, misuse,
abuse, neglect, product modification,
improper installation, incorrect line
voltage,unauthorizedrepairorfailure
tofollowinstructionssuppliedwiththe
product, or damage occurring during
returnshipmentoftheproduct.Specific
license conditions and copyright notices for
thesoftwarecanbefoundviawww.dualav.
com.
What to do?
1.Beforeyoucallforservice,checkthe
troubleshootingguideinyourowner’s
manual.Aslightadjustmentofany
customcontrolsmaysaveyouaservice
call.
2.Ifyourequireserviceduringthe
warrantyperiod,youmustcarefully
packtheproduct(preferablyinthe
originalpackage)andshipitbyprepaid
transportationwithacopyoftheoriginal
receipt from the retailer to an
authorizedservicecenter.
3. Please describe your problem in
writingandincludeyourname,a
returnUPSshippingaddress(P.O.Box
notacceptable),andadaytimephone
numberwithyourshipment.
4.Formoreinformationandforthe
location of the nearest authorized
servicecenterpleasecontactusbyone
ofthefollowingmethods:
•Callustoll-freeat1-866-382-5476
•E-mailusat[email protected]
ExclusionofCertainDamages:This
warrantyisexclusiveandinlieuofany
andallotherwarranties,expressedor
implied,includingwithoutlimitationthe
impliedwarrantiesofmerchantabilityand
fitness for a particular purpose and any
obligation, liability, right, claim or remedy
incontractortort,whetherornotarising
fromthecompany’snegligence,actual
orimputed.Nopersonorrepresentative
is authorized to assume for the company
anyotherliabilityinconnectionwiththe
saleofthisproduct.Innoeventshallthe
company be liable for indirect, incidental or
consequentialdamages.

8
Configuration/Setup
Theinputlevelcontrol(gain)isusedtoobtainthebest
possiblematchbetweentheheadunitaudiooutputandthe
amplifier input.
• Beginbyturningtheinputlevelcontrolfully
counterclockwise.
• Next,turnuptheheadunitvolumecontrolaround3/4
ofthewayup.
• Adjusttheinputlevelcontrolclockwiseuntilaudible
distortionisheard,thenslightlycounterclockwiseto
providethebestmatch.
• Repeatforallinputlevelcontrols.
Select2 CHmodeiftheheadunitonlyhas1pairofRCA
outputs.PlugtheRCA’sfromtheheadunitintoeitherthe
frontorrearchannel.All4amplifierinputswillreceivea
signal.
Note:Thereisnofaderfunctionwhenusing2 CH mode.
Select4 CHmodeiftheheadunithas2pairsofRCAoutputs.
PlugtheRCA’sfromtheheadunitintoeitherthefrontor
rear channel.
Thecrossoverisusedtofilteroutfrequenciesaboveor
belowacertainpoint.ChooseLPFwhenusingtheamplifier
withsubwoofers,HPFwhenusingwithmidrange/tweeter
combinations and OFFwhenusingwithcoaxial-type
speakers.
Note: Choose OFFwhenusingtheamplifierinstereo/
bridgedsimultaneousmode.Inthismode,passive
crossoversarerequired.Failuretousethecorrectpassive
componentsmaydamagetheamplifierand/orspeakers.
Consultaqualifiedprofessionalforrecommendations.
Thiscontrolallowspreciseadjustmentofthecrossover
frequency.
Thiscontrolprovidesadditionalboost@45Hzwhenused
withsubwoofers.Adjustthiscontrolwithcaution-as
improperusecandamagespeakers!
TheLEDindicatorilluminatesblueduringnormaloperation
(POWER)andredwhentheamplifierdetectsafault
(PROTECT).
Input level Control
Input Mode Switch
(XPR540)
Crossover Mode
Crossover Frequency
Control
Bass Boost
LED Indicator
Power and Speaker Connections
Ground Connection
RemoteConnection
+12VDCBatteryConnection
1
2
3
Fuse(s)
SpeakerConnection(s)
4
5
5
XPR522
132 5
4
132 5
4
XPR522
XPR540

6
Fuse Rating
Whenreplacingfuses,makesurenewfuse
is the correct type and amperage. Using an
incorrect fuse could damage the amplifier.
XPR52230ampATOx1
XPR54025ampATOx2
Main Power Connections
Connect+12V,GNDandREMwiresaccordingly.AsuitablefuseMUSTbeinstalledonthe
+12Vleadwithin18"ofthebatteryforprotectionofthevehicle’selectricalsystem.
Typical Wire Routing
Power/Ground Wire Size
Foroptimumperformance,useonlythewire
sizelistedbeloworlarger.Makesuretouse
thesamesizepowerandgroundwire.
XPR52210awg
XPR5408awg
7
Amplifier Connections
Speaker Connections
Connectspeakerwiresobserving
polarity. Theminimumimpedance
loadfortheXPR522orXPR540
is 2 ohms stereo and 4 ohms
bridged.Useofloadslowerthan
these is not recommended and
maycauseamplifierdamage.The
XPR522andXPR540canbewired
forstereo,bridgedorstereo/
bridged simultaneous operation.
Input Signal Connections
Low Level Input (RCA)
Lowlevel(RCA)inputsignalispreferredforbestperformance.Typicaltrunk-mount
amplifierinstallationsrequirea17-20footRCAcable.Mosttrucksandunder-seat
applicationsrequirea6-9footRCAcable.UsingtwistedpairconstructionRCAcableswill
minimize noise.
High Level Input (Speaker Wire)
High level inputs should only
be used when RCA outputs are
not available from the head unit.
Connecttheheadunitspeaker
outputstothehighlevelinput
connectorasshownbelow.The
blackwire(signalreferenceground)
mayormaynotrequireaconnection
tochassisground-dependingon
your particular installation.
Subwoofer (mono)
Typical Bridged Wiring
(4 ohms minimum)
2 Speakers (stereo)
Typical Stereo Wiring
(2 ohms minimum)
HI-LEVEL INPUT CONNECTION
Grey = Right (+)
Grey/Black = Right (-)
Black = Ground
White/Black = Left (-)
White = Left (+)
CAUTION
Donotusebothlowandhighlevelinputsatthesametime-connectonlyoneortheother.
XPR522speakerconnectionsshown