Kicker Warhorse WX 10000-1 User manual

WX10000.1
Technical Paper
SignalModulatedMonoChannel
SubwooferAmplifier

WX10000.1TechnicalManual
Warhorse: Defined as “Horses specially trained for use in battle or individual combat”.
As early as the 19th Century BC the Warhorse was used in chariot warfare. By the first century BC
the Warhorse carried Parthian archers into battle. By the Middle Ages the Warhorse had developed
into a large horse with the strength and stamina to carry a Knight and his heavy armor into battle. The
Warhorse of this era wore its own armor and was a magnificent beast. The best were selected for speed
and trainability. It was an expensive feat to train and outfit these tools of war. It took a lot of time to
overcome the natural aversion to the smell of blood and its natural disinclination to trample people. They
were even trained to kick, strike and bite on command.
In light of all this, Kicker’s newest and largest amplifier is named Warhorse. Born to do battle and
trained to excel, the Warhorse is like nothing available in the car audio arena. Conventional wisdom and
technology weren’t good enough for Kicker when we designed this 10,000 watt beast. Traditional Class
A/B design was entirely too inefficient and even more advanced Class D architecture wasted too much
battery power.
Efficiency is the “Holy Grail” of car stereo amplification, especially in SPL competition lanes. Warhorse’s
ultra-high efficiency allows competitors (as well as power hungry consumers) to create the huge
amounts of power they demand without relying on huge banks of amplifiers and the correspondingly
huge charging systems required with conventional amplifiers. By approaching the challenge of delivering
massive power from a new direction, Kicker engineers have created a system that lets users concentrate
their investments where they count – in actual sound reproduction equipment, instead of batteries,
alternators, or other charging system components. Signal quality is also critical to the demanding
high-end user, so in addition to the amplifier’s prodigious output capability, a full complement of built-in
control (crossovers, subsonic filter, bass boost, limiter, and more) allow precise tuning of your bass. A
broad assortment of protection and diagnostic circuits are also provided, allowing further performance
optimization.
KICKER’S signal-modulated power supply technology represents the first significant advance in amplifier
efficiency since Class D designs overtook Class A/B. Even though Class D was a great improvement
over A/B, Around 30% of available power was still wasted. While earlier technologies use power supplies
combined with gain circuits to amplify the audio signal, the Warhorse amplifies the audio signal directly
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WX10000.1TechnicalManual
from its signal-modulated power supply, eliminating many power-wasting components common to
conventional designs. The signal-modulated power supply amplifies each polarity of the audio signal
separately through two voice coil outputs, each driving one coil of a dual-voice coil subwoofer or DVC
subwoofer array. This fresh approach… essentially a power supply with gain… results in efficiencies
greater than 90%! SPL competitors will find this very attractive and advantageous as they seek to
wring those elusive last few decibels from their vehicle. Consumers anxious to experience cutting edge
technology will appreciate the amplifier’s ability to interface with a broad range of components and
vehicles.
The idea of a signal modulated power supply directly driving the subwoofers is an idea that we have
thought about for a few decades. Combining the conventional power supply with the amplifier section
results in higher efficiency than is possible with established designs. When building an amplifier this
powerful, efficient conversion of battery power to audio power is critical.
The basis for the Warhorse is anchored in conventional designs. There are two large DC-to-DC pulse
width modulated converters with ratios of 1:19. One converter is a positive power supply and the other
is a negative supply. Combined they are capable of 400V of peak to peak output. These power supplies
are designed to have no output until they are told to by the audio signal. Without a signal the converters
are running with the minimum pulse width.
These large converters have to be bulletproof. The MOSFETs used to do the switching are rated at
75 Volts and 170 Amps. Since there are 32 of these MOSFETs on each side of the power supply the
combined current capability is 10,880 Amps! With the output short-circuit protected at 90 Amps, the
maximum capability of the Warhorse is 12,690 Watts. That should qualify as overbuilt. The MOSFETs
chosen are the best devices to get the job done. Their typical 3.6 mili-ohms of “on” resistance is the best
available for this application, resulting in best-case efficiency.
The small-signal processing is done in the digital domain using a modern Texas Instruments 150 M Hz
CMOS 32 bit CPU. This processor has a 12 bit ADC and 16 channels.
The Warhorse has multiple “housekeeping” power supplies to operate the processors, LEDs, protection
circuits and preamp parts. They include a + 12 Volt, +/- 5 Volt and a +3.3 Volt supply.
Transformers are among the most important
parts in a high-powered mobile amplifier.
KICKER engineers were tasked with
building a no-compromise amplifier, so no-
compromise transformers were paramount.
Back in the 80’s our military began using
Planar transformer design for their desirable
properties. We use very special proprietary
Planar transformers designed and prototyped
in the Kicker R&D department. Production of
the transformers in quantity has been sourced
from Tunisia. There is only one source for
transformer cores this large. The cores are
rated at 5,000 watts each and four are in
each Warhorse amplifier.
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WX10000.1TechnicalManual
There are five extremely good reasons why the Planar design is best for the Warhorse.
By design, a Planar style of transformer has the lowest leakage inductance. This is very important1.
from an engineering standpoint because of the extremely high current level needed to produce 10,000
Watts. The coupling between the primary and secondary is much better than with any other design.
They have an ultra low profile for the electrical rating. With the winding being flat and glued to2.
the ferrite core the transformers are very tough. The primary windings are screwed to the buss bars,
increasing stability and providing reliable high-current connections.
Since they have the best surface-to-volume3.
ratio, cooling is better than that of conventional
toroidal transformers.
With other types of transformers, it is difficult4.
to get consistent properties relating to the
wrapping of the windings. The physical layout
of the Planar transformer allows it to be built the
same way each time for very consistent results.
A high turn ratio is impractical with the other5.
transformer designs. In the Planar transformer we
can easily reach the 19:1 ratio needed to get the
voltage used in a 10,000 Watt amp.
The switching frequency is 24 KHz, yielding a much easier to filter 48 KHz ripple after the full wave
rectifiers. The output of this signal-modulated power supply is filtered by two over-built toroidal output
coils. Spike suppression is accomplished with filters utilizing eight 35 Watt snubber resistors. Worst case
for these filters is seen at full output.
The printed circuit board (PCB) for an amplifier this large has to be stronger than normal. The Kicker
Warhorse components are mounted on a thicker (.090”, 2.5 mm) than usual fiberglass PCB with much
heavier (4 ounce) copper traces.
In order to optimize the circuit board layout the battery power connectors needed to be near the top
center of the amplifier chassis. There are three 1/0 gauge sized proprietary gold plated brass connectors
for the negative ground connections and three more for the positive connections. These connectors are
bolted to symmetrical copper buss bars for power distribution within the chassis.
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WX10000.1TechnicalManual
Since the output current to the subwoofers can reach 90 amperes, the connectors must be extremely
rugged. We chose AndersonTM connectors because they have been proven to hold up under demanding
high current applications (such as industrial fork lifts). They are also ideal due to the fully enclosed design
which helps eliminate the chance for electrocution. The output current is monitored by surface mount
resistors that are referenced to ground and calibrated for 90 amps RMS. When that level is reached the
DSP controller shuts the amplifier down in microseconds to prevent damage to any components.
The switching MOSFETs need to be bulletproof, so they utilize thermally conductive interface material.
This insulated metal substrate minimizes the thermal impedance and conducts heat away from the
MOSFETs more efficiently than conventional mounting methods.
In conclusion, the Kicker Warhorse WX10000.1 has the highest power output available in a single
channel mobile amplifier, the best conversion efficiency from battery power to audio power, the lowest
idle current and the best power to size/weight ratio.
0
20
40
60
80
100
%EFFICIENCY
KICKER PATENT PENDING SIGNAL-MODULATED DESIGN
HIGH QUALITY CLASS D DESIGN
POWER OUTPUT (KW)
0.1 0.2 0.5 1.0 2.0 4.0 8.0 10
90%
75%
4
01302008-b+WX10000

WX10000.1AMPLIFIER
Authorized Kicker Dealer:
Purchase Date:
Amplifier Model Number:
Amplifier Serial Number:
__________________________
__________________________
__________________________
__________________________
WX10000.1
Signal-ModulatedMonoChannel
WX.1SeriesAmplifier
Owner’sManual
Congratulations on your
KICKER purchase!
Please record your purchase
information and keep your sales
receipt for validation of warranty.
INSTALLATION
0
20
40
60
80
100
%EFFICIENCY
KICKER PATENT PENDING SIGNAL-MODULATED DESIGN
HIGH QUALITY CLASS D DESIGN
POWER OUTPUT (KW)
0.1 0.2 0.5 1.0 2.0 4.0 8.0 10
90%
75%
The Kicker Warhorse amplifier was specifically designed for competition car audio. Sporting 10,000
RMS watts of pure Kicker power, the ultra-high-efficiency design of the WX amplifier revolutionizes
traditional methods of amplification. While most amplifiers use a power supply combined with an
amplification circuit to amplify the audio signal, the Warhorse skips a step by amplifying the audio
signal directly from its patent pending signal-modulated power supply. The signal-modulated power
supply amplifies each polarity of the audio signal separately through its two voice coil outputs to
optimally drive dual-voice coil subwoofers and provide a competitive edge in SPL contests. From gold
plated power connectors and low profile planar transformers to the latest Texas Instruments DSP
technology, no expense was spared to make the Warhorse the most powerful and efficient mono
amplifier in mobile audio.
Installation . . . as easy as 1, 2, 3
1. Mounting Choose a structurally sound location to mount your Kicker amplifier. The amplifier should
be mounted as close as possible to the battery network and be electrically isolated from the vehicle
ground. The distance from the battery network to the amplifier should not exceed 48” (122cm). It is
important to mount the amplifier before running any wires or supplying power to the amplifier. The
amplifier secures to the vehicle with an insertable mounting bracket used in combination with two
mounting holes located on the bottom plate of the control panel. You are solely responsible for securely
fastening the WX amplifier in your vehicle.
Before mounting the amplifier, the control panel shield must be removed. The control panel should
remain accessible for adjustment, leaving enough room to access the mounting holes and remove or
attach the control panel shield. Make sure there are no items behind the area where the screws will be
driven. Choose a location that allows at least 4” (10cm) of open ventilation for the amplifier. After
choosing the best location, secure the mounting bracket to the vehicle. Use the bracket as a template
to drill nine (9) holes with a 3/16” (4.8mm) bit into the appropriate locations. Attach the bracket to the
mounting location with the nine (9) supplied #10 (5mm) screws inserted through the nine (9) included
screw insulators.
Next, slide the amplifier over the mounting bracket and into the mounting slot. Make sure the mounting
bracket is properly inserted into the mounting slot and locate the two mounting holes on the bottom
plate of the control panel. Use the mounting holes as a template and drill two (2) holes using a 3/16”
(4.8mm) bit into the appropriate locations. Secure the bottom plate of the control panel with the two (2)
#10 (5mm) screws.
Caution The Kicker WX amplifier outputs extremely high voltage signals
from the voice coil (speaker) outputs and can cause serious injury or death
from electrocution. It is imperative to read the manual carefully and follow all
of the recommended safety precautions before installing the WX amplifier.
The patent pending signal-modulated
design of the Warhorse amplifier is the
most powerful and efficient design
available in mobile audio, rated at 90%
efficiency at full power with a 2 ohm load.
The graph compares the Warhorse
amplifier’s efficiency ratings to those of
industry standard Class D amplifiers.
Figure 1
Model:
SubwooferAmplifier
WX10000.1
5

6
Figure 2
Control Panel Shield
Mounting Bracket
Nine (9) Supplied
Screw Insulators
Nine (9) Supplied
#10 (5mm) screws
Mounting Bracket
Warhorse Amplifier
Mounting Holes
Control Panel
(Top View)
Remove the two (2) screws
securing the control panel
shield to the amplifier chassis.
Remove the control panel shield from the
amplifier so the mounting holes on the bottom
plate of the control panel will be accessible.
Before mounting the amplifier, be sure there is adequate space in the mounting position
to take the control panel shield on or off and to easily access the amplifier’s controls.
After determining the best mounting position for the amplifier, use the mounting bracket as a template to drill
nine (9) holes with a 3/16” (4.8mm) bit into the appropriate locations. Attach the bracket to the mounting
location with the nine (9) supplied #10 (5mm) screws inserted through the nine (9) included screw insulators.
Slide the Warhorse over the mounting bracket and insert the mounting
bracket into the mounting slot on the bottom of the amplifier.
Locate the additional mounting holes on the bottom plate of the control panel. Use the mounting holes as a template
to drill two holes using a 3/16” (4.8mm) bit into the appropriate locations. Secure the bottom plate of the control panel
with the two (2) #10 (5mm) screws. You are solely responsible for securely fastening the amplifier in your vehicle.
INSTALLATION
1.
2.
3.
4.
5.
The amplifier is very heavy.
Assistance may be necessary
to lift and position the amplifier.

7
2. Wiring Before wiring the Warhorse amplifier, disconnect the vehicle’s batteries to avoid an electrical
short. Eight (8) identical, high-quality, 800-cold-cranking-ampere (cca), 12-volt batteries are
recommended to power the WX amplifier. All power and ground wires should be as short as possible
and utilize 1/0 gauge wire. Remove the wire guide and power hood from the amplifier as shown in
Figure 3. Connect three (3) ground wires from the amplifier’s negative power connector to the negative
terminals of three (3) batteries in the battery network.
From two (2) of the batteries in the battery network, connect 1/0 gauge ground wire from the negative
terminals of the batteries to a paint-free and corrosion-free solid-metal area of the vehicle's chassis.
Make the ground wires short, 18” (45cm) or less. To reduce noise, make sure the ground wires connect
to the same piece of metal and are within 18” (45cm) of each other.
With the control panel shield removed, connect a twisted pair of RCA (low-level) interconnect cable,
carrying the incoming audio signal, to the RCA inputs on the amplifier. Connect the speaker wires to the
supplied AndersonTM connectors. Use 8 gauge wire and strip 9/16” (14mm) from the end being
inserted into the metal contacts. See Figure 5. The wire should be secured by placing the metal contact
into a vise and melting solder inside the metal contact. Then, insert the stripped wire into the molten
solder within the contact. Do not use acid core solder.
The Warhorse amplifier requires at least two (2) 200-ampere-output-capacity alternators. For each
alternator, connect a 250 ampere fuse within 18” (45cm) of each alternator and a second 250 ampere
fuse within 18” (45cm) of the battery network. Without adequate charging capability, the WX amplifier
can draw enough current to shut down your vehicle’s computer system. This may adversely affect your
ability to control your vehicle. See Figure 4.
The three (3) positive 1/0 gauge power wires should be the last wires connected in the installation.
Install the supplied Kicker three (3) gang ANL fuse holder within 18” (45cm) of the battery network and
in-line with the three (3) power cables connected to the amplifier’s positive power connector. Improper
connections will damage the amplifier and/or cause serious injury or death. If you ever need to remove
the amplifier from the vehicle after it has been installed, the ground wires should be the last wires
disconnected from the amplifier, just the opposite as when you installed it. See Figure 4.
INSTALLATION
WX10000.1AMPLIFIER
If you have more questions about the installation or operation of your new KICKER product, see the
Authorized KICKER Dealer where you made your purchase. For more advice on installation, click on the
SUPPORT tab on the Kicker homepage, www.kicker.com. Choose the TECHNICAL SUPPORT tab,
choose the product or subject you are interested in, and then view the corresponding information. Please
E-mail [e-mail] or call Technical Services [phone] for unanswered or specific questions.
Power Hood
Wire Guide
Note: To get the best performance from your new Kicker Amplifier, we recommend using genuine Kicker Accessories and Wiring.
All specifications and performance figures are subject to change. Please visit the www.kicker.com for the most current information.
Figure 3

8
Figure 5
Strip Wire
9/16” (14mm)AndersonTM Connector
8 Gauge Speaker Wire
Metal ContactsSecure wire to metal
contacts by soldering.
ModelWX10000.1 Fuse Three (3) x 250 Ampere PowerGroundWire Three (3) x 1/0 Gauge
+12V
+12V
+12V
+12V
+12V
18"
Or Less
(45cm)
18"
Or Less
(45cm)
18"
Or Less
(45cm)
18"
Or Less
(45cm)
+12V
+12V
+12V
18"
Or Less
(45cm)
At least two (2) 200-ampere alternators are
required to power the Warhorse amplifier.
Run two (2) ground wires from
separate negative battery
terminals. Ground wires should
connect to vehicle chassis
within 18” of each other.
Eight (8) identical, high-
quality, 800-cca, 12-volt
batteries are recommended
for optimum performance. 250 ampere
fuse
250 ampere
fuse
250 ampere
fuse
250 ampere
fuse
ANL fuse holder
contains three (3) 250
ampere fuses. The fuse
holder should be
installed within 18” of
battery network.
Mount Amplifier within 48”
(122cm) of Battery Network
-
+
Figure 4
3. Configuration The following diagram shows the recommended mono configuration for your
Kicker WX amplifier. The WX amplifier can only drive extremely high-power-rated, dual-voice coil
speakers. We recommend using one or more Kicker SoloX Subwoofers. Each voice coil (speaker)
output is rated at 2 ohms minimum.
Warning: This amplifier is not like anything you
have ever hooked up before. Pay close
attention to the wiring diagrams in this manual.
Improper connections will damage the amplifier.
Negative Power
Connector
Positive Power
Connector
CONFIGURATION
Without adequate
charging capability, the
WX amplifier can draw
enough current to shut
down your vehicle’s
computer system. This
may adversely affect
your ability to control
your vehicle.
The WX amplifier outputs dangerous voltage levels from the voice
coil (speaker) outputs and can cause serious injury or death from
electrocution. Never contact the voice coil outputs, connect
speakers, or contact speaker wires while the amplifier is turned on.
Caution The Kicker WX amplifier outputs extremely high voltage signals
from the voice coil (speaker) outputs and can cause serious injury or death
from electrocution. It is imperative to read the manual carefully and follow all
of the recommended safety precautions before installing the WX amplifier.
Improper connections will damage the
amplifier and/or cause serious injury or
death. Be sure that all wiring is
connected to the appropriate polarity.
or less
or less
or less
or less
or less

9
The WX amplifier outputs dangerous voltage levels
from the voice coil (speaker) outputs and can cause
serious injury or death from electrocution. Never
contact the voice coil outputs, connect speakers, or
contact speaker wires while the amplifier is turned on.
Voice Coil 1 Voice Coil 2
Voice Coil 1 Voice Coil 2
Voice Coil 1 Voice Coil 2
Figure 7
Mount the metal bracket
Back View
Side View 4 Conductor
Phone Cable
Slide the
housing until
it snaps into
the metal
bracket
Voice Coil 1 Voice Coil 2
Coil 1
Use 8 Gauge Speaker Wire
2 Ohm Dual-Voice Coil Subwoofer
Two (2) 4 ohm Dual-Voice Coil Subwoofers
-+
Coil 2
Figure 6
Minimum
2 Ohm
Load
Minimum
2 Ohm
Load
Minimum
2 Ohm
Load
Minimum
2 Ohm
Load
-+
-+
Minimum
2 Ohm
Load
Minimum
2 Ohm
Load
-+
Coil 1
Coil 2
Coil 1
Coil 2
Coil 1
Coil 2
Coil 1
Coil 2
Four (4) 2 ohm Dual-Voice Coil Subwoofers
WX10000.1AMPLIFIER
-+-
+
CONFIGURATION
-
+
-
+
-
+
-
+
-
+
-
+
-
+
-
+
-
+
-
+
Use 8 Gauge Speaker Wire
Use 8 Gauge Speaker Wire
Coil 1
Coil 2
-
+
-
+
Coil 1
Coil 2
-
+
-
+
Voice Coil 1 +
Voice Coil 1 -
Voice Coil 2 +
Voice Coil 2 -
Series Wire
Wiring Key
Use 8 Gauge Speaker Wire