PL-AUDIO PowerPac 4003 DSP User manual

USER MANUAL
PowerPac 4003 DSP
FREE PROGRAMMABLE SYSTEM AMPLIFIER
✔3-Channel Amplifier with DSP „Handmade in Germany“
✔massive Power (1 x 2.500W + 2 x 800W at 4Ohm)
✔free programmable DSP with 80 Memorypresets
✔audiophile presence & light weight
© PL Audio GmbH & Co.KG | Siegener Straße 6 | 57482 Wenden | www.pl-audio.de Stand: 09-2020 V 1.20 Seite: 1

Table of content
Chapter Page
Introduction 3
Safety instructions and intended usage 3
Transport and storage 4
Guarantee terms and conditions 4
Product short description 4
Scope of delivery , technical data overview 5
Detailed product description 5
Technical data detailed 6
Construction and control interface 8
Connections and opearting options 9
Bridged mode operation 11
Mains connection 12
Usage on a mains power generator, XLR- and speaker connection 13
USB and network communication 15
Installation 16
Limiter table 17
DSP control via Display & Encoder wheel 18
Loading and editing of presets on the device / Routing 19
DSP control via Software PL-Audio DSP Control, Firmware update process 20
Restore firmware and bootloader 21
Internal wiring diagram & signal flow 22
Block diagram DSP 23
Display information overview 24
MENÜ-overview diagram 25
Safety during operation, maintenance, disposal, Impressum 26
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USER MANUAL PowerPac 4003 DSP
© PL-Audio GmbH & Co.KG | Siegener Straße 6 | 57482 Wenden | www.pl-audio.de Version: October 2021 V 1.0

Introduction
Congratulations on purchasing a PL-AUDIO product! Your investment in the PL-AUDIO brand guaranteed quality and
products "Made in Germany", excellent functionality, an almost unbeatable price / performance ratio, as well as
direct and uncomplicated customer service.
We created this manual to ensure an easy start with your newly purchased product. Before you start using your new
product please read this manual carefully and keep it at your hands for future reference
Safety instructions and intended usage
In order to enjoy your device for a long time please make sure to follow the informations noted hereunder:
•The device complies with the necessary directives of the EU and therefore it carries a CE mark.
•This device left our factory in perfect technical condition. In order to ensure safe opereation, the user must
absolutely observe the following safety and warning notices:
•The devicve is supplied with dangerous mains voltage (>50 Volt AC). Therefore
never intervene on the device on yourself! There is a risk of electric shock!
Connection cables has to be protected against crushing, tensile load and bending.
Cables and wires are to be laid or secured in such a way that no one can trip over it
or may fall.
•Use the device only for the applications recommended by PL-AUDIO or which can be found in this manual. In the
event of improper use any warranty claims become obsolet and void.
•Use the device only indoor and protect it against dripping and splashing water, high humidity, heat and direct
sunlight.
•Do not place any objects filled with liquids, such as drinking water glasses,…, on the product.
•The heat generated by the amlipier modules must be dissipated by technical forced ventilation. The built in fan
switches on at a device temperature exceeding 60 and switches of at a device temperature of 40 degrees. For this
reason, do not cover the ventilation openings on the housing under any circumstances. The device exhausts the
warm air through the front grille.
•Do not put the device into operation and immediately pull the power plug of the device out of the socket:
1. if there is visible damage to a device or to the power cord,
2. if after a crash or compartable mishandling there is a suspicion of a defect,
3. if malfunctions occur.
•In any case, send the devices back to PL-AUDIO for inspection / repair. Please send any devices in sufficient outer
packaging to the PL-AUDIO production site. You can find this on the website www.pl-audio.de. Transport damage
due to insufficient packaging on the part of the sender cannot be claimed. A corresponding pre-registration of a
claim with a precise description of the fault - so that the devices sent in are correctly assigned - is inevitable.
•Never pull the power plug out of the socket by just pulling on the cable, always take hold of the power plug.
•Only use a dry, soft cloth for cleaning; never water or chemicals.
When using compressed air please pay attention to lubricant-free
compressed air and keep a minimum distance of 20 cm to the
individual parts.
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USER MANUAL PowerPac 4003 DSP
© PL-Audio GmbH & Co.KG | Siegener Straße 6 | 57482 Wenden | www.pl-audio.de Version: October 2021 V 1.0

Transport and storage
Secure and smart handling of our products helps you to keep the value of your device. In addition to this you
benefit for a longer time from the quality of your product.
For this reason, we ask you to note the following information in relation to above mentioned content point:
It is essential to install the device in a–ideally shock-absorbing –19“-Flightcase, to protect the device from
transport- and handling damage. Please note that these flight cases are not the proper housing for shipping with
parcel services. Please ensure that there is sufficient air ventilation when installed. Make sure to handle the device
as gently as possible during transport. We recommend to transport the unit in a horizontal position as shown on
the cover (page 1). Always store the device at a minimum temperatrure of 05° Celsius with low humidity and
without large temperature fluctuations. Avoid to expose the device to permanent direct sunlight.
Guarantee terms and conditions
PL-AUDIO gives its customers a manufacturer's guarantee of 5 years on the PowerPac 4003 DSP product. This
guarantee is retained even if the product is resold within the EU and Switzerland. The guarantee period begins with
the purchase from an authorized sales or distribution partner or directly ex works. Please keep the original invoice.
This must be submitted for the submission and acceptance of any warranty claims. This manual is an essential part
of the product. Devices without a serial number (illegible or removed serial numbers) cannot be accepted under
any guarantee.
PL-AUDIO disclaims liability for transport damage, rough handling and / or incorrect use, external manipulation on
and inside the housing, unauthorized repair attempts, faulty mains voltage or mains connection, operation of the
amplifier below the minimum ohmic value specified in the operating instructions, effects of moisture, massive
contamination from dust, incorrect operation of emergency power systems (power generators, UPS systems, ...)
and faulty feeds into the device. Furthermore, PL-AUDIO does not recognize any warranty or guarantee claims for
any direct or indirect damage caused by installation, configuration, manipulation or storage of the specified
software and its components.
Devices which are covered under the guarantee conditions must be sent back to PL-AUDIO after prior notification.
Please send the devices in sufficient outer packaging (ideally in the original packaging) to the PL-AUDIO production
site. You can find this on the website www.pl-audio.de. Please note that any service manipulation can lead to data
errors or complete data loss on the device sent in. Data errors and / or data loss are not covered by warranty or
guarantee. You should therefore save your presets several times on different storage media in the course of the
configuration in your own interest.
In the event of any claim, no guarantee or subsidiary liability is assumed for upstream / downstream products.
Individual goodwill decisions on the part of PL-AUDIO are always related to the respective individual case and in no
case represent an acknowledgment of any defects. In a recognized warranty case, PL-AUDIO decides on repair or
replacement at its own discretion.
Product short description
The PowerPac, low weight and top performance
The PowerPac 4003 DSP product is a digital 3-channel amplifier with integrated DSP G-2.3 controller. The PowerPac
4003 DSP is ideal as a base for a multitude of applications from solo entertainers to small PA-solutions, fixed
installations up to medium-sized PA-systems. Using several PowerPac 4003 DSPs, these can be customized very
easily to multiple system solutions. The power of 2.5kW on the bass-channel and 2 x 0.8kW on the Fullrange-
channels offers versatile configuration possibilities which offers highest flexibility to your rental equipment as well
as to any personalized PA-system. Easy programming and operation plus small mechanic dimensions are an
additional benefit which makes the PowerPac 4003 DSP a very interesting solution for almost any requirement.
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USER MANUAL PowerPac 4003 DSP
© PL-Audio GmbH & Co.KG | Siegener Straße 6 | 57482 Wenden | www.pl-audio.de Version: October 2021 V 1.0

USER MANUAL PowerPac 4003 DSP
5© PL-Audio GmbH & Co.KG | Siegener Straße 6 | 57482 Wenden | www.pl-audio.de Version: October 2021 V 1.0
Scope of delivery
Beside the PowerPac 4003 DSP you can find following components in the carton box:
•Mains cable with PowerCon®-male connector. Please do just use this cable without any manipulation on the cable
itself.
3 CHANNEL CLASS D AMPLIFIER: 1 X 2500 W + 2 X 800 W INPUT-LIMITER AND PEAKLIMITER
switch-on current limitation Protection circuit
Mains fuse protection Under- and overvoltage protection
DC –protection temperature monitoring
silent fan Damping factor >1000 ( 8 Ohm, 1Khz)
Distrotion THD+N under 0,05% (20 Hz –20 Khz) Signal-noise rate < 120 db (20 Hz –20 Khz)
Wide range power supply with voltage detection and
automatic switching 120V –230V 2 HE aluminum casing
Weight 4,7 kg Detph 230 mm
Powercon In –out Switch on/off on front
2 x XLR in and out 2 x Speakon® 4 pole out
1 x Speakon® out as Bi-Amp 1 x Speakon® out as separate Bass
HIGH END DSP, ON BOARD ETHERNET AND USB
Simple operation Manual operation on front
80 Presets internally 96 Khz Sampling-Rate
120 db Dynamic Range flexible Routing
X –Over Function 20 parametric EQ’s
Limiter- and Noisegate-Function Short-Delay and long delay
Phase Firmware –Upgrade over interface
APP in in preparation
Product detailed description
As described above, the PowerPac 4003 DSP is a system output amplifier with a total of 3 amplifier channels. Here,
the two smaller dimensioned amplifier channels 2 + 3 are offering 800 watts at 4Ωeach for the operation of
classic passive tops, as well as a drive for 1 bi-amp top (e.g. banana array,TS 42,TS 61,TS 62,LA206,LA208,
LA210).The amplifier channel 1 is 2500 watts at 4Ωfor driving a subwoofer (8Ohms) and the connection of
corresponding additional subwoofers (B12 Sub, B15 Sub, B18 Sub,etc.) with a nominal impedance of at least 8
ohms. The signal distribution in the device takes place by means of a built-in DSP controller DSP G-2.3. This has 2
signal inputs (Input A + Input B) and 3 signal outputs (Out 1, Out 2, Out 3). The signal outputs of the DSP are
internally connected to the respective amplifier modules. The signal output Out 1 is for the 2500 watt amplifier
module - bass applications - occupied. The signal outputs Out 2 + 3 are awarded for the smaller amplifier modules
of 800 watts each.The XLR input signal can be looped through to other devices via the XLR Out socket. Depending
on the operating mode of the device, both XLR inputs are processed, or if in mono mode, only the Input A used.

1.2 Technical data / detailed
Output Power 8Ω @ 1% THD+N 1kHz Output Power 4Ω @ 1% THD+N 1kHz
Ch 1 1550W –8Ω
450W –8Ω
Ch 1 2500W –4Ω
800W –4ΩCh 2/ Ch 3 Ch 2/ Ch 3
Ch2+3 Bridge 1600W –8Ω
Amplification factor: Amplifier-Technology Class D
Ch 1 32dB
Ch 2/ Ch 3 26dB
(Ch2+3 Bridge 32dB)
DSP-Technology
Preset memory (internal)
Input-Impedancy
Max. Input level
Bit rate
DSP-G2.3
80
20kΩ
+24dBu / 12V RMS
64Bit
Sampling rate 96kHz Sample-Rate
120dB (A)
0,6 ms
0,005% /8Ω, 1kHz
118dB (A) /8Ω, 1kHz
10Hz-25kHz
USB 1.1
Input Dynamic Range
Latency DSP
Distortion factor THD+N
Signal to noise-rate
Frequency range
USB
Ethernet
Input-Delay
Output-Delay
10MBit, with DHCP Server, Auto/Manual IP-Adress
800 ms / 274m (Input 1+2)
5 ms / 1,715m (Output 1+2+3)
USER MANUAL PowerPac 4003 DSP
6© PL-Audio GmbH & Co.KG | Siegener Straße 6 | 57482 Wenden | www.pl-audio.de Version: October 2021 V 1.0
Voltage
range
Automatic
voltage detection
AC Range 1 / 120V
85V
- 138V AC (US-Voltage)
AC Range 2 / 230V
170V
- 265V AC (Europe-Voltage)
Frequency
range
45Hz
–65Hz
Power
consumption at 230V
Standby
6 Watt / 0,026A
Idle
35 Watt
/ 0,15A
Rated
power consumption (without reactive current)
480 Watt
/ 1,73A (Ch1 4Ω, Ch 2+3 8Ω)
685 Watt
/ 2,97A (Ch1 4Ω, Ch 2+3 4Ω)
Maximum
2400 Watt / 10,43A
Switch on
peak voltage @230V
32,5A
pk
Switch on
peak voltage @115V
17,0A
pk
= Amplifier ON –operation ready with no Input/Output-signal

USER MANUAL PowerPac 4003 DSP
7© PL-Audio GmbH & Co.KG | Siegener Straße 6 | 57482 Wenden | www.pl-audio.de Version: October 2021 V 1.0
Protection
circuits
True
-RMS Compressor & Limiter for all Inputs and Outputs
Switch On and Switch Off
-Delay of Outputs
ICL
Inrush Current Limiter
Intelligent
current limitation prevents the triggering of fuses
Peak
current Limiter on the speaker outputs
DC
-Protection on the speaker outputs
High
frequency protection on the outputs (>30kHz, 2Sek)
Temperature
observation with output power reduction by overheating
Measurements
Width
482mm (19“)
Heigth
89mm (2HE)
–with rubber feets 92mm
Depth
225mm
–with operation controls 245mm
Weight
4,7
kg
Temperature
range
Environment
tempereature
-
5°C bis +40°C not condensing!
Fan switch on
temperature
60
°C
Fan switch off
temperature
40
°C
Output power
reduction
85
°C
Temperature
–Emergency shut down
95
°C
Colling
concept
Air, back
to front, 1-speed
Fan
80mm, 30cbm/h, 35db(A)

2. Construction and control interface
2.1 Following elements are located on the front side of the device (from left to right):
1 2 3 4 5 6 7
2.2 Following connectors and elements are located on the backside of the unit (from left to right):
8 9 10 11 12 13 14 15 16 17
Nr.
1
Element
Mains switch
2LED Signal chain / Signal -24dB to -6dB yellow 0dB Red Clip/Limiter (red blinking = Mute)
3
4
5
6
7
Button Exit / leaving the menue
Button Menu / call up the menue and confirmation of a name or password
LCD Display / upper line: device name lower line: loaded preset
Encoder selector / turn=Select, push=confirmation/execute
Lüftungsschlitze
8 XLR Out symmetric signal pass through
9 XLR Input symmetric
10
11
12
13
14
15
16
17
Ethernet connector for network connection to the DSP via Router or Computer
USB Buchse Typ USB B for connection of the DSP to an external computer
Fan
4 pol. Speakon® connector for system cabling L+R (1+/1- Top, 2+/2- Bass)
4 pol. Speakon® connector for Bi-Amp operation (CH 2= 1+/1-; CH3= 2+/2-) red
4 pol. Speakon® connector only for Subwoofer (CH1= 1+/1- and 2+/2-)
Mains pass through connection 16A Powercon® OUT grey
Mains connection 16A Powercon® IN blau
USER MANUAL PowerPac 4003 DSP
8© PL-Audio GmbH & Co.KG | Siegener Straße 6 | 57482 Wenden | www.pl-audio.de Version: October 2021 V 1.0

2.3 Connections/Operating options
The PowerPac 4003 DSP offers the user numerous possible uses:
The power amplifier has 3 output channels, 1x 2500W @ 4Ω and 2x 800W @ 4Ω. A second subwoofer á 8 ohms
and up to 4 top parts á 8 ohms can be connected. Channel 1 of the PowerPac 4003 DSP drives the subwoofer (8Ω).
This receives 1250W into 8Ω. (see application 1)
If you add another subwoofer (8Ω) to channel 1, the impedance is reduced to 4Ω. The 2500W (which are available
on 4Ω) are now shared between both subwoofers and each speaker receives 1250W into 8Ω. (see application 2)
•Calculation example: 1250W 8Ω + 1250W 8Ω = 2500W 4Ω
For all stereo applications the LINE signals from the mixer has to be connected to the PowerPac 4003 DSP as
follows:
XLR L/R
2.3.1 Stereo + Sub operation
–Application 1 –
2.1 PA-System
•1 x PowerPac 4003 DSP
•1 x Subwoofer passive, eg. PL-Audio B18Sub
•2 x Fullrange-Tops á 8Ω, eg. PL-Audio F10pro
•2 x 2pole-Speakon® cables
•1 x 4pole-Speakon® cable
USER MANUAL PowerPac 4003 DSP
2-pole Speakon®cable
4-pole Speakon®cable
9© PL-Audio GmbH & Co.KG | Siegener Straße 6 | 57482 Wenden | www.pl-audio.de Version: October 2021 V 1.0

•1 x PowerPac 4003 DSP
–Application 2 –
•2 x Subwoofer passive 8Ω, eg. PL-Audio B18Sub
•2-4 xFullrange Tops á 8Ω eg.PL-Audio F10pro
•2-4 Stk 2pole-Speakon® cables
2.2/4 PA-System :
•2 Stk 4-pole Speakon® cables
OR
4-pole Speakon®cable
4-pole Speakon®cable
2.3.2 Bi-Amp operation –Application 3 –
4.2 PA-System :
•
•
•
2 x PowerPac 4003 DSP
4 x Subwoofer passive á 8Ω, eg. PL-Audio B18Sub
2 x Fullrange Tops á 8Ω without built-in X-Over eg.
PL-Audio TS 42/61/62, LA206/208/…
6 x 4-pole-Speakon® cables
•
All speaker cables
4-pole Speakon®
USER MANUAL PowerPac 4003 DSP
2-pole Speakon®cable 2-pole Speakon®cable
10© PL-Audio GmbH & Co.KG | Siegener Straße 6 | 57482 Wenden | www.pl-audio.de Version: October 2021 V 1.0

Bridged mode
The bridged operation (BTL) couples the power from channel 2 (800W / 4Ω) and channel 3 (800W / 4Ω) to a strong
1x 1600W / 8Ω mono channel. The lowest impedance is 8Ω, do not connect less than 8Ω! The BTL bridge operation
increases the voltage gain from 26dB to 32dB (+ 6dB)!
Attention: The bridged mode can NOT be set or recognized on the display of the amplifier!
A computer with the DSP software is required to set the BTL bridged mode.
Method
1.
2.
3.
4.
5.
a)
b)
c)
Connect the DSP to the PC. Start the software and open the control window.
In the MAIN window, switch on the blue link button channel 2 + 3. (Linking Ch2 + 3)
Make all the settings for your loudspeaker in output Out 2 of the DSP.
Please calculate the limiter with a gain factor of 32dB and set it correctly!
Now switch on the bridge mode in the PC software:
In the menue click Hardware
Select Configure -> Output Mode -> Outputs 2 and 3
Bridge Mono
Click on
In the bridge-mono operating mode, all buttons of the Out 3 are out of operation on the software side!
All settings in the DSP controller must be made in Out 2.
Connecting the loudspeaker in BTL mode: Only use the red bi-amp socket in the connection panel for bridge
operation! Make sure that the Speakon® connectors are wired properly and protected against short circuits.
Bi-Amp connector, red Speaker,8Ω
+ Plus pole speaker
- Minus pole speaker
1+ Pluspole, Output 2 (+)
1- Minuspole, Output 2 (-)
2+ Pluspole, Output 3 (+)
2- Minuspole, Output 3 (-)
Never connect impedances with less than 8Ω to the amplifier in bridged mode !!!
These instructions are only valid for devices with a red or black bi-amp socket!
USER MANUAL PowerPac 4003 DSP
11© PL-Audio GmbH & Co.KG | Siegener Straße 6 | 57482 Wenden | www.pl-audio.de Version: October 2021 V 1.0

Mains connection
The device may only be connected to an electrical installation that complies with the VDE regulations DIN VDE 0100.
The electrical installation must be equipped with a residual current circuit breaker (RCD) with> 30mA rated residual
current.
The devicve is supplied with dangerous mains voltage (>50 Volt AC). Therefore never intervene on the device on
yourself! There is a risk of electric shock! Connection cables has to be protected against crushing, tensile load and
bending. Cables and wires are to be laid or secured in such a way that no one can trip over it or may fall.
Damaged Mains-Power cables must not be used and should immediately be rendered unusable against further use,
e.g. cut off both plugs.
The device is powered by a Neutrik Powercon® connector. In contrast to a plug-in device (such as a safety plug), the
Powercon® plug-in connection must not be plugged in or disconnected under load and also not under voltage! The
consequences are stuck or burned-out contacts and the resulting loose contacts lead to failures or even destruction
of the electronics or even the risk of fire. You should therefore only switch the device ON or OFF using the
2-pole power switch on the front panel of the unit.
The mains plug may only be connected to an earthed safety socket with the associated mains connection cable. If
extension cables are used, it must be ensured that the wire cross-section is dimensioned and approved for the
power supply required for the device! Make sure that the mains voltage of the socket corresponds to the permissible
voltage values in this manual.
The power supply of the amplifier is equipped with an intelligent mains voltage detection. It allows worldwide
operation on all power grids. After switching on, the electronics check the mains voltage and switches the power
pack to the correct voltage range 115VAC or 230VAC.
If a three-phase current generator is used at events on which the device is to be operated, the correct mains
voltage must be checked before connecting the amplifier! In the event of faulty three-phase power supplies
without a neutral conductor, a so-called neutral point shift can result in up to 400Volt being applied to the
protective contact sockets. This overvoltage leads to the destruction of the electronics in the amplifier.
The device has a PowerCon®-Out (16) over the existing Powercon®-IN (17). This is provided for the option of
connecting another device through a short interlink PowerCon®-cable eg. when built in in a rack with other amplifiers
or other devices. Please make sure that the overall power consumption of all connected devices does not exceed the
maximum power of 16 Ampere, or the maximum allowed power limited by the upstream line circuit breaker.
Please refer to the technical data for detailed information regarding power consumption of the PowerPac 4003 DSP.
Best option is to connect the PowerPac 4003 DSP to its own circuit with a 16A fuse (characteristic curve C).
Please refer to the technical data for the power consumption in the different operating states.
The device corresponds to protection class 1.
In the event of a thunderstorm or danger, pull the power plug out of the socket immediately.
To avoid ground loops, we recommend using symmetrical signal routing and the power distribution in the so-called
star point earthing, which means, all ground connections meet at one single point.
Never interrupt the contact to the protective conductor (e.g. by cutting off the protective conductor, disconnecting
the connection to the protective conductor through insulation, etc.), because in the event of a defect this increases
the risk of a electric shock over the metal housing.
USER MANUAL PowerPac 4003 DSP
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Power generator operation
If the amplifier is operated on a power generator, this is done at your own risk!
Extensive precautionary measures must be taken before connecting and operating your device on a power
generator:
•Use only high-quality, generously dimensioned power generators
•perPowerPacat least3kVArated power
•If possible, switch on an under / overvoltage shutdown, this should be at U min.200VAC undervoltage and
U max. 250VAC overvoltage!
•Always load three-phase generators equally to avoid unbalanced loads, e.g. PowerPac 1 on L1, PowerPac 2
on L2, PowerPac 3 on L3
•Load the generator permanently with a stable base load in order to absorb voltage fluctuations. e.g. 1000W
halogen lamp, electric heater etc.
XLR connection
XLR inputs can be connected both balanced and unbalanced. Symmetrical cables are to be preferred, as they
provide better protection against external interferences on long cable routes. The inputs Input A and Input B can be
controlled with signals up to +24dBu. The user has the option of further processing the fed-in XLR signals via the
XLR Out socket, e.g. in another PowerPac. Pay attention to the following assignment of the XLR connection.
Speaker connection
Before loudspeakers are connected to the Speakon® outputs of the PowerPac 4003 DSP, reduce the output level of
the upstream components to the lowest possible value (e.g. fader down or left stop; ) in order to reduce/avoid
any unwanted and possibly damaging noises in the connected loudspeakers. Make absolutely sure that any
upstream crossover or any upstream limiter is set correctly. Due to the high output power of the PowerPac 4003
DSP, non complete or incorrect settings can damage the connected loudspeakers due to overload!
The Speakon® sockets (13, black) on the back of the device (page 9) are intended for
the loudspeaker system cabling. The sockets transmit the signal processed by channel 2 and 3 via
pins 1 + / 1- on the Speakon® connector, while the processed signal of channel 1 via pins 2 + / 2 +
on the Speakon® connector.
With this system cabling from PL-AUDIO (also from numerous other manufacturers), only a single
4-pin Speakon® cable is laid between the power amplifier and a sub / top combination to each side
of the system. With PL-AUDIO, pins 1 + / 1- are wired for the tops, pins 2 + / 2- for the bass.
The Bi-Amp socket (14, red) provides the processed signal of channel 2 on the pins 1+ / 1- and the processed signal
of channel 3 on pins 2+ / 2-. This socket is the easiest way to connect bi-amped fullrange tops via bi-wiring using a
4-pole Speakon® cable.
Socket 15 provides the processed signal of channel 1 on pin 1+ / 1- AND 2+ / 2- for easy connection of subwoofers
or high power fullrange tops.
When connecting the system using prefabricated connection panels, patchbays or adapter plugs / adapters,
make sure that the signals are correctly assigned to the correct components! This is of top importance when
using the PowerPac 4003 DSP for wiring bi-amp systems. Special care must be taken, as possible incorrect
cabling can quickly lead to the destruction of the mid-range or high-frequency driver!
13
Important notice: Do never load the output channels with less than 4Ω!
8
USER MANUAL PowerPac 4003 DSP
Shield
Input Output
To connect a XLR-connection with non-symmetrical
Signal, Pin 1 and Pin 2 must be bridged.
Speakon® connector
Backside
© PL-Audio GmbH & Co.KG | Siegener Straße 6 | 57482 Wenden | www.pl-audio.de Version: October 2021 V 1.0

2.6 Speaker connection
Before loudspeakers are connected to the Speakon® outputs of the PowerPac 4003 DSP the corresponding preset
must be loaded on the signal processor! Only with the correct presets specially developed for the loudspeakers by
PL-AUDIO reach their maximum performance, the best possible sound and the necessary operational reliability. By
loading the wrong the speakers my sound bad and / or may be damaged through overload!
If you want to operate loudspeakers from other manufacturers on the PowerPac 4003 DSP, there are enough free
preset memory spaces available on the device! As a starting point we recommend the "01.Sub + Top Standard“
preset to be loaded and sent to your speakers plus conducting the absolutely necessary adjustments (gain, HPF,
LPF, EQ, limiter, etc.).
The Speakon® sockets (13)on the rear of the device (section 2.2.) are for the system cabling intended. The system
cabling is between the power amplifier and a sub / top combination and only a single 4-pole Speakon® cable has
to be laid to each side of the system. Pins 1 + / 1- are wired for the tops, while pins
2 + / 2- are wired for the bass. 2-way actively separated loudspeakers do not have a built-in passive crossover. On
such loudspeakers, each path has its own amplifier channel. An amplifier channel operates the midrange speaker
(s) (e.g. channel 2 - mid) while another amplifier channel drives the Tweeter(s) (e.g. channel 3 - high). This Bi-Amp
system uses a 4-pole Speakon® cable between Speakon® connector (14, red) and loudspeaker, where pins 1 + / 1-
transmit the processed and amplified signal of channel 2, while the processed and amplified signal of channel 3 is
transmitted via pins 2 + / 2-. When wiring bi-amp systems it must be worked out with particular care, as incorrect
cabling quickly leads to possible destruction of the high-frequency driver!
SELECTING THE CORRECT PRESET IS ABSOLUTELY CRUICAL FOR CORRECT OPERATION, CORRECT
CONFIGURED OUTPUT AND MAXIMUM SOUND QUALITY!!!
PL-Audio Bi-Amp presets are usually locked in the signal processor with password protection in order to prevent
unintentional changing of the parameters. If you make changes here do this very carefully, with caution and
expertise! The signal processor allows very deep and detailed, but also serious changes in the transmission
parameters of the speaker system! To change the bi-amp presets, log in with the password:"Admin1" in the
administrator user level of the signal processor. Now you have full access to change all necessary parameters.
This is easy and convenient with the PL-Audio DSP-CONTROL software on the PC.
PL-Audio Bi-Amp speakers without built in X-Over are:
TS 42
TS 61
TS 62
Banana Array
Big Banana Array Line
Array LA210
Line Array LA206
Line Array LA208
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2.6 Speaker connection
IMPORTANT NOTICE FOR NORMAL OPERATION:
NEVER LOAD THE OUTPUT CHANNELS IN NORMAL MODE WITH LESS THAN 4Ω!!!
Example: 2 x 8Ω loudspeakers, connected in parallel result in 4Ω
2 x 16Ω loudspeakers, connected in parallel result in 8Ω
IMPORTANT NOTICE FOR BRIDGED MODE ON CHANNEL 2+3:
NEVER LOAD OUTPUT CHANNEL 2+3 IN BRIDGED-MODE WITH LESS THAN 8Ω!!!
2.7 USB / Network communication
•2.2 Bild (Item 11) USB-Interface
You can connect the DSP controller with a commercially available USB cable (USB A to USB B).
Connect your PC or Mac via USB interface to use the PL-Audio DSP-CONTROL software to make software
configurations and settings.
Please note that the length of USB signal transmission is limited. We only recommend to use USB cables up to a
maximum length of 3m.
The USB-Interface is designed as USB 1.1.
If ever possible please preferably use the Ethernet connection (RJ 45 socket).
•2.2 (Item 10) Netzwork-/ Ethernet Interface
With the network interface you can integrate the DSP controller into a local network, to control and operate it
remotely through longer distances with the PL-Audio DSP-CONTROL software. If you connect a wireless router to
the network port, you can take advantage of wireless remote control with a W-LAN-enabled device!
The network port also offers the option of connecting the DSP directly via a commercially available network cable
(up to 100m in length, CAT5e or higher) directly to a computer.
If the DSP is not automatically registered in the IP universe of the computer through the direct connection PC →
DSP , an intermediate router is required, which has DHCP server functionality that automatically assigns an IP
address that can be located by the computer.
The network port is designed as 10-Mbits Ethernet. RJ-45 connector standard.
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Limiter settings
If you program your own presets in addition to the factory presets, we strongly recommend that you calculate and
set the limiter settings for the respective channels precisely in order to protect your connected speakers from
overload! The limiters are already set at the factory presets.
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2.8 Installation
Please note that if the device is cold and transported into a warm environment, condensation will form inside the
device. To avoid damage and malfunctions due to condensation / moisture, let the device acclimatise first.
To avoid unpleasant and possibly damaging noises in the loudspeakers, always switch the individual components
on in the direction of the signal path. So first the player, then the mixer and only at the end the power amplifiers.
When switching off, just proceed in reverse order.
After switching on the device, a self-test and initialization are carried out. The fan runs up once for approx. 4
seconds. During the start-up process, the loudspeaker outputs of the power amplifier are muted and are
activated automatically as soon as the power amplifier is ready for operation. This protective circuit prevents
unpleasant "cracking" noises in the loudspeakers.
The amplifier is ready for operation approx. 10 seconds after switching on.
ATTENTION: The power amplifier has no gain control on the front panel! The setting of all output levels is made in
the Digital Signal Processor (DSP) either by using the built in encoder wheel and the display or the PL-Audio DSP-
Control Software on a computer.
Before switching on the power amplifier for the first time, it is not possible to check which volume or which
speaker preset is set! Therefore, please always turn the volume level of your signal source (mixer) to a
minimum.
When you have made all connections, switch on the amplifier, check whether the correct preset is loaded and
increase volume gently until you hear the signals from your speaker system. If you do not hear an output signal on
the connected loudspeakers, check the cabling again before turning the level up any further. In any case, avoid the
limiter LED lighting up continuously (page 9, upper figure, item 2). This not only leads to a loss of sound, but can
also damage connected speakers!

The table below shows the limiter settings for the majority of the loudspeakers from PL-AUDIO:
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3. DSP control via Display & Encoder wheel
Note: Certain settings can only be configured using the PL-AUDIO DSP-Control software.
Push the MENÜ-button once to call up the main menue.
The main menue contents 5 menue points:
–
–
–
–
–
Load Presets
Save Presets
Password protection / Access Level
Device informationen read out (5 additiopnal points in this sub menue)
Routing, configuration (Input routing to Outputs) Mixer in OUT 1,2,3
By pushing the MENÜ-button you can navigate in the main menue in an endless loop.
Encoder-wheel turn to select parameters and navigate in the sub menue.
Encoder-wheel pushing to confirm a setting or to jump to the next module.
EXIT-button: push once to jump back to previous menue point.
EXIT-button pushing several timnes to exit the configuration menue and take over the changed parameters.
MENU
TURN to
PL-Audio 4003
2 B18+F10pro L
SELECT
PUSH to
ENTER
EXIT
Upper line: Name of the individuak PowerPac PL-Audio 4003
Lower line: Number of Preset 2& short description of the preset B18+F10pro L
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3.4 Loading and editing of presets on the device / Routing
In the flash memory of the DSP-controler up to 80 presets can be stored. With the encoder wheel and the MENÜ-
button the presets can be loaded. Presets can be named with up to 16 characters.
Please use NO special characters for naming the presets.
Load preset:
–
–
Push the MENÜ-Button one time
Choose the desired preset by turning the encoder wheel. The presets stored in
the memory will one by one appear on the display.
For loading the selected preset push the encoder wheel.
–Confirm the appearing security query by turning the encoder wheel to the right until YES will appear in
the display with capitalisation.
–By pushing the encoder wheel again the selected preset will be loaded into the DSP.
Routing, pre setting (Input to Outputs) Mixer in →Out 1,2,3
By pushing the MENÜ-button five times the sub menue „Routing“ will be called up on the display.
This consist of two settings:
1)
2)
Stereo + Sub
Mono 3-Way
This pre-selection changes the mixer for the signal selection in the outputs 1, 2 and 3.
By selecting 2 (Mono 3-Weg) only XLR-Input A is active!
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–
Stereo + Sub:
Out 1 Out 2 Out 3
Mono 3-way:

4. DSP control via Software PL-Audio DSP Control
4.1 Benutzerebenen / Access-Level (Password protection)
To prevent inadvertent or undesired changes to the signal processor during operation or when renting / lending,
the DSP can be locked with password protection. (Access Level: Locked)
In the PL- Audio DSP-Control software click in the control window on the menu item:
Hardware → Lock Unit → Confirm the upcoming advise with OK.
The DSP has 3 user levels, which can be called up by entering the corresponding password.
1: Locked –Level
2: User –Level
3: Admin –Level
DSP Locked
Passwort: PLAudio1
Passwort: Ad_min
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If you have blocked DSP access via the display or the control window on the PC, all setting options in the
controller cannot be configured.
To regain access, enter the passwords for either the user or admin level via the display or the control window on
the PC and activate the user rights. All setting options can now be called up again.
The input field for the password in the computer software can be found in the control window under the
menu item
Hardware → Enter Passwort→ now the input window opens in the software.
4.2 Firmware update process
In order to always have the latest firmware on the signal processor, you should carry out a firmware update
regularly. The update can only be carried out with a PC. Please always download the latest DSP control software
from the PL-Audio homepage and install it on your computer.
This application contains 2x the firmware uploader.
Once in the network manager for a complete new installation and in the control window under the menu item
Hardware → Firmware Update
Important: Please note that with a firmware update all presets saved on the flash memory of the DSP will be
lost. It is therefore essential to save these presets on your computer BEFORE an update!
For the firmware update you should preferably use the network interface on the DSP, since the bootloader of the
network chip is updated at the same time.
Attention: There are exceptions where an update via network is not possible. In this case, please use the USB
port on the DSP.
To check whether your controller can receive an update via the network port, you must first check the hardware
version on the display. To do this, press the MENU button four times on the display and press the encoder wheel
twice.
The display now shows: Version Info / HW: 3.6.x
HW: 3.6.4 = update ONLY possible via USB port
HW: 3.6.5 = update via network & USB possible
HW: 3.6.6 = update via network & USB possible