Rockford Fosgate punch 160X4 User manual

®®
INSTALLATION & OPERATION
MANUAL

®
trans• ana
4
®
trans • ana
4-CHANNEL AMPLIFIERS

Dear Customer,
Congratulations on your purchase of the world's finest brand of car audio
amplifiers. At Rockford Fosgate we are committed to musical reproduction at its
best, and we are pleased you chose our product. Through years of engineering
expertise, hand craftsmanship and critical testing procedures, we have created a
wide range of products that reproduce music with all the clarity and richness you
deserve.
For maximum performance we recommend you have your new Rockford Fosgate
product installed by an Authorized Rockford Fosgate Dealer, as we provide
specializedtrainingthroughRockfordTechnicalTrainingInstitute(RTTI). Please
read your warranty and retain your receipt and original carton for possible future
use.
ToaddthefinishingtouchtoyournewRockfordFosgateimageorderyourRockford
accessories, which include everything from T-shirts and jackets to hats and
sunglasses.
To get a free brochure on Rockford Fosgate products and Rockford accessories, in
the U.S. call 602-967-3565 or FAX [phone]. For all other countries, call
+001-602-967-3565 or FAX [phone].
The serial number can be found on the outside of the box. Please record it
in the space provided below as your permanent record. This will serve as
verification of your factory warranty and may become useful in recovering
your amplifier if it is ever stolen.
Serial Number: ____________________
Model Number:____________________
If, after reading your manual, you still have questions regarding this
product, we recommend that you see your Rockford Fosgate dealer. If you
needfurtherassistance,youcancallusdirectat1-800-795-2385.Besureto
have your serial number, model number and date of purchase available
when you call.
PRACTICE SAFE SOUND™
CONTINUOUS EXPOSURE TO SOUND PRESSURE LEVELS
OVER100dBMAYCAUSEPERMANENTHEARINGLOSS.HIGH
POWEREDAUTOSOUNDSYSTEMSMAYPRODUCESOUND
PRESSURE LEVELS WELL OVER 130dB. USE COMMON SENSE
AND PRACTICE SAFE SOUND.

TABLE OF CONTENTS
Introduction ...................................................................................... 1
Punch 4-Channel Amplifier Accessory Pack...................................... 1
Rockford Fosgate Accessories............................................................ 2
Technical Design Features ................................................................ 3
Design Features................................................................................. 6
Installation Considerations ................................................................ 8
Mounting Location............................................................................ 9
Battery and Charging....................................................................... 10
Wiring the System ........................................................................... 10
Using the XCard.............................................................................. 13
Using the Signal Input Switch.......................................................... 14
Basic Connections........................................................................... 15
System Diagrams............................................................................. 22
Troubleshooting .............................................................................. 26
Dynamic Power Measurements....................................................... 29
160x4Specifications ....................................................................... 31
240x4Specifications ....................................................................... 32
Warranty Information...................................................................... 33
GETTING STARTED
Welcome to Rockford Fosgate! This manual is designed to provide
informationfortheowner,salespersonandinstaller.Forthoseofyou
who want quick information on how to install this product, please
turn to the Basic Connections in the Installation section of this
manual. Other information can be located by using the Table of
Contents. We, at Rockford Fosgate, have worked very hard to make
sure all the information in this manual is current. But, as we are
constantlyfindingnewwaystoimproveourproduct,thisinformation
is subject to change without notice.

INTRODUCTION
ThePunch160x4 and240x4are4-channelamplifierswhichcan
deliver 160 watts and 240 watts RMS respectively. Both ampli-
fiers utilize a 2/4-channel input switch to eliminate the need for
signal splitters. A pair of internal XCard crossovers allow the
amplifiers to be configured for use with many popular system
designswithouttheaddedcostofexternalprocessors.ThePunch
160x4and 240x4are powerful 4-channel amplifiers with inte-
grated features which are offered at a competitive price.
We strongly recommend you have your Authorized Rockford
FosgateDealerinstallthenew Punchamplifier.If youdochoose
to install it yourself, please be sure to read the entire manual
before beginning.
PUNCH 4-CHANNEL AMPLIFIER
ACCESSORY PACK
The accessory pack shipped with the Punch 4-channel amplifier
includes the mounting hardware necessary to secure the amp to
the vehicle as well as attach the end caps.
Installation & Operation Manual
Punch Verification Certificate
(10)Allen Head Screws for speaker and power connectors
(4) Mounting Screws for end caps
(4) Mounting Screws for amplifier
(1) Allen Wrench 7/64"
(1) Allen Wrench 3/32"
(1) ATC In-line Fuseholder (160x4)
(1) AGU In-line Fuseholder (240x4)
(1) ATC 30 Amp Fuse (160x4)
(1) AGU 50 Amp Fuse (240x4)
– 1 –

ROCKFORD FOSGATE ACCESSORIES
Thefollowingaccessorieswere designed to enhance the perfor-
mance of the Punch 160x4and 240x4amplifiers.
Energy Storage Capacitor
ThePunchcapacitorsareusedtoprovideextracurrentneededby
amplifiers to reproduce musical transients. The Punch Caps also
havethenaturalabilitytofilterACripplecausedbythealternator,
reducing the chance of noise in the system. The Punch Caps will
maximizeboththesoundqualityandperformancethatRockford
Fosgate amplifiers can deliver.
Punch Link (FG-LINK)
The Punch Link is a specially cast heatsink interconnect which
allows you to join any of our current Punch or Punch Power
amplifiers together. While providing additional cooling through
thecouplingprocess, the PunchLink adds thefinishing touch by
giving you the look of one awesome amplifier.
XCard
Additional crossover card frequencies are available for special-
ized requirements. You can get the following XCards from your
Authorized Rockford Fosgate Dealer.
XM50 = 50Hz XM275 = 275Hz
XM70 = 70Hz XM400 = 400Hz
XM100 = 100Hz XM4.5k = 4,500Hz
XM150 = 150Hz XM6.5k = 6,500Hz
XM200 = 200Hz XM00 = Blank card for
custom crossover
– 2 –

TECHNICAL DESIGN FEATURES
– 3 –
◆TRANS•ANA (TRANSconductance Active
Nodal Amplifier)
The TRANS•ANA (TRANSconductance Active Nodal Amplifier)
is a circuit that allows the audio signal to pass through the
amplifierat low voltage .Thesignal isdirectly level-shifted tothe
fixed high voltage rails via a pair of driver transistors. Signal
linearity is assured by an active node formed by the driver
transistorsatultrasonicfrequencies. Thisallowsamplifierperfor-
mance similar to trans• nova which is highly stable and linear
while utilizing the advantages of a non-floating power supply.
THE RESULT: An extended frequency bandwidth accurately
supplied to the output stages of the amplifier.
◆TOPAZ (Tracking Operation Pre-Amplifier Zone)
The TOPAZ (Tracking Operation Pre-Amplifier Zone) circuitry
solves ground loop noise problems common to automotive
amplifierdesign.Thisinnovativenewdevelopmentallowsvastly
improved isolation of the input signal grounds from the power
supplygroundoftheamplifier.Thisisaccomplishedbyallowing
the source unit to control the potential “environment”of the
entire input structure or “zone”of the amplifier. This process
improves the noise rejection of the amplifier by 30-40dB –an
astounding 30-100 times better than amplifiers without TOPAZ.
THE RESULT: Elimination of troublesome ground loop noise
between source and amplifier.

◆DSM (Discrete Surface Mount) Technology
The DSM (Discrete Surface Mount) manufacturing process com-
binestheadvantagesofbothdiscretecomponentsandintegrated
circuitry.RockfordFosgateistheonlyAmericanamplifiermanu-
facturertohaveinvestedmillionsintothisprocess.DSMcompo-
nents differ from conventional discrete components in three
ways.They aremore compact,more rugged,and theyefficiently
dissipate generated heat. Using them wherever appropriate al-
lows the advantages associated with discrete circuitry to be
retained while also providing room for both highly advanced
processing features and generous PC board copper paths where
needed. Their short lead-out structures allow maximum audio
performance and highest signal-to-noise ratios to be obtained in
amplifiers of desirable package size without resorting to “ampli-
fier-on-a-chip”shortcuts.TheseadvantagesareshowninFigure1.
Surface Mount
Thru-Hole
Solder Solder
Component
Figure 1
THE RESULT: Fewer connections, improved reliability, shorter
signal paths, superior signal-to-noise ratio and awesome sonic
performance.
◆XCard (Internal Crossover)
The Punch and Power amplifiers utilize internal active cross-
overs.Thesecrossovershavemanyperformanceadvantagessuch
as using discrete components for exact frequency adjustments
whicharefarsuperiortopotentiometers.Additionally,theXCard
can be configured for high-pass, low-pass and full range opera-
tion. With slight modifications, many crossover frequencies and
slope configurations can be achieved.
THE RESULT: Increased system design flexibility with a precise
electronic crossover without the limitations of conventional
potentiometer designs.
– 4 –

◆RTP (Real Time Protection)
NOMAD (NOn-Multiplying Advanced Decision)
ThePunchandPoweramplifiersusean analogcomputerprocess to
maximize safe output power under all operating conditions. Rock-
ford Fosgate pioneered and developed RTP (Real Time Protection),
a crucial element in the performance edge of our amplifiers. The
innovative NOMAD (NOn-MultiplyingAdvancedDecision)system
is the most sophisticated version of this technique ever used,
bringing previously unavailable levels of accuracy, stability, tem-
perature immunity and reliability to this critical process. NOMAD
makes advanced decisions based on device voltages to precisely
control the awesome levels of current available in the output
MOSFETs to safe values – but only when absolutely needed.
THE RESULT: Extremely fast protection system that always protects
the amplifier and never degrades the sound.
◆MOSFET Devices
Rockford Fosgate is one of the few manufacturers in the sound
community to utilize MOSFET devices in both the power supply
and the output stages . MOSFET (Metal Oxide Semiconductor
Field Effect Transistor) devices offer several important inherent
advantages over the 30 year old technology of bi-polar design.
These advantages include: thermal stability, switching speed,
ultra low output impedance and wider bandwidth linearity. In
addition, MOSFETs operate very similar to vacuum tubes in
which they are more linear than bipolar transistors. However,
MOSFETscandeliverthemidrangeclaritywithoutthelimitations
oftransientresponse andhigh frequency phaseshifting normally
associated with tube operation.
THE RESULT: Operational characteristics similar to vacuum
tubes without the performance limitations of tube designs.
– 5 –

DESIGN FEATURES
1. Cast Aluminum Heatsink – The cast aluminum heatsink of the
Punch amplifier dissipates heat generated by the amplifier's
circuitry. The inherent advantage of casting provides a 30%
improvement of cooling over conventional extrusion heatsink
designs.
2. End Caps – Interchangeable end caps conceal the wiring and
input cables, giving the amplifier a clean “stealth” look.
3. SpeakerTerminals–Theheavyduty,gold-platedterminalblock
connectors (+ and –) will accept wire sizes from 8 AWG to 18
AWG. These gold-plated connectors are immune to corrosion
that can cause signal deterioration.
4. Power Terminals – The power and ground connectors on the
Punch amplifier are gold-plated and will accommodate up to 8
AWG wire maximizing the input current capability of the
amplifier.
5. REM Terminal – This spade terminal is used for the auto power/
remote turn-on of the Punch amplifier.
3 68 83
5 4 9
– 6 –

6. RCA Input Jacks – The industry standard RCA jacks provide
easyconnections forsignal levelinput.Theyaregold-plated to
resist the signal degradation caused by corrosion.
7. SignalInputSwitch– Thisswitchallowsselectionof2-channel
or 4-channel source unit feed.
8. Input Sensitivity Controls – The input level controls are preset
for 500mV which will match the output of most source units.
Theycanbeadjustedtomatchinputlevelsrangingfrom150mV
to 3V.
9. LED Power Indicator – The LED illuminates when the unit is
turned on.
10. XCard(InternalCrossover)–Thesebuilt-incrossovercardsare
configurable for a multitude of operating frequencies. The
orientation of the card in its socket determines the function of
high-pass, low-pass, or full range operation.
ROCKFORD CORPORATION
MADE IN THE USA
®
2 Channel Input
4 Channel Input
®
20 Watts x 4 into 4Ωat 0.05% THD
40 Watts x 4 into 2Ωat 0.1% THD
AMPLIFIER
Low Pass Full RangeHigh Pass
FULL
↕
HP
➝
➝
LP
HP
➝
➝
LP
®
trans • ana
XCard 1 XCard 2
10
7
– 7 –

INSTALLATION CONSIDERATIONS
This section focuses on some of the vehicle considerations for
installing your new Punch amplifier. Checking your battery and
presentsoundsystem,aswellaspre-planningyoursystemlayoutand
best wiring routes will save installation time. When deciding how to
lay out your new system, be sure that each component will be easily
accessible for making adjustments.
Beforebeginninganyinstallation,besuretofollowthesesimplerules:
1. Be sure to carefully read and understand the instructions before
attempting to install the amplifier.
2. For safety, disconnect the negative lead from the battery prior to
beginning the installation.
3. For easier assembly, we suggest you run all wires prior to
mounting your amplifier in place.
4. Route all of the RCA cables close together and away from any
high current wires.
5. Use high quality connectors for a reliable installation and to
minimize signal or power loss.
6. Thinkbeforeyoudrill! Becarefulnottocutordrillintogastanks,
fuel lines, brake or hydraulic lines, vacuum lines or electrical
wiring when working on any vehicle.
7. Never run wires underneath the vehicle. Running the wires
inside the vehicle provides the best protection.
8. Avoid running wiresoveror through sharpedges. Use rubberor
plastic grommets to protect any wires routed through metal,
especially the firewall.
9. ALWAYS protect the battery and electrical system from damage
withproperfusing. Installtheappropriatefuseholderandfuseon
the+12Vpowerwirewithin18”(45.7cm)ofthebatteryterminal.
10. When grounding to the chassis of the vehicle, scrape all paint
from the metal to ensure a good, clean ground connection.
Groundingconnectionsshouldbeasshortaspossibleandalways
beconnectedtometalthatisweldedtothemainbody,orchassis,
of the vehicle.
The following is a list of tools you will need for installing the Punch
amplifier:
Allen wrenches 7/64" & 3/32" (included) Voltmeter
Wire strippers Battery post wrench
Electric hand drill w/assorted bits Wire cutters
Wire crimpers Assorted connectors
– 8 –

MOUNTING LOCATION
Themountinglocationandpositionofyouramplifierwillhaveagreat
effect on its ability to dissipate the heat generated during normal
operation. The design of our cast aluminum heatsink serves to easily
dissipate the heat generated over a wide range of operating condi-
tions.However,tomaximizetheperformanceofyouramplifier,care
should be taken to ensure adequate ventilation.
Trunk Mounting
Mounting the amplifier vertically on a surface with the fin grooves
running up and down will provide the best cooling of the amplifier.
Mountingtheamplifieronthefloorofthetrunkwillworkbutprovides
less cooling capability than vertical mounting.
Mountingtheamplifierupsidedowntothereardeckofthetrunkwill
not provide proper cooling and will severely affect the performance
of the amplifier and is not recommended.
Passenger Compartment Mounting
Mounting the amplifier in the passenger compartment will work as
longasyouprovideasufficientamountofairfortheamplifiertocool
itself. If you are going to mount the amplifier under the seat of the
vehicle, you must have at least 1" (2.54cm) of air gap around the
amplifier's heatsink.
Mounting the amplifier with less than 1" (2.54cm) of air gap around
the amplifier's heatsink in the passenger compartment will not
providepropercoolingandwillseverelyaffecttheperformanceofthe
amplifier and is not recommended.
Engine Compartment Mounting
Rockford Fosgate amplifiers should never be mounted in the engine
compartment.Not only willthis voidyourwarranty butcould create
an embarrassing situation caused by the ridicule from your friends.
– 9 –

Amplifiers will put an increased load on the vehicle's battery and
charging system. We recommend checking your alternator and
battery condition to ensure that the electrical system has enough
capacity to handle the increased load of your stereo system. Stock
electrical systems which are in good condition should be able to
handle the extra load of any Rockford amplifier without problems,
although battery and alternator life can be reduced slightly. To
maximize the performance of your Rockford Fosgate amplifier, we
suggesttheuseofaheavydutybattery,highoutputalternatorandan
energy storage capacitor.
BATTERY AND CHARGING
WIRING THE SYSTEM
CAUTION: Avoid running power wires near the low level input
cables,antenna,power leads,sensitiveequipmentor harnesses.The
powerwirescarrysubstantialcurrentandcouldinducenoiseintothe
audio system.
• For safety, disconnect the negative lead from the battery prior to
beginning the installation.
1. Plan the wire routing. Take care when running signal level RCA
cablestokeepthemclosetogetherbutisolatedfromtheamplifier's
power cables and any high power auto accessories, especially
electric motors. This is done to prevent coupling the noise from
radiated electrical fields into the audio signal. When feeding the
wires through the firewall or any metal barrier, protect them with
plastic or rubber grommets to prevent short circuits. Leave the
wires long at this point to adjust for a precise fit at a later time.
2. Prepare the Power cable for attachment to the amplifier by
stripping 5/8" of insulation from the end of the wire. The use of 8
gauge power cable can interfere with the installation of the end
caps. Proper wire dress can prevent this from occurring. To
prevent the wire from fraying, strip the insulation at a 45°angle.
Insertthebared wireintotheB+terminal withthelongsideofthe
insulationonthetop.Bendthecabledownata90°angle.Tighten
the set screw to secure the cable in place.
– 10 –

3. Punch 160x4
Trimthepowercabletowithin18"ofthebatteryandinstallthe
protective rubber boot packed with the fuseholder over the
endofthewire.Strip3/8"ofinsulationfromthewireandinsert
it into the end of the fuseholder, then crimp it in place. Slide
the rubber boot into place to cover the connection. Use the
sectionofcabletrimmedearlierandconnectittotheotherend
of the fuseholder.
Punch 240x4
Mountthefuseholderwithin18"ofthebatteryusingtwo(2)#8
screws.Disassemblethefuseholder.Youshouldhave2black
plasticend caps,2 gold-platedfuse clips,a plasticspacer and
the fuseholder body. Trim the amplifier power cable to reach
thefuseholderandstripthewire3/8".Slideoneoftheendcaps
over the wire (narrow end first) and insert the wire into one of
the fuse clips. Tighten the set screw. Screw the black end cap
to the fuseholder body to secure the cable. Use the section of
cablethat wastrimmedearlier andconnectittothe otherend
of the fuseholder. Install the plastic spacer in the fuseholder
and attach the cable to the fuseholder body.
NOTE: The B+ cable MUST be fused 18" or less from the
vehicle's battery. Install the fuseholder under the hood and
prepare the cable ends as stated above. Connections should
be water tight.
4. Strip 3/8" from the battery end of the power cable and crimp
the large ring terminal to the cable. Use the ring terminal to
connecttothebatterypositiveterminal.Donotinstallthefuse
at this time.
5. Preparealengthofcabletobeusedforthegroundconnection.
Strip 5/8" of insulation from the end of the cable as described
previously and connect to the appropriate terminal of the
amplifier. Prepare the chassis ground by scraping any paint
fromthemetalsurfaceandthoroughlycleantheareaofalldirt
and grease. Strip the other end of the wire and attach a ring
connector. Fasten the cable to the chassis using a screw.
– 11 –

6. Prepare the REM turn-on wire for connection to the amplifier
bystripping5/8" ofinsulationfrom thewireendandcrimping
an insulated spade connector in place. Slide the connector
overtheREMterminalontheamplifier.Connecttheotherend
of the REM wire to a switched 12 volt positive source. The
switched signal is usually taken from the source unit's auto
antennaortheaccessorylead.Ifthesourceunitdoesnothave
these outputs available, the recommended solution is to wire
a mechanical switch in line with a 12 volt source to activate
the amplifier.
7. ConnectthesourcesignaltotheamplifierbypluggingtheRCA
cables into the input jacks at the amplifier.
8. Connect the speakers. Strip the speaker wires 5/8" and insert
intotheappropriateterminalontheamplifier.Insertthebared
wire into the speaker terminal and tighten the set screw to
secureintoplace. Besuretomaintainproperspeakerpolarity.
DO NOT chassis ground any of the speaker leads as unstable
operation may result.
9. Performafinalcheckofthecompletedsystemwiringtoensure
thatallconnectionsareaccurate.Checkallpowerandground
connections for frayed wires and loose connections which
could cause problems.
After the final inspection is complete, install the power fuse
and enjoy listening. During the initial listening period, you
may need to “fine tune” any phasing and level settings within
your particular vehicle. To aid in this procedure, play a track
with high musical content and cruise around your neighbor-
hood. After fully evaluating the transient response of your
system and making any final adjustments, all your neighbors
within a 1 mile radius will assume that you have just success-
fully completed another upgrade to your audio system for
which they will probably spill thumbtacks on your driveway.
10.
– 12 –

USING THE XCARD
The crossover functions are controlled through the use of an
XCard and can be set for high-pass, low-pass or full range
operation. Each crossover card has two faces: one face operates
FullRange,theotherhasarrowstoindicatetheedgeforselecting
HP (high-pass) or LP (low-pass) operation. Orient the card with
the desired operating edge, indicated by the arrow, toward the
socket terminals inside the amplifier. Firmly, but carefully, plug
the card into the socket.
Thecrossoverpointcanbealteredbychangingtheresistorvalue.
Usethefollowingformulatoselecttheappropriateresistorvalue
to be placed on the XCard.
3386
fo= R (in kΩ) for .047µf cap
= R (in kΩ) for .022µf cap
7234
fo
Where: R = ohms
fo= desired crossover frequency
c = capacitor in farads
ex: .047 x 10-6 for .047µf cap
Crossover Card
High Pass
Low Pass
Full Range
R1 R2 R1 R2
FULL
The actual formula is:
R = 1
2πfoc
Low-Pass Full RangeHigh-Pass
FULL
↕
HP
➝
➝
LP
HP
➝
➝
LP
– 13 –

USING THE SIGNAL INPUT SWITCH
2-Channel Input Input
1 2
Rear XCard Front XCard
+ L– + R–
LR LR
– R+– L+
4-Channel Input
+ L– + R–
L F R F
12
– L+ – R+
LR RR
Input
Rear XCard Front XCard
34
– 14 –
•RCAs connected to Front inputs
• Signal Input Switch set to 2-channel input
• This configuration eliminates the need for signal splitters
•RCAs connected to Front & Rear inputs
• Signal Input Switch set to 4-channel input
• This configuration allows for Front & Rear fading

BASIC CONNECTIONS
*Keep grounds as short as possible.
Power Connections
REM Power
Connect to remote
turn-on lead of
source unit
Connect to B+ of battery
with proper fuse
Connect to chassis
ground of vehicle*
B+ GND
Less than 18"
P160x4
P240x4
- 30A
- 50A
– 15 –

Stereo Operation
+L– +R–
Input
2-Ch.
{
+ – + –
Rear XCard Front XCard
4 ohm 4 ohm
*Note: XCard can be inserted in HP, LP, or Full Range
Rear XCard* Front XCard*
LP LP
2-Channel Input
– R +– L+
•RCAs are connected to front inputs
•Signal Input Switch set to 2-channel input
•Gain for front and rear must be set equally to balance left and right
channels
•Impedance for left bridged channel should be no less than 4Ω
•Impedance for right bridged channel should be no less than 4Ω
•XCards for front and rear are set identically as High-Pass, Low-Pass or
Full Range
– 16 –