Rockford Fosgate punch 160X4 User manual

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INSTALLATION & OPERATION
MANUAL
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4
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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
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