Rockford Fosgate Punch 40I User manual

2-CHANNEL DSM AMPLIFIERS
P UNCH 40I/ P UNCH 60IX
P UNCH 100IX / P UNCH 200IX
OWNER’SMANUAL

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 specialized training through Rockford
Technical Training Institute (RTTI). Please read your warranty and
retain your receipt and original carton for possible future use.
To add the finishing touch to your new Rockford Fosgate image
order your Rockford 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, please call 602-967-3565 or FAX [phone]. In
Canada, call Korbon Trading at 9 05-567-1929. For International
orders, FAX +001-l-602-967-8132 or call +001-l-602-967-3565.
PRACTICE SAFE SOUND™
CONTINUOUS EXPOSURE TO SOUND PRESSURE LEVELS OVER 1OOdB
MAY CAUSE PERMANENT HEARING LOSS. HIGH POWERED
AUTOSOUND SYSTEMS MAY PRODUCE SOUND PRESSURE LEVELS
WELL OVER 130dB. USE COMMON SENSE AND PRACTlCE SAFE SOUND.
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:

............................................................................ 8
Trunk Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Passenger Compartment
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Wiring the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
Mono Bridging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
Using the Internal Crossover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Sample Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
Dynamic Power Measurements
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Warranty
Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
TABLE OF CONTENTS S
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
Punch Accessory Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Operating Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Design
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .. . 5
Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Tools Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Battery and Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
Mounting Location

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PUNCH ACCESSORY PACK
12’ (365.76cm)
Blue Remote
Turn-on Wire
17’ (518.16cm)
Red Power Wire
1.5’ (45.72cm)
Black Grounding Wire
Power Ring
Terminals
Remote Turn-on Wire
Connector Plug
Hex Head and
Mounting Screws
Power Fuse Holder with
fuse for Punch 200ix
Power Fuse Holder
with Fuse for Punch
40i, 60ix, and 100ix
Punch
Owner’s
Manual
3-

INTRODUCTION
This manual provides information on the features, installation and
operation of the Punch 40i DSM, 60ix DSM, 1
00ix DSM and 200ix
DSM amplifiers. We suggest you save this manual for future refer-
ence.
We strongly recommend you have your Authorized Rockford Fosgate
Dealer and Service Center install the new amplifier. If you do choose
to install the amplifier yourself, please be sure to read the entire
manual before beginning.
O PERATING F EATURES
The Punch 2-channel amplifiers offer unmatched quality and reliabil-
ity in high performancesound systems. The Punch amplifiers are built
using integrated Discrete Surface Mount (DSM) technology. All
components are mounted directly on the main circuit board. This
shortens the signal path resulting in improved sound quality and
reliability. Features include:
Input level Controls -The adjustable input level controls are preset
atthefactoryto match with most popular source units. However, they
may be adjusted to allow precise matching with a wide range of
sources.
Punch Equalization Controls - The Punch bass and treble are finely
calibrated equalizer controls which are designed to correct for
frequency response problems found in most automobile interiors.
These controls make it possible to fine tune and adjust for the listening
environment when you are not using an external equalizer. When
used in combination with an equalizer the Punch controls should be
set to the flat position, fully counterclockwise.
Cast Aluminum Heatsink - The oversized heatsink used on all the
Punch amplifiers is of cast aluminum construction. This provides
better heat dissipation to protect the circuit from thermal damage and
improve long term reliability.
End Caps- The bolt-on end caps add a visually symmetrical finish to
the amplifier. After the installation is complete, use the end caps to
cover the wires and give your system a clean, uncluttered look.
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1. Speaker Terminals
The custom heavy duty speaker terminals are resistant to loosening
under the continuous vibration which plagues car audio. The
terminals will accept bare wire sized from 18 to 8 gauge.
2. Power Terminals
The same type of terminal is used on the B+ and GND for the battery
power and ground connections.
3. REM Terminal
The source unit auto-antenna or accessory lead supplies power to
turn on the amplifier.
4. Gold-Plated RCA Jacks
The input jacks are gold-plated. This reduces interference in the
audio signal caused by contact degradation.
5. Input Sensitivity Controls
The input level controls are preset for 500mV which will match the
output of most source units. They can be adjusted to match input
levels ranging from 150mV to 3V.
6. Punch Equalization Controls
The Punch Equalization Controls allow for precise matching to
correct for acoustic deficiencies of the listening environment. The
Punch bass control allows a narrow band adjustment of up to
18dB
centered at 45Hz. The treble control is a wide band, hinged
adjustment with a maximum of 12dB at 20kHz. With the controls
adjusted fully counter clockwise the equalization is set flat and does
not affect the signal.
7, LED Power Indicator
The LED, located near the REM terminal, gives a visual indication
of the status of the amplifier, lighting when the unit is turned on.
*Rockford Fosgate’s Perfect Interface lineof accessories includes high quality
power and speaker wire, gold plated RCA interconnecting cable and other
products to complete your installation. Ask your Authorized Rockford
Fosgate Dealer about Perfect Interface.
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INSTALLATION C ONSIDERATIONS
This section focuses on some of the vehicle considerations for
installing your new Punch Amplifier. Checking your battery and
present sound system, as well as pre-planning your system layout and
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.
Before beginning any installation, be sure to follow these simple rules:
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. See your Authorized
Rockford
Fosgate Dealer for Perfect Interface wire enhancements.
6. Think before you drill! Be careful not to cut or drill into gas tanks,
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 for best protection.
8. Avoid running wires over or through sharp edges. Use rubber or
plastic grommets to protect any wires routed through metal,
especially the firewall.
9. ALWAYS protect the battery and electrical system from damage
with proper fusing. Install a fuseholder and fuse on the +12V
power wire within 18” (45.7 cm) of the battery terminal.
10. When grounding to the chassis of the vehicle, scrape all paint
from the metal to ensure a good, clean ground connection.
Grounding connections should be as short as possible and always
be connected to metal that is welded to the main body, or chassis,
of the vehicle.
-7-

TOOLS NEEDED
The following is a list of tools you will need for installing the Punch
amplifier:
Allen Wrenches
(7/64” & 3/32”) Voltmeter
Wire Strippers
Battery Post Wrench
Electric Hand Drill w/assorted bits
Wire Crimpers (i.e., Perfect Interface
heatsink designed for efficient heat dissipation
and internal shut-off circuitry to avoid overheating, so it is reasonably
tolerant of mounting variations. However, care should be taken to
ensure adequate ventilation.
TRUNK MOUNTING
The temperature inside a trunk can reach as high as 175” F (80” C)
during the summer months. Since the thermal shut-off point for the
Punch is 195” F (90° C), it is easy to see that the amplifier must be
mounted for maximum coolingcapability. Mounting theamplifieron
the floor of the trunk prevents sufficient convectional air flow cooling.
Mounting the unit vertically on a surface with the fin grooves running
up and down usually results in the best cooling.
PASSENGER COMPARTMENT MOUNTING
Under the seat or floor mounting will work as long as there is a
minimum of 1 "
(2.5cm) of air gap above the amplifier’s heatsink.
Vertical mounting is still the best and under dash mounting is
satisfactory as well.
-8-
RT-KT1)
BATTERY AND CHARGING
Punch amplifiers will naturally put an extra load on your battery and
charging system. We recommend you check your alternator capacity
to ensure ample charging capability to handle the additional load of
your new Punch equipment. Stock electrical systems in good condi-
tion should typically handle the extra load of any individual Punch
unit without problems, although battery and alternator life may be
slightly reduced. If problems arise, we suggest you use a heavy dutybattery and a high output alternator.
MOUNTING LOCATION
The mounting location and position of the Punch will have a great
effect on its ability to dissipate the heat generated in normal opera-
tion. The Punch has a

WIRING THE SYSTEM
1.
2. Punch 40i, 60ix, 1 00ix
Plan the wire routing. Take care when running the signal level
RCA cables to keep them close together but isolated from the
amplifier’s power cables and any high power auto accessories,
especially electric motors. This is to prevent coupling the noise
from radiated electrical fields into the audio signal. When feeding
the wires through the firewall or any other 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 later.
Prepare the fuseholder supplied with the amplifier. For the Punch
4Oi, 6Oix, 1 OOix start by trimming the amplifier power cable to
within 18” of the battery. Strip
1/2” of insulation from the end.
Remove the protective rubber boot packed with the fuseholder
and slide it over the end of the wire. Insert the wire into the end
of the fuse holder, then crimp it in place. Slide the rubber boot into
place to cover the connection. Use the section of cable that was
trimmed earlier and connect it to the other end of the fuseholder
in the same manner.
Punch 2OOix
Due to the high current requirements of the Punch 2OOix, the
fuseholder is larger and has different preparation requirements.
Mount the fuseholder within 18 inches of the battery using two (2)
#8 screws. Disassemble the fuseholder. You should have 2 black,
plastic end caps, 2 gold-plated fuse clips, a plastic spacer and the
fuseholder body. Trim the amplifier power cable to reach the
fuseholder. Strip the wire
3/8”, slide one of the end caps over the
wire (narrow end first) and insert the wire into one of the fuse clips.
Tighten the set screw and ensure it has a firm grip on the cable.
Screw the black end cap to the fuseholder body to secure the
cable. Prepare the battery cable for attachment of the fuse by the
same method. Install the plastic spacer in the fuseholder and
attach the cable to the fuseholder body.
3. 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 connect
to the battery positive terminal. Do not install the fuse at this time.
4. Mount the amplifier in the desired location and secure it using the
enclosed hex head sheet metal screws. To ease the installation, it
is recommended you drill the mounting holes first. Set the
crossover cards for the desired operation before permanently
mounting the amplifier.
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5.
6.
7.
8.
9.
Prepare the power cable for attachment to the amplifier by
stripping 5/8”of insulation from the end. The use of 8 gaugecable
can interfere with the installation of the end bells. Proper wire
dress can prevent this from occurring. To stop the wire from
fraying strip the insulation at a 45” angle. insert the bared wired
into the B+ terminal with the long sideof the insulation on the top.
Bend the cable down at a 90° angle. Tighten the hex head set
screw to lock the wire into place.
Prepare the black, ground wire, strip the end5/8” and insert in the
GND terminal. Tighten the hex head set screw to lock the wire in
place. Prepare the chassis ground and clean all paint and dirt from
your grounding point. Trim the ground wire to the proper length
and strip 3/8”. Select the small, yellow ring terminal and crimp the
terminal to the wire. Attach the terminal to the prepared ground
point with a
#8 sheet metal screw.
Prepare the REM turn-on wire for connection to the amplifier by
stripping 3/8” and crimping the insulated spade connector in
place. Slide the connector over the REM terminal on the amplifier.
Connect theotherend of the blue wire to the amplifier’s switching
signal. The switch signal is usually taken from the source unit’s
“auto-antenna” or “accessory” lead. If your source unit does not
have these outputs available, the recommended solution is to wire
a mechanical switch to activate the amplifier.
Connect the signal to the amplifier by plugging the RCA cables
into the left and right input jacks.
Connect the speakers. Strip the speaker wires5/8”, and insert into
the appropriate terminal. Be careful to use the proper terminals for
the left and right channels and the proper polarity for the speakers.
The Punch amplifiers are rated for operation into
2S2 loads for
each stereo channel and
4Q bridged mono. Running speaker
loads less than the amplifier’s rated impedance can reduce the
amplifier’s reliability and jeopardize the warranty.
10. Perform a final check of the completed wiring. Look to make sure
the right and left channels are not exchanged and that the polarity
of the connection is maintained. Make sure all connections are
tight and will not come loose from vibration. After the final
inspection is complete, install the power fuse and enjoy listening.
-10-

MONO BRIDGING
The Punch amplifiers are capable of bridged mono operation. This
configuration enables you to:
l Run a single woofer in a stereo system
l Run two bridged amplifiers as a high power stereo system
l Run one amplifier with a bridged mono woofer and another as a
high-frequency stereo amplifier, etc.
For more information refer to the wiring diagrams beginning on page 12.
Caution! Punch amplifiers are not recommended for impedance
loads below
2Q stereo or 4Q bridged.
Be sure to observe proper speaker terminal polarity throughout the
system. It is critical for the Punch to use the correct negative
terminals for right and left channels, since the RIGHT NEGATIVE
(-) terminal is the “hot” terminal for the right speaker. DO NOT
chassis ground any of the speaker leads as unstable operation may
result.
When wiring speakers to the amplifiers, we recommend using fuses
for speaker protection. (See your Authorized Rockford Fosgate Dealer
for more information.)
USING THE INTERNAL CROSSOVER
The Punch 60ix, 1 00ix and 200ix come with built-in crossovers. The
crossover functions are controlled through the use of plug in circuit
cards and can be set for high-pass, low-pass and full range operation.
The cards are built for each operating frequency and their orientation
in the socket determines the operating mode. As supplied, the cards
are
1
00Hz operating in high-pass or low-pass modes. Each crossover
card has two faces, one face operates full range, the other has arrows
to indicate the edge for selecting high-pass and low-pass operation.
Orient the card with the desired filter function facing toward the input
end of the amplifier. Orient the card with the desired operating edge,
indicated by the arrow, toward the socket inside the amplifier. While
avoiding the use of excessive force, firmly plug the card into the
socket.
One of the most popular uses for these crossovers is to use two
amplifiers in a bi-amp system. One amplifier is set for low-pass
operation at 1 00Hz to power the subwoofers, the other amplifier is set
for high-pass operation at 1
00Hzfor the midrange and tweeters.
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TROUBLESHOOTING
Problem
Amplifier will not play - Remote turn-on light is off.
Solution
1. Check the DC voltage at the amplifier’s B+ terminal with a
voltmeter. The voltage should measure between 11.5V
- 15.5V.
If voltage is not found, check the battery, fuse, fuse housing and
wire connections. Fix, repair, or replace accordingly.
2. Check the voltage at the amplifier’s remote turn-on lead. The
voltage should measure between 11 V - 15V.
a. If voltage is above or below the prescribed measurements, have
the head unit checked by an Authorized Dealer or Service
Center.
b. If the remote turn-on current draw from the head unit is
connected to multiple amps and/or electronics, the current
draw may be too great. Check for proper connections. (Use a
relay to suppress the excessive current draw.)
If you are still having problems, have the amplifier checked out by an
Authorized Rockford Fosgate Dealer.
Problem
Amplifier will not play - Remote turn-on light is on.
Solution
1. Unplug the head unit and test the amplifier with another working
source unit (i.e., bench-test radio, walkman, etc.) If the amplifier
plays, check the in-dash leads for cuts, breaks and/or shorts.
2. Disconnect the existing speakers and connect a set of test speakers
to the output of the amplifier (any type of speaker will do - i.e.,
simple home box type, bookshelf, raw speaker, etc.). If the amp
Rockford Fosgate Dealer.
- 15-
plays, check for shorts or blown voice coiIs in the vehicle’s speaker
system.
If you are still having problems, have the amplifier checked out by an
Authorized

Problem
Amplifier gets too hot.
Solution
1. Be sure the amplifier is properly mounted. You should be able to
place your hand a few inches above the amplifier housing and feel
the heat rising when the unit is on.
2. Be sure the amplifie ris properly vented. An ideal situation is to have
the air flow through theheatsink fins. Hot air rises, so mount the
heatsink by aligning the fins vertically. This allows the air to flow
freely, carrying away the heat. Check to see that the heatsink fins
are free of any obstruction (i.e., carpet, seats, etc.).
3. Check to see that the impedance of the overall system is not less
than 2Q as described on page 11. Using an AC impedance meter
(Perfect Interface IM-1), sweep from 20Hz - 20kHz, and look for
dips below the 251 rating.
Be sure to test the bass region
(20Hz - 150Hz) of your system. If the
amplifier is bridged to those speakers, the load the amp sees is one-
half (1/2) of the reading on the AC impedance meter.
If the impedance level is below
2Q check for bad speakers and/or
crossovers, proper use of passive crossovers, or try rewiring the
entire system.
Problem
Amplifier Noise (Turn-On Pop)
Solution
1. Disconnect the RCA plugs from the amplifier and recheck the amp
by turning the unit on and off. If turn-on pop goes away, connect
a delay turn-on module (Perfect Interface DT-1) to the amplifier.
(See your Authorized Rockford Fosgate Dealer for more informa-
tion.)
2. Disconnect the turn-on wire from the head unit and use a different
12 volt power source to turn on the amplifier (i.e., battery direct).
If the noise is gone, use a relay to switch from the clean power
source.
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Problem
Engine Noise (Whine)
Solution
1. Disconnect the speakers from the amplifier. Connect a test speaker
to the amplifier output terminals. If the noise goes away, check
your speaker leads, speakers and crossovers.
2. Use a ”shorting plug” to mute the input signal at the amplifier. If the
noise goes away:
a. Bypass all of the other equipment (i.e., crossovers and equaliz-
ers) and connect the head unit directly to the amp. If the noise
disappears, reconnect the equipment one piece at a time,
making sure to test for noise after each install. Logic indicates
that the last unit installed is the culprit. Refer to the unit’s
owner’s manual for more information.
b. Connect a new RCA line from the head unit to the amplifier. If
there is no noise, replace the RCA cable.
c. Run the RCA cable on a different route.
d. Run a new RCA line from your head unit so there is only one
grounding point. If the noise disappears, install the radio, using
only one (1) grounding point. Isolate the radio chassis from the
grounding on the dash, and use an antenna grounding loop
isolator on the antenna.
If noise persists, see your Authorized Rockford Fosgate Dealer.
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