Rockford Fosgate punch 40X2 User manual

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2-CHANNEL AMPLIFIERS
OPERATION & INSTALLATION
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Dear Customer,
Congratulations on your purchase of the world's finest brand of car audio amplifiers.
AtRockfordFosgatewearefanaticsaboutmusicalreproductionatitsbest,andweare
pleasedyouchoseourproduct.Throughyearsofengineeringexpertise,handcraftsman-
ship 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.
Greatproductandcompetent installationsareonlyapieceofthepuzzle whenitcomes
to your system. Make sure that your installer is using 100% authentic installation
accessories from Connecting Punch in your installation. Connecting Punch has
everything from RCA cables and speaker wire to Power line and battery connectors.
Insist on it! After all, your new system deserves nothing but the best.
To add the finishing touch to your new Rockford Fosgate image order your Rockford
wearables,which include everything from T-shirts and jackets tohats and sunglasses.
To get a free brochure on Rockford Fosgate products and Rockford accessories, in the
U.S.call602-967-3565orFAX602-967-8132.Forallothercountries,call+001-602-
967-3565 or FAX [phone].
If, after reading your manual, you still have questions regarding this product,
we recommend that you see your Rockford Fosgate dealer. If you need further
assistance, you can call us direct at 1-800-795-2385. Be sure to have your serial
number, model number and date of purchase available when you call.
PRACTICE SAFE SOUND™
CONTINUOUS EXPOSURE TO SOUND PRESSURE LEVELS OVER
100dBMAY CAUSE PERMANENT HEARING LOSS. HIGH
POWERED AUTOSOUND SYSTEMS MAY PRODUCE SOUND
PRESSURE LEVELS WELL OVER 130dB. USE COMMON SENSE
AND PRACTICE 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
verificationofyourfactorywarrantyandmaybecomeusefulinrecoveringyour
amplifier if it is ever stolen.
Serial Number: ________________________________
Model Number:________________________________

TABLE OF CONTENTS
Introduction .............................................................................................1
Punch Amplifier Accessory Pack .............................................................. 1
Technical Design Features .......................................................................2
Design Features........................................................................................5
Installation Considerations ....................................................................... 7
Mounting Location................................................................................... 8
Battery and Charging................................................................................9
Wiring the System .................................................................................... 9
Using the XCard..................................................................................... 12
Resistor Chart......................................................................................... 13
Installation .............................................................................................14
System Diagrams.................................................................................... 18
Rockford Fosgate Accessories................................................................. 22
Troubleshooting ..................................................................................... 26
Dynamic Power Measurements.............................................................. 29
Specifications......................................................................................... 31
Warranty Information............................................................................. 33
International Information........................................................................ 34
Sections marked
ADVANCED OPERATION
include in-depth
technical information
Sections marked
TROUBLESHOOTING
include recommendations
for curing
installation problems
Sections marked
INSTALLATION
include “slam dunk”
wiring connections
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Welcome to Rockford Fosgate! This manual is designed to provide
information for the owner, salesperson and installer. For those of you
who want quick information on how to install this product, please turn
to the Installation Section of this manual or refer to the icons listed
below.OtherinformationcanbelocatedbyusingtheTableofContents.
We, at Rockford Fosgate, have worked very hard to make sure all the
information in this manual is current. But, as we are constantly finding
newways to improve our product, thisinformationissubject to change
without notice.
GETTING STARTED

INTRODUCTION
Rockford engineers designed the Punch 40x2, 60x2, 100x2 and
200x2 amplifiers to withstand the rugged automotive environment
while delivering superior sound quality in a flexible, reliable, and
efficientpackage.TRANS•ANAisalowvoltagecircuitinthepreamp
stageofallPunchx2amplifiersthatletsthemusicsoundcrystalclear
and very real, even when played at high volume levels. This is
matched with TOPAZ, a unique grounding circuit used to eliminate
noise problems associated with car audio systems and their installa-
tion. Flexibility is accomplished with the use of a built-in XCard.
Reliability is all but guaranteed with the use of a protection circuit
called NOMAD, while MOSFET and DSM (Discrete Surface Mount)
technologyimproveamplifier efficiency. The result of these compo-
nents give the Punch amplifier awesome sound quality in a “Bullet
Proof”package.Anexplanationofthesetechnologies,mostofwhich
areexclusivelydesigned andpatentedbyRockford,aredescribedin
the Technical Design Features.
– 1 –
PUNCH AMPLIFIER ACCESSORY PACK
The accessory pack shipped with the Punch 2-channel amplifiers
includes the mounting hardware necessary to secure the amp to the
vehicle as well as attaching the end caps.
Installation & Operation Manual
Punch Verification Certificate
(6) 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 Inline Fuseholder (Punch 40x2, 60x2, 100x2)
(1) AGU Inline Fuseholder (Punch 200x2)
(1) ATC 20 Amp Fuse (Punch 40x2)
(1) ATC 30 Amp Fuse (Punch 60x2)
(1) ATC 40 Amp Fuse (Punch 100x2)
(1) AGU 50 Amp Fuse (Punch 200x2)

TECHNICAL DESIGN FEATURES
– 2 –
◆TRANS•ANA
(TRANSconductance Active Nodal Amplifier)
The TRANS•ANA (TRANSconductance Active Nodal Amplifier) is a
circuitthatallowstheaudiosignaltopassthroughtheamplifieratlow
voltage. The signal is directly level-shifted to the fixed high voltage
rails via a pair of driver transistors. Signal linearity is assured by an
active node formed by the drive transistors at ultrasonic frequencies.
This allows amplifier performance similar to trans• nova which is
highly stable and linear while utilizing the advantages of a non-
floating power supply.
THERESULT:Anextendedfrequencybandwidthaccuratelysupplied
to the output stages of the amplifier.
◆TOPAZ (Tracking Operation Pre-Amplifier Zone)
The TOPAZ (TrackingOperationPre-AmplifierZone)circuitrysolves
groundloopnoiseproblemscommontoautomotiveamplifierdesign.
Thisinnovativenewdevelopmentallowsvastlyimprovedisolationof
the input signal grounds from the power supply ground of the
amplifier.Thisisaccomplishedbyallowingthesourceunittocontrol
the potential “environment”of the entire input structure or “zone”of
the amplifier. This process improves the noise rejection of the ampli-
fier by 30-40dB –an astounding 30-100 times better than amplifiers
without TOPAZ.
THERESULT:Eliminationoftroublesomegroundloopnoisebetween
source and amplifier.

◆DSM (Discrete Surface Mount) Technology
The DSM (Discrete Surface Mount) manufacturing process combines
the advantages of both discrete components and integrated circuitry.
RockfordFosgateistheonlyAmericanamplifiermanufacturertohave
invested millions into this process. DSM components differ from
conventional discrete components in different ways. They are more
compact, more rugged, and they efficiently dissipate generated heat.
Using them wherever appropriate allows 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
maximumaudioperformanceandhighestsignal-to-noiseratios tobe
obtained in amplifiers of desirable package size without resorting to
“amplifier-on-a-chip”shortcuts. These advantages are shown below
in Figure 1.
Figure 1
THE RESULT: Fewer connections, improved reliability, shorter signal
paths,superiorsignal-to-noiseratioandawesomesonicperformance.
◆XCard (Internal Crossover)
The Punch and Power amplifiers utilize internal active crossovers.
These crossovers have many performance advantages such as using
discrete components for exact frequency adjustments which are far
superiortopotentiometers.Additionally,the XCard canbeconfigured
for high-pass, low-pass and full range operation. With slight modifi-
cations,manycrossoverfrequenciesandslopeconfigurationscanbe
achieved.
THE RESULT: Increased system design flexibility with a precise
electronic crossover without the limitations of conventional potenti-
ometer designs.
– 3 –
Solder Solder
Component
Thru-Hole Surface Mount
PC
Board PC
Board

◆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 (MetalOxideSemiconductor FieldEffect
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 imped-
ance and wider bandwidth linearity. In addition, MOSFETs operate
verysimilarly to vacuumtubesin whichtheyare more linearthanbi-
polartransistors.However,MOSFETscandeliverthemidrangeclarity
without the limitations of transient response and high frequency
phase shifting normally associated with tube operation.
THE RESULT: Operational characteristics similar to vacuum tubes
without the performance limitations of tube design.
◆NOMAD (NOn-Multiplying Advanced Decision)
ThePunchand Poweramplifiers usean analogcomputer process to
maximize safe output power under all operating conditions. The
innovative NOMAD (NOn-Multiplying Advanced Decision) system
isthemostsophisticatedversionofthistechniqueeverused,bringing
previously unavailable levels of accuracy, stability, temperature
immunity and reliability to this critical process. NOMAD makes
advanceddecisionsbasedondevicevoltagestopreciselycontrolthe
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.
– 4 –

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.
+R–+L–Bass
Right
Gain
Right
Input
Left
Input
Left
Gain
Treble
Speaker Speaker
3 8 7 7
6 6 83
3. Speaker Terminals –Theheavy duty, gold-plated terminal block
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
Punchamplifieraregold-platedandwillaccommodateupto8AWG
wire maximizing the input current capability of the amplifier.
5. REM Terminal –This gold-plated spade terminal is used for the
auto power/remote turn on of the Punch amplifier.
6. RCAInputJacks–TheindustrystandardRCAjacksprovide easy
connections for signal level input. They are gold-plated to resist
the signal degradation caused by corrosion.
Punch Status
Display
49 5
GNDB+
LED
REM
11
– 5 –

7. Input Sensitivity Controls –The input level controls are preset
for 500mV which will match the output of most source units.
Theycanbeadjustedtomatchinputlevelsrangingfrom150mV
to 3V.
8. Punch Equalization Controls –ThePunchEQhelpscorrect for
acoustical deficiencies of the listening environment. The 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. The Punch EQ
can be bypassed by turning the controls to their minimum or
counterclockwise position.
9. LED Power Indicator –The LED illuminates when the unit is
turned on.
10. XCard (Internal Crossover) –This built-in crossover card is
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.
11. PunchStatusDisplay–TheRJ11interfaceallowsconnectionof
an LED display used to monitor amplifier performance.
®
Front
XCard
10
Low-Pass Full RangeHigh-Pass
HP
➝
➝
LP
HP
➝
➝
LP FULL
↕
®
AMPLIFIER
100 Watts RMS continuous power per
channel into 4 Ohms with less than 0.05%
Total Harmonic Distortion from 20-20kHz.
ROCKFORD CORPORATION
®
XCard
MADE IN THE USA
– 6 –

INSTALLATION CONSIDERATIONS
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
17' (518.16cm) Red Power Wire Assorted connectors
12' (365.76cm) Remote Turn-On Wire Wire crimpers
1.5' (45.72cm) Black Grounding Wire
– 7 –
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. RoutealloftheRCAcablesclosetogetherandawayfromanyhigh
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. Neverrunwiresunderneaththevehicle. Runningthewiresinside
the vehicle provides the 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 appropriate fuse on
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.