zapco Z-150.4 II User manual

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Z-II SERIES
Owner’s Manual
Before o erating the unit, lease read this manual throughly and retain it for future reference.

MISSION STATEMENT
Comm tted to Excellence
ZAPCO is dedicated to the pursuit o audio idelity. Our prime objectives are to
design and manu acture audio products o unsurpassed quality, to provide
unparalleled support and service or these products and to conduct business
in a manner that will enhance the quality o li e or all involved.
Exper ence
(Knowledge from do ng)
There is absolutely no substitute or experience; that is a simple act o li e.
Another simple act is that ZAPCO has, or over orty years, been the leader in
de ining quality standards or the car audio industry.
These years o experience have led to a thorough understanding o the
challenges that are unique to the world o car audio. ZAPCO's relentless quest
or sonic purity consistently yields imaginative designs that utilize the most
innovative technologies. The resulting products set the criteria by which all
others in the industry are judged.

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Table of Contents
The new Zapco Z-Series Ampli iers ................................................................. 2
The re-birth o the Z-Series .................................................................... 2
Improved Circuit Board and Functionality Class AB .................................. 3
Improved Circuit Board and Functionality Class D .................................... 4
Be ore you start your Installation ................................................................... 5
Planning your Power Connections ................................................................. 6
Wire size ................................................................................................. 7
Mounting your Z-II Series Ampli ier ................................................................ 8
The Z-II Class AB SQ Competition Ampli iers .................................................. 9
Z-150.2 II Input and Controls ................................................................... 9
Z-150.4 II Input and Controls ................................................................... 10
Z-150.6 II Input and Controls ................................................................... 11
Z-150.2 II Speaker Wiring ........................................................................ 12
Z-150.4 II Speaker Wiring ........................................................................ 14
Z-150.6 II Speaker Wiring ........................................................................ 17
The Z-II Class D SQ Competition Bass Ampli iers ............................................ 20
Z-KD II Input and Controls ....................................................................... 20
Z-KD II Speaker Wiring ............................................................................ 22
Technical Speci ications ................................................................................... 24

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The New Zapco Z-Ser es Ampl f er
Congratulations, on the purchase o your new Zapco Z-Series ampli ier. We
believe you now have the inest sound available in a car sound ampli ier, and we
think you should know a little bit about what makes this amp unique in a world
o so many so-so products.
The re-b rth of the Z-Ser es
In 2012 Zapco introduced the new Z-Series o SQ amps. These amps were not
conceived so much by our engineers, as by input rom audiophiles and car sound
anatics around the world. Starting about 2004, at Zapco training seminars in
Asia and in the EU, we began running into audiophiles who were changing
certain internal components in our ampli iers to achieve what they elt was
better quality sound.
With that in our minds, we developed the Z-Series amps with less measuring
and more listening. So or the Z-Series o Zapco ampli iers, we experimented
with internal components and new circuits to see i we could take our amps to
the next level o sound quality by investing in di erent internal components
and circuit designs, and the resulting Z-Series amps were the results o this
unique development method.
Over the last years we have developed two specialized ampli iers to take auto
sound to a di erent level. The Z-Series LX amp, the ultimate SQ amp. No controls
except gain. A pure SQ amp. We also brought out the ZSP-Series amps or the
anatics that want to play ull-volume ull-time but still get audiophile sound.
This year we stepped back and took a look at the amp that started it all. The
Z-Series ampli ier. We knew we could bring the price down, because over the
last ew years. This allowed us to build the Z-series LX and amps cost only a
little more than the original Z-Series so the prices weren't that ar apart. Now
we have brought the Z-Series into the same plant as the newer models. This
saves money!
That lowers the price, but what could we do the make it better? We saw that a
lot o the non-critical parts rom the LX and amps could used in the new Z-Series
as well. Even with some o the SQ parts we save by buying more so we can use
those in the Z-series also.

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Bottom line, we have improved the ampli ier at the same time we brought the
price down. Who ever does that!
O course, that's just talk, but here's the bee .
For the Class AB ull range Competition Amps:
• A new TI op-amp that give the Z considerably better signal to noise ratio,
with a lower loor noise
• We used the same audiophile grade caps that we use in the LX and amps
• We bee ed up the power supply with more storage and less internal
resistance and lower inductance or higher e iciency
• We added more MOSFETS to the power supply or e iciency and current
handling
About unctionality:
• The end plates are now recessed like the LX amps or a cleaner look
• The plastic controls have been replaced by new metal pots and switches.
The new pots also have detents (like the amps) at 40ea so you can accurately
set crossovers gains identical or right and le t channels
• The new Z-II AB amps have band pass crossovers on all models so you
won't need any outboard devices to make a band pass
• x-10 the multiplier switches rom the amps are on the New Z to extend
the crossover ranges. This means Z-150.2 II can have higher requency
crossover or a dedicated tweeter amp and the Z-150.6 II can do tweeter,
midrange, and bass all with internal crossovers

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• The new Z-Series amps have the same panel mount RCA connectors as
the LX amps. Even the tightest RCA connector can't hurt them
For the Class D Competition Bass Amps:
The Z-II bass amps also get a number o improvements.
• A bee ed up power supply
• Increased power
• New high end audio caps like the SQ amps
• New TI low noise op-amps like the SQ amps
• Improved ti any style panel mount RCA connectors
• The end plates are now recessed like the LX amps or a cleaner look
• The plastic controls have been replaced by the new metal pots and
switches. The new pots also have detents (like the SP amps) at 40ea so you
can accurately set crossovers and gains identical with multiple ampli iers
So there you are! Functionality improvements to make the amps more use ul and
sound quality improvements you'd never expect rom a Class D bass amp.
Z-KD II; more use ul, better looking and even better sounding.
Class A/B amps or ull range use and Class D amps or bass. Whatever your
needs, the new Zapco Z-II Competition series ampli iers bring you better eatures,
better power, and better sound.
As we promised when we started: We will never re-paint an amp and call it a new
model. Every run o ampli iers must be better than the last or we won't make it.
We sincerely hope you enjoy your new Z-II Series ampli ier as much as we
enjoyed the time we spent developing it.

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Before you start your nstallat on
ZAPCO highly recommends that a use or circuit breaker be placed within 18"
o the battery. Although you will add a use or use block near the ampli ier it
is still a possibility that a pinched power wire between the component use
and the battery could result in a short, or even a ire. The protection device
should be placed where it can be accessed easily and all wiring should be
routed sa ely and correctly according to the ollowing guidelines:
Do not run wiring close to hot or spinning objects.
Always use wire grommets when routing wire through the irewall or any
other metal panels.
Make sure that the potential or pinched wiring is avoided by routing all wires
away rom moving hinges and seats. This also includes brake, gas and clutch
pedals, hood and trunk hinges, etc.
Continuous exposure to excessive sound pressure levels may cause permanent
hearing loss. ZAPCO strongly advises that you use common sense when setting
volume levels. I you experience ringing in the ears, it could cause permanent
hearing damage!
When connecting our ampli iers to pre-wired stock speakers, care must be
taken that there are no common connections between le t and right speaker
wires, i.e. two or more speakers using the same ground connection (very
common in pre-85 cars), as this will cause the ampli ier to go into immediate
protection or may cause damage to the ampli ier. Output connections are not
common chassis ground. Please ollow the hookup instructions in this owner's
manual. Any questions should be directed to your local ZAPCO dealer.
Caut on: Continuous exposure to excessive sound pressure levels may cause
permanent hearing loss. ZAPCO strongly advises that you use common sense
when setting volume levels. I you experience ringing in the ears, it could
cause permanent hearing damage!

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Plann ng your power connect ons
The power end plates o the Zapco Z-series ampli iers carry the power connections
and the Speaker connections and vary somewhat by the number o channels.
For example, the power end o the Z-150.6 II has (o course) Speaker connections
or six channels. One model, the Z-150.2 II has on-board uses, while all other
models will require and in-line use. Please ollow the rating guidelines as in the
Speci ications page at the end o this manual.
That said, the main 12-volt power input, the 12-volt turn-on wire, and the main
Ground connections are common to all models.
• The connection at the interior o the end plate is the main power input.
This must be connected the vehicle battery's positive (+) terminal, and a
main system use should be placed close to the battery
• The connection at the outside o the end plate is the main ground or negative
connection. This must be securely attached to bare metal at the vehicle rame,
or other heavy chassis component with a direct connection to the rame
Note: Seat bolts and seat belt bolts are NOT good ground po nts
• The small terminal between the main power and ground is the +12 turn-on
input and can be connected to the head unit turn-on output wire. I none
is available it can be connected to an accessory (ACC) terminal. You should
avoid using any ignition-on (IGN) wire, as they can be noisy
Note: The Z-Ser es ampl f ers have term nals that do not requ re connectors. You s mply nsert
a bare port on of w re and t ghten the connect on w th the suppl ed Hex tool. As the w re
conforms to the connector the connect on can loosen. You should re-t ghten the connect on
after about a week.
Turn-on tr gger w re
+12 volt at Baery pos ve term nal Ground to chass s

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Some words about Power and Ground
Note: The second most common cause of underperform ng ampl f ers s nsuff c ent power
current or a pour power connect on. The most common cause of underperform ng ampl f ers s
nsuff c ent ground current or a bad ground connect on.
12-volt current: Battery Power works only i it travels in a complete circuit rom
the battery positive terminal to the battery negative terminal. Main power
input, o course, is attached to the battery positive terminal. Ground current is
returned to the battery through the chassis to the point where the battery is
grounded.
The current available or your ampli ier to use to produce power will be
restricted by the smallest gauge o wire in the circuit and by the weakest physical
connection in the circuit.
W re S ze
It's o ten surprising how many people will obsess about signal wire but routinely
provide the ampli ier with only a raction o the current it needs to do its job.
The most common wire gauge used in car audio is 10-gauge, and the most
common location or ampli iers is in the trunk.
W re S z ng Chart
4 t 7 t 10 t 13 t 16 t 19 t 22 t 28 t
0-20 amps 14 12 12 10 10 888
20-35 amps 12 10 886664
35-50 amps 10 8866444
50-60 amps 88644442
65-85 amps 66442220
85 -105amps 66422220
105-125 amps 44422000
125-150 amps 22220000
Let's look at a airly small system. I you use a 50 watt/ch amp (25 amps)
or the highs and a 100 watt/ch amp (40 amps) or the woo ers, you need at
least a 4-gauge and maybe a 2-Guage wire to provide 65 amps at the trunk.
Anything less and your car won't go boom. It'll just go Blap!
Length of Run

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Note: It takes lots of current to make lots of power!
Remember! An electrical circuit is just that... a complete circuit. For current to
travel, you must complete the circuit rom the positive terminal to the negative
terminal (which is connected to the vehicle rame). So what ever Gauge wire
you use or power (B+) you must also use or ground (B-).
Note: A 4-gauge power w re needs 4-gauge ground w re!
Use the Wire Sizing Chart! Add up the use values on the ampli ier(s) then
choose the proper size wire based on the distance rom the car battery to the
ampli ier location. Again, always use the same gauge wire or the main ground
as you do or the main power. Always make your ground as short as possible
and secure it to a clean solid sur ace, pre erably the vehicle rame.
Mount ng your Z-II Ser es ampl f er
Mounting your Zapco ampli ier is easy. Just keep in mind a ew guidelines:
• The ampli ier can be mounted in any direction, on wood, metal, or carpet
• The metal chassis o the amp can be grounded or le t isolated
• The ampli ier requires adequate ventilation. Creating power creates
heat, and cooling requires air. Position the ampli ier with su icient
surrounding area or air supply and keep the end plate and side vents
clear or internal cooling
• Keep the ampli ier out o the engine compartment or other locations
that may cause excessive heat or moisture
• Do not mount the ampli ier to a subwoo er box or other place that may
have excessive vibration
Sett ng Ga ns: Gain pots are not volume controls. Be ore you irst turn on your
system, you should make sure all gain controls are set to minimum. Gain
controls should be used only i absolutely necessary. Turning up gain controls
causes increased noise, makes distortion more likely and reduces the dynamic
range o your system. I you head unit does not have su icient output, you will
get much better results by investing in a line driver to provide more signal to
the ampli ier.