Hifonics BRX160.2, BRX320.4, BRX640.4, BRX1200.4, BRX5000.5 User Manual

BRX

BRX160.2 / BRX320.4 / BRX640.4 / BRX1200.4

BRX5000.5

GENERAL INSTALLATION PROCEDURE

System Design

The success of any car stereo system relies on several factors, such as the system design, execution of the installation, and system setup. Please
remember that any system is only as good as its weakest link.

Please remember that higher power systems are not necessarily useful purely for high sound pressure levels, but also to establish a headroom capability, to
reproduce musical peaks cleanly without distortion. Lower power amplifiers will clip earlier than their more powerful cousins, and cause loudspeaker failure when
overdriven, due to the harmonics generated by a clipped signal, thus overheating voice coils.

Amplifiers should be mounted with the fins running horizontally for best convection cooling, to minimize overheating. Purchase the best quality RCA cables you can
afford, for reliability and less engine noise interference in the audio system.

Installation

BRUTUS

WOOD

It is highly recommended that the amplifier be mounted to a board of MDF or other solid
structure using the 4 mounting screws provided. Avoid mounting the
amplifier to metal as this can introduce noise and other unwanted issues. When mounting
the amplifier, ensure that it is mounted HORIZONTALLY, as shown in the diagram above, for
optimal heat dissipation. Mounting amplifiers to speaker enclosures is not recommended as
this can cause damage to the amplifier components. When choosing a location for
mounting the amplifier, ensure that you check for clearance from wires, gas tank, electrical
devices and brake lines etc.

General:

Run the wiring so that RCA cables are at least 18“ away from power and speaker cables. Keep RCA cables away from electrical devices in the vehicle that can cause
electrical noise, such as electric fuel pumps, emission control modules and other on-board electronic modules.

Power and ground connections(see the features matrix on page 12 for proper gauge cables per amplifier):

Use a sufficient gauge power cable and ground cable using the chart below as reference to what size wire you require. Brutus series amplifiers require at least 4
gauge power wire. In a multi amplifier system, add the total value of the manufacture recommended fusing to get your total system amperage. Some applications
may require multiple runs of power wire to meet the system requirements. In multi amplifier systems it is advisable to mount a large enough fuse right at the battery,
and run one or multiple +12 volt power cables to a fused distribution block near the amplifiers. It is then a simple matter to connect the +12 volt terminal of each
amplifier to the distribution block. During this process, please ensure that the main power fuse is removed to avoid shorting the electrical system. The main fuse must
be within 12” of the vehicles battery.

Ground each amplifier with as short a ground lead as possible directly to the vehicle chassis using at least 4 gauge wire or equivalent to the size of the amplifiers’
power wire. Use a ground distribution block, if you wish, but it is extremely important to keep the main ground lead from this distribution block to the chassis as short
as possible , not more than 12“. The ground connection integrity to the chassis is very important, and the best way to achieve a good, solid electrical and mechanical
contact is to use a large round crimp lug, crimped and soldered to the ground cable. The next step is to scrape the paint off the vehicle chassis , slightly larger than
the ground lug, at the connection point. Drill a clearance hole in the chassis, the same size as the lug hole, and use a bolt, spring washer and nut to securely fasten
the ground lug. Use petroleum jelly to coat the bolt/lug connection, to prevent oxidization with time.

TIP: Use the same approach when installing head units, equalizers or any audio equipment for that matter - run short individual grounds from each piece directly to

the vehicle chassis, to minimize ground loops and system noise. All power, ground and speaker connections should be crimped and soldered for reliability. Make sure
that none of the cable insulation can chafe against exposed metal in the vehicle, causing short circuits to the chassis.

WIRE LENGTH

SYSTEM
AMPERAGE

35-50

50-65

68-85

85-105

105-125

125-150

7-10 ft. 10-13 ft. 13-16 ft.

8

6

4

4

4

2

6

4

4

2

2

0

4

4

2

2

0

0

16-19 ft. 19-22 ft. 22-28 ft.

4

4

2

2

0

0

4

4

2

2

0

0

4

2

0

0

0

0

WIRE GAUGE

Safe connection sequence:

After all cables are run, connect speaker wires to the speakers and amplifiers, then run and plug in RCA cables. Next, connect all power, ground, and remote turn on
leads. Now connect all +12 volt cables to the amplifier/s and distribution blocks and fuse holders. Finally, connect the main +12 volt cable to the battery, with the main
fuse removed, and we are almost ready to power up the system.

Power up the system:

The following procedure may seem like overkill, but there is nothing more frustrating when turning on a system for the first time, and it does not work properly
immediately.
First, make sure the head unit is off, and turn all level controls to minimum (counterclockwise), including the head unit volume control. Set all equalizers to 0 dB (no
boost), and all crossover frequency controls at approximate frequencies, as recommended by the loudspeaker manufacturer. Set all input selector and crossover
switches as required for the application. Remove all amplifier fuses, and insert the main fuse at the battery. If the fuse does not blow, you can insert the fuse in one of
the amplifiers, and we are ready to turn on the system. Turn the head unit on, insert a CD, or select a radio station, and increase the head unit volume control. If the
system sounds fine, turn off the head unit, and install fuses in the remaining amplifiers, one by one, till the complete system is powered up and functioning properly.

AMPLIFIER FEATURE DESCRIPTIONS

BRUTUS BRX AMPLIFIERS:

Each model is capable of 4 & 2-Ohms stereo per channel, or 4-Ohms mono bridged operation except the
mono amps which are capable of 4, 2 and 1-Ohm loads.
Tri-Mode operation with any stereo pair of amplifier channels is possible, as with all bridgeable amplifiers.
The input sensitivities for rated output powers are variable from 0.2V to 6V for the multi channel amplifiers
and 0.2V to 9V for the mono models.
All crossovers are fully variable in their respective ranges.
Crossover filters are 12dB/Octave.

1 set for channels 1 & 2.
The X-OVER slide switch selects the internal crossover functions:

-The input signal is routed directly to the LINE OUT RCA jacks, regardless of the X-OVER setting simplifying
daisy chaining of amplifiers.

-HPF: Selects the built in HI PASS filter.

-FULL: Bypasses all crossovers for full frequency range operation.

-LPF: Selects the built in LOW PASS filter.
MODE: Selectable Stereo or MONO operation.
HPF: Variable low frequency cut off from 60Hz to 1.3kHz.
LPF: Variable high frequency cut off from 30Hz to 250Hz.
BASS EQ: 45Hz bass boost variable from 0dB to 12dB.
LEVEL: Variable LEVEL (GAIN) control from 6.0V to 0.2V.
LINE INPUT: The line input accepts unbalanced (RCA) inputs from 0.2V to 6V.
LINE OUTPUT: The line output passes through signal from the line inputs which allows you to daisy chain

multiple amplifiers from one signal.

The 4 channel amps have the same features as the 2 channel models except that there are 2 sets of
controls.
1 set for channels 1 & 2 and 1 set for channels 3 & 4.
In addition, the 4 channel models have a Mode switch which allows you to select 2 or 4 channel operation.
Switch to 2 channel if you only have 1 set of RCA’s in CH 1/2 and the unit will automatically
supply signal to channels 3/4. Select 4 channel if you are providing RCA’s to channels 1/2 and 3/4.
The X-OVER slide switch selects the internal crossover functions:

-The input signal is routed directly to the LINE OUT RCA jacks, regardless of the X-OVER setting simplifying
daisy chaining of amplifiers.

HI PASS: Variable low frequency cut off from 10Hz to 1.5kHz.
LOW PASS: Variable high frequency cut off from 30Hz to 150Hz.
BASS EQ: 45Hz bass boost variable from 0dB to 10dB.
LEVEL: Variable LEVEL (GAIN) control from 6.0V to 0.2V.

A POWER LED indicates the powered up and turned on condition.
All Hifonics amplifiers feature a comprehensive diagnostic system, with speaker lead short circuit, and
amplifier DC faults indicated by the red “PROTECT” LED.

CAUTION: DO NOT OPERATE ANY AMPLIFIER BELOW THE INTENDED IMPEDANCE. YOU WILL
CAUSE DAMAGE TO THE AMPLIFIER THAT WILL NOT BE COVERED UNDER THE WARRANTY
PRINTED IN THE BACK OF THE MANUAL. 2 & 4 Channel amps are capable of 4 and 2-Ohms wired
stereo and 4-Ohms wired mono bridged. The mono amps are capable of 4, 2 and 1-Ohm.

BRX160.2 2-CHANNEL AMPLIFIERS

LINE OUT LINE INPUT LEVEL BASS EQ X-OVER HPF LPF MODE

L

R

Note that the LOW PASS signal is MONO.

-In the LPF position, the HPF filter acts as a subsonic filter.

-When the LPF mode is selected, a 0 to +12dB, at 45Hz, BASS EQ is also switched in.

L

6V 0.2V 0dB 12dB 60Hz 1.3kHz 30Hz 250Hz

R

FULL LPF HPF

MONO STEREO

POWER

PROTECT

BRX320.4 / BRX640.4 / BRX1200.4 4-CHANNEL AMPLIFIERS

CH1/2 CH3/4 REMOTE HI PASS CH1/2 X-OVER LOW PASS BASS EQ LEVEL POWER LINE OUTPUT

R

L

Note that the LOW PASS signal is MONO.

-In the LP/BP position, the HI PASS filter acts as a subsonic filter.

-When the LP/BP mode is selected, a 0 to +10dB, at 45Hz, BASS EQ is also switched
in.

R

L

2CH 4CH

LINE INPUT MODE HI PASS CH3/4 X-OVER LOW PASS BASS EQ LEVEL

HI FULL LP/BP

10Hz 1.5kHz 30Hz 150Hz 0dB 10dB 6.0V 0.2V

HI FULL LP/BP

10Hz 1.5kHz 30Hz 150Hz 0dB 10dB 6.0V 0.2V

PROTECT

R

L

The 5 channel amps have the same features as the 4 channel models except that there are 3 sets of
controls.
1 set for channels 1 & 2, 1 set for channels 3 & 4 and 1 set for channel 5.
In addition, the 4 channel models have a Mode switch which allows you to select 2, 4 or 5 channel operation.
Switch to 2 channel if you only have 1 set of RCA’s in CH 1/2 and the unit will automatically
supply signal to channels 2/4/5. Select 4 channel if you are providing RCA’s to channels 1/2 and 3/4 and
signal will be internally routed to Ch5. Select 5 if you are supplying RCA’s to each INPUT.
The X-OVER slide switch selects the internal crossover functions:

-The input signal is routed directly to the LINE OUT RCA jacks, regardless of the X-OVER setting simplifying
daisy chaining of amplifiers.

HI PASS: Variable low frequency cut off from 10Hz to 1.5kHz.
LOW PASS: Variable high frequency cut off from 30Hz to 150Hz. (CH3/4 & 5)
BASS EQ: 45Hz bass boost variable from 0dB to 10dB.
LEVEL: Variable LEVEL (GAIN) control from 6.0V to 0.2V.
REMOTE: This is a remote input jack for the remote level control on Ch5.

SUBSONIC: Crossover filter from 15Hz to 35Hz.
LOW PASS: Crossover filter from 35Hz to 250Hz.
LEVEL: Adjusts the input sensitivity from 0.2 volts to 9 volts.
BASS EQ: Adjustable bass boost from 0db to 10dB.

The Phase Shift is fully adjustable from 0 to 180 degrees and this allows you to control time

PHASE:

alignment.

REMOTE: This is the input jack for the remote Level control.
BALANCED INPUT:
LINE INPUT: The line input accepts unbalanced (RCA) inputs from 0.2V to 9V.
LINE OUTPUT: The line output passes through signal from the line inputs which allows you to daisy chain

multiple amplifiers from one signal.

-The LINE INPUT signal is routed directly to the LINE OUT RCA jacks, and not affected by the settings on the
amplifier simplifying daisy chaining of amplifiers.

The BRX2400.1D is identical to the other BRX mono amplifiers except that the BRX2400.1D is a
linkable amplifier and features a MASTER / SLAVE selection switch and IN / OUT RCA connection. This
allows for a pair of amps to link at 2-Ohms and produce 4800 watts rms.

Accepts line level balanced input from 0.4v to 18v.

BRX5000.5 5-CHANNEL AMPLIFIERS

LINE INPUT CH1/2 X-OVER HI PASS LEVEL HI PASS CH3/4 X-OVER LOW PASS LEVEL

HI FULL

Ch2

Note that the LOW PASS signal is MONO.

-In the LP position, the HI PASS filter on Ch3/4 acts as a subsonic filter.

10Hz 1.5kHz 6V 0.2V 10Hz 1.5kHz 30Hz 150Hz 6V 0.2V

Ch4

30Hz 150Hz 0dB 10dB 6V 0.2V POWER

Ch3Ch1

REMOTE LOW PASS BASS EQ LEVEL CH5 MODE

HI FULL LP

PROTECT

Ch5

2CH 4CH 5CH

BRX1100.1D / BRX1600.1D / BRX2000.1D MONO BLOCK AMPLIFIERS

INPUT OUTPUT INPUT LEVEL PHASE REMOTE BASS EQ SONIC LOW PASS

L L

R R

The mono amps are capable of 4, 2 & 1-Ohm loads.
Operating the amp below 1-Ohm can cause damage to the amp not covered in the
warranty.

BALANCED

9V 0.2V 0 180 0dB 10dB 15Hz 35Hz 35Hz 250Hz

SUB

POWER

PROTECT

BRX2400.1D MONO BLOCK AMPLIFIERS

OUTPUT

MASTER

POWER
PROTECT

INPUT
SLAVE

IN

OUT

BALANCED

INPUT OUTPUT INPUT LEVEL PHASE REMOTE BASS EQ SONIC LOW PASS

L L

R R

9V 0.2V 0 180 0dB 10dB 15Hz 35Hz 35Hz 250Hz

SUB

The mono amps are capable of 4, 2 & 1-Ohm loads.
Operating the amp below 1-Ohm can cause damage to the amp not covered in the
warranty.

BRX160.2 2-CHANNEL AMPLIFIER APPLICATIONS

2 CHANNEL FULL RANGE SYSTEM

Here we show how to use the 2 channel amplifiers as straightforward discrete 2
channel full range units.

Interconnect cable checklist:

- Connect the four inputs of the amplifier to a Radio/CD with quality RCA cables.

Switch setting checklist:

- 1/2CH X-OVER: FULL

LINE OUT LINE INPUT LEVEL BASS EQ X-OVER HPF LPF MODE

R

L

BRUTUS

6V 0.2V 0dB 12dB 60Hz 1.3kHz 30Hz 250Hz

FULL LPF HPF

MONO STEREO

PROTECT

POWER

Level control checklist:

- Refer to the section “Setting up systems after installation for best performance”

Minimum final loudspeaker impedances:

- 2 ohm per channel.

BRIDGED

RIGHT LEFT

- + - +

FUSE

POWER INPUT

GND REM BATT+12V

MONO

Here we show how to use the 2 channel amplifiers as a 1 channel unit by taking
advantage of the mono bridging capability of all Hifonics amplifiers

Interconnect cable checklist:

- A MONO signal source is required to bridge channel pair 1/2, such as would be
available from the mono sub bass output of an active crossover, whether
standalone, or built into a head unit or equalizer. If you only have 1 set of RCA
outputs from your headunit, you can simply connect those to the inputs for ch
1/2 and switch the MODE to MONO. The amplifier will auto sum the signal and
provide mono output for bridged channels 1/2 once the X-OVER is switched to
LP.
Important: Do not be tempted to connect the hot, or positive outputs, from any
source together to obtain a mono signal, as this could very well damage the
output stage of that source.

- It is necessary to feed the SAME signal to both left and right inputs via a Y­adapter RCA cable.

- Connect the mono speaker positive terminal to the LEFT +, and its negative
terminal to RIGHT - as shown.

LINE OUT LINE INPUT LEVEL BASS EQ X-OVER HPF LPF MODE

R

L

BRUTUS

MONO LINE INPUT

(Unless using procedure
listed above for 3ch)

6V 0.2V 0dB 12dB 60Hz 1.3kHz 30Hz 250Hz

FULL LPF HPF

Switch setting checklist:

- 1/2CH X-OVER: LP

MONO

-MODE:

Level control checklist:

- Refer to the section “Setting up systems after installation for best performance”

Minimum final loudspeaker impedances:

- 2 ohm per channel in stereo mode.

- 4 ohm mono bridged.

BRIDGED

RIGHT LEFT

- + - +

FUSE

MONO STEREO

PROTECT

POWER

POWER INPUT

GND REM BATT+12V