Rockford Fosgate 240X4, 160X4 User Manual

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4-CHANNEL AMPLIFIERS

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INSTALLATION & OPERATION

MANUAL

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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, in
the U.S. call 602-967-3565 or FAX [phone]. For all other countries, call
+001-602-967-3565 or FAX [phone].

PRACTICE SAFE SOUND™

CONTINUOUS EXPOSURE TO SOUND PRESSURE LEVELS
OVER 100dB MAY CAUSE PERMANENT HEARING LOSS. HIGH
POWERED AUTO SOUND SYSTEMS MAY PRODUCE SOUND
PRESSURE LEVELS WELL OVER 130dB. USE COMMON SENSE
AND PRACTICE SAFE SOUND.

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.

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:____________________

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

160x4 Specifications ....................................................................... 31

240x4 Specifications ....................................................................... 32

Warranty Information...................................................................... 33

GETTING STARTED

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 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
constantly finding new ways to improve our product, this information
is subject to change without notice.

INTRODUCTION

The Punch 160x4 and 240x4 are 4-channel amplifiers which can
deliver 160 watts and 240 watts RMS respectively. Both ampli­fiers 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
designs without the added cost of external processors. The Punch
160x4 and 240x4 are powerful 4-channel amplifiers with inte­grated features which are offered at a competitive price.

We strongly recommend you have your Authorized Rockford
Fosgate Dealer install the new Punch amplifier. If you do choose
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

The following accessories were designed to enhance the perfor­mance of the Punch 160x4 and 240x4 amplifiers.

Energy Storage Capacitor

The Punch capacitors are used to provide extra current needed by
amplifiers to reproduce musical transients. The Punch Caps also
have the natural ability to filter AC ripple caused by the alternator,
reducing the chance of noise in the system. The Punch Caps will
maximize both the sound quality and performance that Rockford

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
the coupling process, the Punch Link adds the finishing touch by

giving you the look of one awesome amplifier.

XCard

Additional crossover card frequencies are available for special­ized 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

◆ TRANS•ANA (TRANSconductance Active

Nodal Amplifier)

The

TRANS•ANA

is a circuit that allows the audio signal to pass through the
amplifier at
fixed high voltage rails via a pair of driver transistors. Signal
linearity is assured by an
transistors at ultrasonic frequencies. This allows amplifier perfor­mance similar to trans•

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.

◆ TOP AZ (Tracking Operation Pre-Amplifier Zone)

The

TOPAZ

solves ground loop noise problems common to automotive
amplifier design. This innovative new development allows vastly
improved isolation of the input signal grounds from the power
supply ground of the amplifier. This is accomplished by allowing
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.

(TRANSconductance Active Nodal Amplifier)

low voltage

(Tracking Operation Pre-Amplifier Zone) circuitry

. The signal is directly level-shifted to the

active node

nova

which is highly stable and linear

formed by the driver

THE RESULT: Elimination of troublesome ground loop noise
between source and amplifier.

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◆ DSM (Discrete Surface Mount) Technology

The

DSM

(Discrete Surface Mount) manufacturing process com­bines the advantages of both discrete components and integrated
circuitry. Rockford Fosgate is the only American amplifier manu­facturer to have invested millions into this process. DSM compo­nents differ from conventional discrete components in three
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 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. These advantages are shown in Figure 1.

Figure 1

Thru-Hole

THE RESULT: Fewer connections, improved reliability, shorter
signal paths, superior signal-to-noise ratio and awesome sonic
performance.

Component

Solder

Surface Mount

Solder

◆ 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 superior to potentiometers. Additionally, the XCard
can be configured for high-pass, low-pass and full range opera­tion. 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.

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◆ RTP (Real Time Protection)

NOMAD (NOn-Multiplying Advanced Decision)

The Punch and Power amplifiers use an
maximize safe output power under all operating conditions. Rock­ford Fosgate pioneered and developed
a crucial element in the performance edge of our amplifiers. The
innovative
is the most sophisticated version of this technique ever used,
bringing previously unavailable levels of accuracy, stability, tem­perature 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.

NOMAD

(NOn-Multiplying Advanced Decision) system

analog computer process

RTP

(Real Time Protection),

to

◆ MOSFET Devices

Rockford Fosgate is one of the few manufacturers in the sound
community to utilize MOSFET devices in both the
and the
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,
MOSFETs can deliver the midrange clarity without the limitations
of transient response and high frequency phase shifting normally
associated with tube operation.

output stages. MOSFET

(Metal Oxide Semiconductor

power supply

THE RESULT: Operational characteristics similar to vacuum

tubes without the performance limitations of tube designs.

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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.

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5 4 9

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3. Speaker Terminals – The heavy 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
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.

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6. RCA Input Jacks – The industry standard RCA jacks provide

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easy connections for signal level input. They are gold-plated to
resist the signal degradation caused by corrosion.

7. Signal Input Switch – This switch allows selection of 2-channel
or 4-channel source unit feed.

8. 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.

9. LED Power Indicator – The LED illuminates when the unit is
turned on.

10. XCard (Internal Crossover) – These built-in crossover cards are
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.

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Low Pass Full RangeHigh Pass

HP

LP

AMPLIFIER

FULL

ROCKFORD CORPORATION

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MADE IN THE USA

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20 Watts x 4 into 4Ω at 0.05% THD

40 Watts x 4 into 2Ω at 0.1% THD

LP

HP

2 Channel Input

4 Channel Input

10

XCard 1 XCard 2

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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
Wire crimpers Assorted connectors

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.

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 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 the appropriate 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.

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