Rockford Fosgate 400x4 User Manual

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4-CHANNEL AMPLIFIER

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: ____________________

TA B L E O F CO N T E N T S
Introduction ......................................................................................	1
Punch 4-Channel Amplifier Accessory Pack ......................................	1
Rockford Fosgate Accessories ............................................................	2
Technical Design Features ................................................................	3
Design Features .................................................................................	7
Installation Considerations ................................................................	9
Mounting Location ..........................................................................	10
Battery and Charging .......................................................................	11
Wiring the System ...........................................................................	11
Using the XCard ..............................................................................	14
XCard Configurations ......................................................................	15
Using the Signal Input Switch ..........................................................	18
Basic Connections ...........................................................................	20
System Diagrams .............................................................................	27
Troubleshooting ..............................................................................	31
Dynamic Power Measurements .......................................................	34
400x4 Specifications .......................................................................	37
Warranty Information ......................................................................	38
G E T T I N G S T A R T E D

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.

I N T R O D U C T I O N

The Punch 400x4 (pronounced “x4” not “by 4”) is a 4-channel amplifier which can deliver 400 watts RMS. This amplifier utilizes a 2/4-channel input switch to eliminate the need for signal splitters. Four internal XCard crossovers allow the amplifier to be configured for use with many popular system designs without the added cost of external processors. The Punch 400x4 is a powerful 4-channel amplifier with integrated features which are offered at a competitive price.

We strongly recommend you have your Authorized Rockford Fosgate Dealer install your new Punch amplifier. If you do choose to install it yourself, please be sure to read the entire manual before beginning.

PU N C H 4-CHANNEL AM P L I F I E R

AC C E S S O R Y PA C K

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) AGU In-line Fuseholder

(1) AGU 50 Amp Fuse

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RO C K F O R D FO S G AT E AC C E S S O R I E S

The following accessories were designed to enhance the performance of the Punch 400x4 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

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TECHNICAL DESIGN FEATURES

TRANS•ANA (TRANSconductance Active

Nodal Amplifier)

The TRANS•ANA (TRANSconductance Active Nodal Amplifier) is a circuit that allows the audio signal to pass through the amplifier at low 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 driver 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.

THE RESULT: An extended frequency bandwidth accurately supplied to the output stages of the amplifier.

TOPAZ (Tracking Operation Pre-Amplifier Zone)

The TOPAZ (Tracking Operation Pre-Amplifier Zone) circuitry 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.

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		Component
	Solder	Solder
Thru-Hole	Surface Mount

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

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 analog computer process to maximize safe output power under all operating conditions. Rockford Fosgate pioneered and developed RTP (Real Time Protection), a crucial element in the performance edge of our amplifiers. The innovative NOMAD (NOn-Multiplying Advanced Decision) system 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.

MOSFET Devices

Rockford Fosgate is one of the few manufacturers in the audio industry to utilize MOSFET devices in both the power supply and the output stages. MOSFET (Metal Oxide Semiconductor 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.

THE RESULT: Operational characteristics similar to vacuum tubes without the performance limitations of tube designs.

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Pass-Thru Output

The Pass-Thru output provides a convenient source for daisychaining an additional amplifier without the need for extra RCA cables or “Y” adapters. The Pass-Thru signal is derived from summing the Front and Rear Left inputs to create a Left output, and summing the Front and Rear Right inputs to create a Right output. When the amplifier is used with 4-channel inputs, the Pass-Thru provides constant output regardless of the source unit fade position. Additionally, the Pass-Thru has an XCard that can be set for High-Pass, Low-Pass or Full Range.

THE RESULT: Constant non-faded output for adding woofer amplifiers.

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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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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.

6.RCA Input Jacks – The industry standard RCA jacks provide easy connections for signal level input. They are gold-plated to resist the signal degradation caused by corrosion.

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

8.RCA Pass-Thru Jacks – The Pass-Thru provides a convenient source for daisy-chaining an additional amplifier without running an extra set of RCA cables from the front of the vehicle to the rear amplifier location. One of the internal XCards can be designated to the Pass-Thru, creating a dedicated low-pass, high-pass, or full range output.

9.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.

10.Phase Switch – This switch enables you to easily invert the rear channel phase without having to disconnect the speaker wires.

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

12.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 highpass, low-pass, or full range operation.

®

® 4 AMPLIFIER

t r a n s • a n a

50 Watts x 4 into 4 Ohms with less than 0.05% THD 100 Watts x 4 into 2 Ohms with less than 0.10% THD

®

ROCKFORD CORPORATION

MADE IN THE USA

High-Pass

LP			H P

Low-Pass

P H	L P

Full Range

FULL ↕

Front XCard

XCard 1

Rear XCards

XCard 2

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Dual Filter

XCard 3

XCard Front

XCard Rear 1

XCard Rear 2

Pass-Thru XCard

XCard 4

XCard Pass-Thru

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IN S TA L L AT I O N CO N S I D E R AT I O N S

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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MOUNTING LOCATION

The mounting location and position of your amplifier will have a great effect on its ability to dissipate the heat generated during normal operation. The design of our cast aluminum heatsink serves to easily dissipate the heat generated over a wide range of operating conditions. However, to maximize the performance of your amplifier, care should be taken to ensure adequate ventilation.

Trunk Mounting

Mounting the amplifier vertically on a surface with the fin grooves running up and down will provide the best cooling of the amplifier.

Mounting the amplifier on the floor of the trunk will work but provides less cooling capability than vertical mounting.

Mounting the amplifier upside down to the rear deck of the trunk will not provide proper cooling and will severely affect the performance of the amplifier and is not recommended.

Passenger Compartment Mounting

Mounting the amplifier in the passenger compartment will work as long as you provide a sufficient amount of air for the amplifier to cool itself. If you are going to mount the amplifier under the seat of the vehicle, you must have at least 1" (2.54cm) of air gap around the amplifier's heatsink.

Mounting the amplifier with less than 1" (2.54cm) of air gap around the amplifier's heatsink in the passenger compartment will not provide proper cooling and will severely affect the performance of the amplifier and is not recommended.

Engine Compartment Mounting

Rockford Fosgate amplifiers should never be mounted in the engine compartment. Not only will this void your warranty but could create an embarrassing situation caused by the ridicule from your friends.

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