Rockford Fosgate 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.

At Rockford Fosgate we are fanatics about 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.

Great product and competent installations are only a piece of the puzzle when it comes
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 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 +001-602­967-3565 or FAX [phone].

PRACTICE SAFE SOUND™

CONTINUOUS EXPOSURE TO SOUND PRESSURE LEVELS OVER

100dB MAY CAUSE PERMANENT HEARING LOSS. HIGH

POWERED
PRESSURE
AND

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:________________________________

AUTOSOUND SYSTEMS MAY PRODUCE SOUND

LEVELS WELL OVER 130dB. USE COMMON SENSE

PRACTICE SAFE SOUND.

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

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ETTING 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

Installation Section

of this manual or refer to the icons listed
below. 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.

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Sections marked

ADVANCED OPERATION

include in-depth

technical information

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Sections marked

INSTALLATION

include “slam dunk”

wiring connections

include recommendations

TROUBLE-

Sections marked

TROUBLESHOOTING

for curing

installation problems

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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
efficient package. TRANS•ANA is a low voltage circuit in the preamp
stage of all Punch x2 amplifiers that lets the music sound crystal clear
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 installa­tion. 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)
technology improve amplifier efficiency. The result of these compo­nents give the Punch amplifier awesome sound quality in a “Bullet
Proof” package. An explanation of these technologies, most of which
are exclusively designed and patented by Rockford, are described in
the Technical Design Features.

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)

– 1 –

TECHNICAL DESIGN FEATURES

◆ TRANS•ANA

(TRANSconductance Active Nodal Amplifier)

The

TRANS•ANA

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 drive transistors at ultrasonic frequencies.
This allows amplifier performance similar to trans•

highly stable and linear while utilizing the advantages of a non­floating 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

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) is a

(Tracking Operation Pre-Amplifier Zone) circuitry solves

nova

which is

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

– 2 –

◆ 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 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
maximum audio performance and highest signal-to-noise ratios to be
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

PC

Board

Thru-Hole Surface Mount

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

Solder

Component

Solder

PC

Board

◆ 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
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 potenti-

ometer designs.

XCard

can be configured

– 3 –

◆ MOSFET Devices

Rockford Fosgate is one of the few manufacturers in the sound
community to utilize MOSFET devices in both the
the

output stages. MOSFET

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 similarly 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 design.

(Metal Oxide Semiconductor Field Effect

power supply

and

◆ NOMAD (NOn-Multiplying Advanced Decision)

The Punch and Power amplifiers use an
maximize safe output power under all operating conditions. 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

to

– 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.

Left
Gain

REM

6 6

Left

Input

49 5

3

8

Right
Input

Right
Gain

Bass

+R–+L–

11

GNDB+

Punch Status

Display

3 8 7 7

Speaker Speaker

Treble

LED

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 gold-plated 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.

– 5 –

7. 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.

8. Punch Equalization Controls – The Punch EQ helps correct 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. Punch Status Display – The RJ11 interface allows connection of
an LED display used to monitor amplifier performance.

AMPLIFIER

®

100 Watts RMS continuous power per
channel into 4 Ohms with less than 0.05%
Total Harmonic Distortion from 20-20kHz.

®

ROCKFORD CORPORATION

MADE IN THE USA

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Low-Pass Full RangeHigh-Pass

LP

HP

10

HP

LP

XCard

Front

XCard

FULL

– 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

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 a fuseholder and appropriate 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.

– 7 –

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 strongly

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.

not

recommended.

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 strongly

not

recommended.

Engine Compartment Mounting

Rockford Fosgate amplifiers should
compartment. Not only will this void your warranty but could create
an embarrassing situation caused by the ridicule from your friends.

– 8 –

never

be mounted in the engine

BATTERY AND CHARGING

Amplifiers will put an increased load on the vehicle's battery and
charging system. We recommend checking your alternator and
battery condition to ensure that the electrical system has enough
capacity to handle the increased load of your stereo system. Stock
electrical systems which are in good condition should be able to
handle the extra load of any Rockford amplifier without problems,
although battery and alternator life can be reduced slightly. To
maximize the performance of your Rockford Fosgate amplifier, we
suggest the use of a heavy duty battery, high output alternator and an
energy storage capacitor.

WIRING THE SYSTEM

CAUTION:

Avoid running power wires near the low level input
cables, antenna, power leads, sensitive equipment or harnesses. The
power wires carry substantial current and could induce noise into
the audio system.

• For safety, disconnect the negative lead from the battery prior to
beginning the installation.

1. Configure the internal XCard crossovers prior to installation. Refer

to “Using the XCard” (page 12) for further information.

2. Plan the wire routing. Take care when running signal level RCA

cables to keep them close together but isolated from the amplifier's
power cables and any high power auto accessories, especially
electric motors. This is done to prevent coupling the noise from
radiated electrical fields into the audio signal. When feeding the
wires through the firewall or any metal barrier, protect them with
plastic or rubber grommets to prevent short circuits. Leave the
wires long at this point to adjust for a precise fit at a later time.

3. Prepare the Power cable for at-

tachment to the amplifier by strip­ping 5/8" of insulation from the
end of the wire. To prevent the
wire from fraying, strip the insula­tion at a 45° angle. Insert the bared

STRIP WIRE

AMP

>

5/8"

>

INSULATION

>

><

wire into the B+ terminal with the
long side of the insulation on the
top. Bend the cable down at a 90°
angle. Tighten the set screw to secure the cable in place.

– 9 –

Punch 40x2, 60x2, 100x

2

Trim the power cable to within 18" of the battery and install the
protective rubber boot, which is packed with the fuseholder, over
the end of the wire. Strip 3/8" of insulation from the wire and insert
into the end of the fuseholder, then crimp it in place. Slide the
rubber boot into place to cover the connection. Use the section of
cable that was trimmed earlier and connect it to the other end of
the fuseholder.

Punch 200x

2

Mount the fuseholder within 18" of the battery using two (2) #8
screws. Disassemble the fuseholder. You should have 2 black
plastic end caps, 2 gold-plated fuse clips, a plastic spacer and the
fuseholder body. Trim the amplifier power cable to reach the
fuseholder and strip the wire 3/8". Slide one of the end caps over
the wire (narrow end first) and insert the wire into one of the fuse
clips. Tighten the set screw. Screw the black end cap to the
fuseholder body to secure the cable. Use the section of cable that
was trimmed earlier and connect it to the other end of the
fuseholder. Install the plastic spacer in the fuseholder and attach
the cable to the fuseholder body.

NOTE: The B+ cable MUST be fused 18" or less from the vehicle's
battery. Install the fuseholder under the hood and prepare the
cable ends as stated above. Connections should be water tight.

4. Strip 3/8" from the battery end of the power cable and crimp a large
ring terminal to the cable. Use the ring terminal to connect to the
battery positive terminal. Do not install the fuse at this time.

5. Prepare a length of cable to be used for the ground connection.
Strip 5/8" of insulation from the end of the cable as described
previously and connect to the appropriate terminal of the ampli­fier. Prepare the chassis ground by scraping any paint from the
metal surface and thoroughly clean the area of all dirt and grease.
Strip the other end of the wire and attach a ring connector. Fasten
the cable to the chassis using a non-anodized screw and a star
washer.

– 10 –

6. Prepare the REM turn-on wire for connection to the amplifier by
stripping 5/8" of insulation from the wire end and crimping an
insulated spade connector in place. Slide the connector over the
REM terminal on the amplifier. Connect the other end of the REM
wire to a switched 12 volt positive source. The switched signal is
usually taken from the source unit's auto antenna or the accessory
lead. If the source unit does not have these outputs available, the
recommended solution is to wire a mechanical switch in line with
a 12 volt source to activate the amplifier.

7. Securely mount the amplifier (with supplied screws) to the vehicle
or amp rack. Be careful not to mount the amplifier on cardboard
or plastic panels. Doing so may enable the screws to pull out from
the panel due to road vibration or sudden vehicle stops.

8. Connect the source signal to the amplifier by plugging the RCA
cables into the input jacks at the amplifier.

9. Connect the speakers. Strip the speaker wires 5/8" and insert into
the appropriate terminal on the amplifier. Insert the bared wire
into the speaker terminal and tighten the set screw to secure into
place. Be sure to maintain proper speaker polarity.

DO NOT
chassis ground any of the speaker leads as unstable operation
may result.

10. Perform a final check of the completed system wiring to ensure
that all connections are accurate. Check all power and ground
connections for frayed wires and loose connections which could
cause problems.

11. After the final inspection is complete, install the power fuse and
enjoy listening. During the initial listening period, you may need
to “fine tune” any phasing and level settings within your particular
vehicle. To aid in this procedure, play a track with high musical
content and cruise around your neighborhood. After fully evalu­ating the transient response of your system and making any final
adjustments, all your neighbors within a 1 mile radius will assume
that you have just successfully completed another upgrade to your
audio system for which they will probably spill thumbtacks on
your driveway.

– 11 –

USING THE XCARD

↕

➝

➝

➝

➝

The crossover functions are controlled through the use of an XCard
and can be set for high-pass, low-pass or full range operation. The
100Hz XCard shipped with your amplifier is set for Full Range. Each
crossover card has two faces: one face operates Full Range, the other
has arrows to indicate the edge for selecting HP (high-pass) or LP (low­pass) operation. Orient the card with the desired operating edge,
indicated by the arrow, toward the socket terminals inside the ampli-

fier. Firmly, but carefully, plug the card into the socket.

Low-Pass Full RangeHigh-Pass

LP

HP

HP

LP

FULL

The crossover point can be altered by changing the resistor value. Use
the following formula to select the appropriate resistor value to be

placed on the XCard.

3386

f

o

7234

f

o

= R (in kΩ) for .047

µµ

µf cap

µµ

= R (in kΩ) for .022µf cap

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The actual formula is:

R =

1

2πfoc

Crossover Card

High Pass

R1

Low Pass
Full Range

R2

R1

FULL

R2

Where: R = Ω

fo = desired crossover frequency
c = capacitor in farads
ex: .047 x 10-6 for .047mf cap

– 12 –