Rockford Fosgate 500.2 User Manual

power

500.2

® ®

new

chrome

heatsink

car audio

for

fanatics

competition Power amplifier Operation & Installation

punch

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 fanatic image order your Rockford Fosgate wearables, which include everything from T-shirts and jackets to hats and sunglasses.

To get a free brochure on Rockford Fosgate products and Rockford wearables, please call 602-967-3565 or FAX 602-967-8132. For International orders, FAX +001-1-602-967-8132 or call +001-1-602-967-3565.

PRACTICE SAFE SOUND™

CONTINUOUS EXPOSURE TO SOUND PRESSURE LEVELS OVER 100dB MAY CAUSE PERMANENT

HEARING WELL

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 1-800-669-9899. 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.

LOSS. HIGH POWERED AUTOSOUND SYSTEMS MAY PRODUCE SOUND PRESSURE LEVELS

OVER 130dB. USE COMMON SENSE AND PRACTICE SAFE SOUND.

Serial Number:_____________________________________________

Model Number: ____________________________________________

ABLE OF

ONTENTS

Introduction.................................................................................................................................................................1

Accessory Pack ...........................................................................................................................................................1

Technical Design Features.............................................................................................................................................2

Design Features ...........................................................................................................................................................5

Installation Considerations ............................................................................................................................................7

Mounting Locations......................................................................................................................................................8

Battery and Charging ...................................................................................................................................................8

Wiring the System........................................................................................................................................................9

Using Passive Crossovers............................................................................................................................................10

Table of Crossover Components...................................................................................................................................11

Using the XCard.........................................................................................................................................................12

Customizing the XCard ...............................................................................................................................................12

XCard Resistor Chart...................................................................................................................................................13

XCard Configurations..................................................................................................................................................14

Installation ................................................................................................................................................................16

Using the Balanced Line Inputs....................................................................................................................................19

Rockford Fosgate Accessories ......................................................................................................................................21

Troubleshooting.........................................................................................................................................................23

Autosound 2000’s Quick Check for Troubleshooting.......................................................................................................25

Dynamic Power Measurements....................................................................................................................................27

500.2 Specifications ..................................................................................................................................................28

Warranty Information .................................................................................................................................................29

International Information.............................................................................................................................................30

ETTING

TARTED

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.

O p

Sections marked

ADVANCED OPERATION

include in-depth

technical information

include “slam dunk”

® ®

N S T A L L A T

I O N

Sections marked

INSTALLATION

wiring connections

TROUBLE-

S H O O T

I N G

Sections marked

TROUBLESHOOTING

include recommendations

for curing installation

problems

INTRODUCTION

The Punch Power series of amplifiers represent the best Rockford Fosgate has to offer! Our engineers devised technical features which would be considered overkill by other audio manufacturers, but not at Rockford Fosgate! Trans•nova, DIAMOND, and TOPAZ, exclusively designed by Rockford, are just a few of these features which are described in the Technical Design Features section of this manual.

ACCESSORY PACK

The accessory pack includes the mounting hardware necessary to secure the amplifier to the vehicle and to attach the end caps to the amplifier.

Punch Power 500.2

Installation & Operation Manual Punch Verification Certificate (4) Amplifier mounting screws (#8 x 3⁄4" phillips) (4) Speaker connector screws (3/32" allen) (2) Power connector screws (1/8" allen) (4) End cap mounting screws (9/64" allen) (1) Allen wrench 3/32" (speaker) (1) Allen wrench 9/64" (end cap) (1) Allen wrench 1/8" (power)

– 1 –

ECHNICAL

◆ trans•nova (TRANSconductance NOdal Voltage Amplifier)

ESIGN

EATURES

The trans• the audio signal to pass through the amplifier at supply and is configured to increase power gain. The increase in power gain allows the drive stage to operate at a lower voltage. A low voltage drive stage is the same principle used in high quality preamplifiers to produce high linearity and wide bandwidth.

The resulting design utilizes an output stage with a simpler gain structure and a shorter total signal path than conventional high voltage (bi-polar) designs. The number of stages is reduced from five or more to three. The output stage is further refined into a trans-impedance stage (current to voltage converter) to achieve a short loop (fast) negative feedback. The output stage is driven cooperatively by a transconductance stage (voltage to current converter).

THE RESULT: Superior sound quality, greater efficiency and higher reliability.

nova

(TRANS conductance NOdal Voltage Amplifier) is a patented circuit (U.S. Patent 4,467,288) that allows

low voltage

E-I I-E

trans•nova circuitry

. Each amplifier channel utilizes its own “fully floating” power

◆ DIAMOND (Dynamically Invariant AMplification Optimized Nodal Drive)

DIAMOND

design which reduces high frequency distortion. Amplifiers which utilize a large array of output MOSFETs cause a high capacitive load on the driver stage. This load can make the high frequencies sound harsh. The DIAMOND circuit eliminates high frequency distortion by allowing the driver to operate with 20dB or more of current headroom, whereas traditional drivers have only 6dB of current headroom.

THE RESULT: Lower distortion and greater inherent stability.

(Dynamically Invariant AMplificiation Optimized Nodal Drive - patent pending) is an important advance in circuit

◆ MEHSA (Maximum Efficiency Heat Sink Application)

The

MEHSA

than traditional FET mounting techniques using the exact same components. A multi-layer insulated metal substrate operating with minimal thermal resistance spreads heat both downward & outward to quickly dissipate heat from each device across the heat sink. This process combined with our DSM technology and MOSFET devices allow us to squeeze more watts per cubic inch from every output device as well as provide consistent thermal stability.

THE RESULT: Optimized power output, enhanced thermal stability, and maximum component reliability.

(Maximum Efficiency Heat-Sink Application) is a proprietary process that yields up to 5 times better heat transfer

– 2 –

◆ 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 20-100 times better than amplifiers without TOPAZ.

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

◆ 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 signalto-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.

Solder

Component

Solder

PC Board

Figure 1

PC Board

Thru-Hole Surface Mount

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

◆ XCard (Internal Crossover)

The 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 be configured for high-pass, low-pass and full range operation. With slight modification, 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.

XCard

can

◆ Stereo Pass-Thru

The

Pass-Thru

cables or “Y” adapters. The original signal(s) fed into the input jack(s) are looped back to the Pass-Thru outputs allowing less signal cable to be used. This results in cleaner system designs and reduces noise pick-up.

THE RESULT: Convenient signal level output for adding extra amplifiers.

output provides a convenient source for daisy-chaining an additional amplifier without the need for extra RCA

– 3 –

◆ Bass EQ

The

Bass EQ

helps correct for acoustical deficiencies in the listening environment. A unique potentiometer that controls bass compensates for the lack of low frequencies present in most car environments. Unlike a conventional tone control, the Bass EQ corrects for the specific problem of poor low bass response.

THE RESULT: Provides better low bass response.

◆ Balanced Line Inputs

Using the Balanced Line Inputs provides the last word in achievable rejection of noise induced in the cable between the source and the amplifier. The differential input circuitry (Figure 2) used

Figure 2

Center

Conductor

RCA Input

Differential

Input

in the balanced input system rejects whatever signals are common to both of the shielded, twisted-pair conductors. Balanced line is universal in concert installations where the stage and mixing consoles are hundreds of feet apart. Long signal cables and electrically-noisy environments make signal integrity

Outer

Shield

Differential inputs only amplify the difference between two conductors. Note: the noise spikes appear on both the center conductor and the outer shield and therefore are not amplified.

and noise rejection an extremely difficult challenge. THE RESULT: Quiet transmission of audio from source to amplifier.

◆ NOMAD (NOn-Multiplying Advanced Decision)

The Power amplifiers use an conditions. The innovative 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.

analog computer process

NOMAD

(NOn-Multiplying Advanced Decision) system is the most sophisticated version of this

to absolutely maximize safe output power under all operating

◆ MOSFET Devices (Metal Oxide Semiconductor Field Effect Transistor)

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

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, MOSFET and vacuum tubes share many important operating characteristics. However, the MOSFET device is much faster, wider in bandwidth, measurably lower in distortion and far more linear than vacuum tubes.

THE RESULT: Operational characteristics of vacuum tubes without the performance limitations of tube design.

– 4 –

power

ESIGN

1. Cast Aluminum Chrome Heatsink – The cast aluminum heatsink of the Punch Power amplifier dissipates heat

2. End Caps – The unique end caps conceal the wiring and input cables, giving the amplifier a clean “stealth” look.

EATURES

generated by the amplifier's circuitry. The inherent advantage of casting provides a 30% improvement of cooling over conventional extrusion heatsink designs.

3 13 8

Speaker

Gain

+ L –

Phase

0 – 180

Balanced

LED

REM GNDB+

Bass

Unbalanced

(Mono)

Pass Thru

Balanced

Input

Pass Thru

4 4

EZ Bridged

Gain

180°- 0

312

Speaker

– R +

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 heavy duty, gold-plated power and ground connectors will accommodate 4 AWG wire for maximum input current capability.

5. REM Terminal – This gold-plated spade terminal is used for the AP (auto power) or remote turn on of the amplifier.

6. RCA Input Jacks – The industry standard RCA jack provides an easy connection for signal level input. They are gold-

plated to resist the signal degradation caused by corrosion.

7. Balanced Line Input– This input will allow the Balanced Line Transmitter (BLT) or any balanced Rockford Fosgate source unit/signal processor to be used in conjunction with the amplifier to provide better noise rejection.

8. Signal Input Switch – This switch allows selection of either the RCA or Balanced Line inputs.

9. RCA Pass-Thru Jacks – The Pass-Thru provides a convenient source for daisychaining an additional amplifier,

eliminating the need for “Y” adapters. The original signal(s) fed into input jack(s) are looped back to the Pass-Thru output(s).

10. Input Sensitivity Controls – The input level controls are preset to match the output of most source units. They can be adjusted to match output levels from a variety of source units.

– 5 –

11. Bass EQ Control – The Bass EQ allows a narrow band adjustment of up to +18dB centered at 45Hz. The bass boost can

ROCKFORD CORPORATION

MADE IN THE USA

500 Watts RMS continuous power per

channel into 2 Ohms with less than 0.10%

Total Harmonic Distortion from 20-20kHz

AMPLIFIER

250 Watts RMS continuous power per

channel into 4 Ohms with less than 0.05%

Total Harmonic Distortion from 20-20kHz

High-Pass

Low-Pass

FULL

Full Range

NOTE: Insert XCards into sockets facing each other.

Please refer to Owner’s manual for possible Input, Output, and

XCard configurations.

For Bridged Mono Wiring

Connect 4Ω mono woofer + to L+ of

amplifier and mono woofer – to R–

of amplifier. Amplifier will operate

mono/stereo simultaneously.

Do Not Chassis

Ground Any Speaker.

–

L+ R–

XCard 1

XCard 2

be bypassed by turning the control to its minimum or counterclockwise position.

12. E-Z Bridge Switch / 0°-180° Phase Switch – This dual purpose switch enables you to E-Z bridge the amplifier or invert

the signal phase of the right channel.

13. Phase Switch – This switch enables you to easily invert the phase of the left channel without having to disconnect the speaker wires.

14. Internal Crossovers – These built-in crossover cards are configurable for a multitude of operating frequencies. The orientation of the card in its socket determines its function of high-pass, low-pass or full range operation.

15. LED Power Indicator – The LED gives a visual indication of the status of the amplifier, lighting when the unit is turned on.

– 6 –

NSTALLATION

Tools Needed

The following is a list of tools you will need for installing the Punch Power amplifier:

Allen wrenches 9/64" , 3/32" & 1/8" (included) Wire Cutters Wire strippers Voltmeter Battery post wrench Wire crimpers Electric hand drill and assorted bits 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 on the layout of 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. 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.

ONSIDERATIONS

4. Route all of the RCA cables close together and away from any high current wires.

5. Use high quality Connecting Punch accessories 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 for 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 fuse on the +12V power wire within 18" (45.7cm) 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 –

OUNTING

The mounting location and position of your amplifier will have a great effect on its ability to dissipate the heat generated under 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.

OCATIONS

not

recommended.

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

Engine Compartment Mounting

Rockford Fosgate amplifiers should but could create an embarrassing situation caused by the ridicule from your friends.

ATTERY AND

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.

NOTE: This amplifier utilizes a large array of power supply capacitance and can draw substantial current at turn-on. The dashboard BATTERY VOLTAGE and/or ALTERNATOR CHARGE lamp may illuminate for a brief period while momentarily recharging the capacitor bank. This may be most noticeable when the amplifier is off for at least a day or two and is considered normal operation.

never

HARGING

not

recommended.

be mounted in the engine compartment. Not only will this void your warranty

– 8 –

IRING

YSTEM

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.

1. Configure the internal XCard crossovers prior to installation. Refer to the XCard Configurations on pages 14 & 15 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 attachment to the amplifier by stripping 5/8" of insulation from the end of the wire. The use of 4 gauge power cable can interfere with the installation of the end caps. Proper wire dress can prevent this from occurring. To prevent the wire from fraying, strip the insulation at a 45° angle. Insert the bared 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.

cables for power and for ground. This will give you the best performance possible.

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 above and connect to the ground 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 cable and attach a ring connector. Fasten the cable to the chassis using a non-anodized screw and a star washer.

6. Prepare the REM turn-on wire for connection to the amplifier by stripping 1/4" 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.

We recommend using 4 gauge

STRIP WIRE

AMP

5/8"

INSULATION

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 vibrations or sudden vehicle stops.

8. Connect the source signal to the amplifier by plugging the RCA cables into the input jack(s) at the amplifier. If using Balanced Line Inputs, refer to pages 19 & 20.

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.

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 from road vibrations.

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

– 9 –

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.

NOTICE!

SING

Amplifiers using the trans•

nova

topology improve in sound quality after warming up. We recommend operating the amplifier for approximately 15 minutes prior to evaluation under judging criteria or tune-ups to establish its normal operating temperature.

* Your friends will call it MAGIC, you can call it Rockford technology! *

a d v

ASSIVE

ROSSOVERS

a n c e d

A passive crossover is a circuit that uses capacitors and/or coils and is placed on speaker leads between the amplifier and speaker. The crossover delegates a specific range of frequencies to the speaker for optimum driver performance. A crossover network can perform one of three functions: High-Pass (capacitors), Low-Pass (inductors or coils) and Bandpass (combination of capacitor and coil).

The most commonly used passive crossover networks are 6dB/octave systems. These are easy to construct and require one component per filter. Placing this filter in series with the circuit will reduce power to the speaker by 6dB/octave above or below the crossover point depending on whether it is a high-pass or low-pass filter. More complex systems such as 12dB/ octave or 18dB/octave can cause impedance problems if not professionally designed.

O p e r a t i o n

Passive crossovers are directly dependent upon the speaker's impedance and component value for accuracy. When passive crossover components are used in multiple speaker systems, the crossover's effect on the overall impedance should be taken into consideration along with the speaker's impedance when determining amplifier loads.

– 10 –

+ 29 hidden pages

Rockford Fosgate 500.2 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual