PUNCH 4020 DSM
4-CHANNEL AMPLIFIER
INSTALLATION & OPERATION
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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, please call 602-967-3565 or FAX 602-967-8132. In Canada, call Korbon Trading at 905-567-1929. 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 OVER100dBMAYCAUSEPERMANENTHEARINGLOSS.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 |
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Introduction ...................................................................................... |
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Punch 4020 Amplifier Accessory Pack .............................................. |
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Rockford Fosgate Accessories............................................................ |
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Technical Design Features ................................................................ |
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Punch 4020 Design Features ............................................................. |
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Installation Considerations ................................................................ |
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Mounting Location ............................................................................ |
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Battery and Charging ....................................................................... |
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Wiring the System ........................................................................... |
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Using the XCard .............................................................................. |
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Sample Wiring Diagrams ................................................................ |
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Troubleshooting .............................................................................. |
18 |
Dynamic Power Measurements ....................................................... |
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Specifications .................................................................................. |
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Warranty Information ...................................................................... |
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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 on the Punch 4020 amplifier for owner, salesperson and installer. To accomplish this, the manual is divided into five main sections: Introduction, Installation, Troubleshooting, Specifications and Warranty Information. For those of you who want quick information on how to install this product, please turn to the Basic System Diagrams 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 4020 is a 4-channel amplifier which offers 20 Watts per channel when driven into 4 Ohms. The amplifier utilizes a 2/ 4 input selector switch and XCard crossovers.
When building a 4-channel amplifier, a major design challenge is to maintain sound quality in a limited space. For the Punch 4020, Rockford Fosgate Engineers designed the Trans•Ana topology which is a fast, short loop circuit allowing the output stage to be driven with a low voltage drive signal. With the addition of a 2/4 input selector switch and XCard crossovers, the 4020 can be configured in many popular system designs without the added cost of external processors. The result is an excellent sounding amplifier in a physically compact area.
The Punch 4020 satisfies the need for a powerful 4-channel amplifier at a competitive price.
We strongly recommend you have your Authorized Rockford Fosgate Dealer install the new Punch 4020 amplifier. If you do choose to install it yourself, please be sure to read the entire manual before beginning.
PU N C H 4020 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 4020 amplifiers include the mounting hardware necessary to secure it to the vehicle as well as attaching the end caps.
Installation & Operation Manual Punch Verification Certificate
(10) Hex 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 13/32"
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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 4020 amplifier.
Energy Storage Capacitor (PCH-C1)
The Punch 1 farad capacitor is used to provide extra current needed by amplifiers to reproduce musical transients. The Punch Cap also has the natural ability to filter DC ripple caused by the alternator which can result in noise in the system. The PCH-C1 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.
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XM50 |
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50Hz |
XM275 = |
275Hz |
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XM70 |
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70Hz |
XM400 |
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400Hz |
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XM100 |
= 100Hz |
XM4.5k = |
4,500Hz |
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XM150 |
= 150Hz |
XM6.5k = |
6,500Hz |
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XM200 = 200Hz |
XM00 |
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Blank card for |
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custom crossover |
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TECHNICAL DESIGN FEATURES
trans•ana
The trans•ana (TRANS conductance Advanced Non-multiplying Amplifier) is a novel circuit that utilizes a short-loop complementary topology and advanced Real Time Protection circuitry.
THE RESULT: An amplifier design with the benefits of tube and bipolar transistor amplifier design without the limitations of either.
MOSFET Devices
Rockford Fosgate is one of the few manufacturers in any of the sound communities 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, 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.
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 different ways. They are more compact and more rugged, and they take much better advantage of the PC board to allow them to get rid of any heat they generate. Using them wherever appropriate allows the advantages associated with discrete thruhole 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
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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.
THE RESULT: Less connections, improved reliability, shorter signal paths, superior signal-to-noise ratio and awesome sonic performance.
Figure 1 |
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Component |
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Solder |
Solder |
Thru-Hole |
Surface Mount |
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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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XCard (Internal Crossover)
The Punch 4020 amplifier utilizes 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 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.
RTP (Real Time Protection)
NOMAD (NOn-Multiplying Advanced Decision)
The Punch 4020 amplifier uses an analog computer process to absolutely 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.
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PUNCH 4020 DE S I G N FE AT U R E S
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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+ L – |
+ R – |
(Bridged Mono)
Front Speakers
Front Gain
R R
L L
Front Rear
Rear Gain
– L + |
– R + |
(Bridged Mono)
Rear Speakers
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POWER
REM |
B+ GND |
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 AP (auto power) or remote turn on of the Punch amplifier.
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