ZX460
4–CHANNEL POWER AMPLIFIER
Based on the same design philosophy as the original KICKER Amplifier,
the ZX460 four–channel amplifier from Stillwater Designs expands and
improves the standards for car audio amplifier performance. Features that
defined the way an amplifier should be built, attention to detail, flexibility,
and pure clean power have been retained and some important new
performance/reliability features have been added.
FEATURES & CONTROLS
The design goals for the ZX-series four-channel amplifier were simple yet crucial: build
the ultimate amplifiers available for the brutal environment of a vehicle.
A new heatsink design provides maximum heat dissipation when air flow isn’t ideal. In
addition to the existing forms of protection already in effect (thermal, overvoltage, and
reverse polarity), a new short circuit protection circuit will allow the amplifier to operate
into a variety of loads including 1 Ohm stereo and 2 Ohm mono.
Gold plated custom tooled speaker and power connectors maximize power transfer and
damping. To improve the thermal stability, sound quality, and output power we have
upgraded the power supply switching MOSFETs.
Surface mount devices are used extensively throughout the design to increase reliability.
Features carried over from the last generation of amplifiers include:
ZRX Crossover Module included.
Active Signal Processing Modules are less expensive than outboard signal processors and
eliminate the possibility for electrical noises to enter the system.
RCA output jacks provide a simple method for daisy chaining multiple amplifiers, espe-
cially when the plug-in modules are used.
Optical isolation between the signal and power grounds has proven very effective to
keep automotive electrical noises from entering the signal path.
For the best sound quality possible we have eliminated coupling capacitors from the sig-
nal path through the use of a DC servo circuit.
Silent turn on/off circuitry eliminates pops to protect your speakers and makes your
system ready for competition.
Multiple amplifiers can be daisy chained without signal degradation because the input
impedance is 22,000 Ohms.
Stillwater Designs recommends that the amplifier be installed at an authorized dealer.
The length of your KICKER amplifier’s warranty is three times as long when installed by an
authorized KICKER dealer.
ꢀ
(Mounting Instructions, continued)
Use KICKER End Caps and KICKER Sink Links
to cover exposed end panels and hiding wiring
in multiple amplifier installations.
SUPPLIED END CAPS SNAP INTO PLACE OVER AMP END PANELS
OPTIONAL SINK LINK COVERS TWO AMPLIFIER END PANELS
3
WIRING INSTRUCTIONS
All power and speaker connectors will accept up to 8 gauge wire. It is very important
that the screws in the amplifiers’ terminal strips are very tight. An allen wrench is included
for this purpose. Always make the ground connection first when installing this amplifier
and disconnect ground last when removing it from the system.
Connect the ground wire, which is 24 inches or less, to a structural chassis member. Be
sure the connection is to bare metal and securely screwed or bolted. (It is not recommend-
ed to run the ground wire to the battery.) Run a positive wire of the size shown below
directly to the positive terminal of the battery and use a fuse of appropriate size within 18
inches of the battery.
This fuse protects the wire run from the battery.
Please refer to this wire gauge selection chart for minimal loss at full rated power under
test conditions:
Model Up to 4 ft 4 to 7 ft
ZX460
7 to10 ft
6
10 to 13 ft 13 to 16 ft 16 to 22 ft
8
8
4
4
4
When running the signal wires keep them away from all power wires in the vehicle to avoid
noise. If a signal wire needs to cross power wires, try to make the junction at 90 degrees.
This will have the least chance of picking up noise.
Note: in the case where the recommended wire size is larger than the amplifier’s connec-
tor, it may be necessary to use a power distribution block or inline connector to adapt
down to the size your amp will accept. Also remember that the current draw and the wire
requirements will be less if the amplifier is used at 4 Ohm stereo.
Inline fuse used at the battery: ZX460 = 60A
IMPORTANT INFORMATION
PLEASE READ BEFORE INSTALLING AMPLIFIER
Your new KICKER power amplifier is equipped with a ZRX Active Electronic Crossover
Module installed in the Module Docking Port.
You may configure the ZRX to function as a low pass filter (12dB/octave at 80Hz) or
high pass filter (12dB/octave at 100Hz) by setting the switch on the ZRX as shown is the
illustration. The ZRX may also be set to bypass, in which case your amplifier will function in
a full-range mode. The ZRX affects only the amplifier in which it is installed. The amplifier’s
output RCA jacks carry a full-range signal regardless of the settings on the ZRX.
4
(continued)
ZXR
–
+
–
+
Setting the ZRX
Bypass Mode - Amplifier reproduces the full frequency range
Low Pass Mode - Amplifier frequencies 80Hz and lower
High Pass Mode - Amplifier frequencies 100Hz and higher
IMPORTANT OPERATION NOTES
An Active Signal Processing Module must be installed in the Module Docking Port in
order for the amplifier to operate. Never power up the amplifier without a module
installed. Never remove or insert a module with the amplifier powered up. Failure to follow
these precautions can result in damge to your speaker(s) and/or amplifier(s) which may
not be covered under warranty.
Typical Installations
Daisy Chaining Two Amplifiers
with ZRX Modules
Adding a KICKER Amplifier and Subwoofer
to your Factory Stereo
SOURCE
America’s Music Machines
Factory Source
(Speaker Level Out)
HIGH
–
+
–
+
Line Out
Converter
+
+
–
–
Midrange
America’s Music Machines
America’s Music Machines
LOW
LOW
–
+
–
–
+
–
+
+
+
–
Subwoofer
To Additional Amps
(Optional)
Subwoofer
ZRX Specifications
Crossover Slope 12dB/octave
Crossover Points 80Hz low pass
100Hz high pass
5
SPECIAL FEATURES
• To understand all the different system possibilities, think of the KICKER ZX460 as two
separate amplifiers in one chassis: Amp 1 and Amp 2, each having two channels.
• When only two RCA cables are plugged into the Amp 1 inputs, the ZX460
automatically distributes the left channel to Amp 1 left and Amp 2 left. The right input
goes to Amp 1 right and Amp 2 right.
• Plugging in a second set of RCAs automatically switches the ZX460 to discreet four
channel operation.
• Amp 2 has an electronic 24dB/octave highpass crossover built in. This crossover is
the same circuitry used in the SWX & MRX KICKER Modules and uses the same frequency
programming chips. The crossover can be bypassed or engaged via a two position slide
switch on the amplifier’s main circuit board. Access to the switch and the frequency
programming chip is through the plastic plug in the bottom plate of your ZX460.
ACCESSING THE CROSSOVERS UNDERNEATH THE ZX460
MODULE
RCA
1. BUILT IN CROSSOVER FREQUENCY
HIGH
PROGRAMMING CHIP
1.
2.
BYPASS
2. BUILT IN CROSSOVER
BYPASS/ENGAGE SWITCH
The frequency programming chip can be removed and replaced
with an IC extraction tool, or by removing the bottom cover
of the ZX460 and using needle nose pliers.
6
SYSTEM DIAGRAMS
FOUR CHANNEL USING FOUR INPUTS
FOUR CHANNEL USING TWO INPUTS
NOTE: When only two RCA's are plugged
in then all four channels automatically
derive their signal from those two inputs.
NOTE: When four RCA's are plugged
in then the amplifier works with
four discreet channels.
Full Range Speakers
(1Ω Minimum)
Full Range Speakers
(1Ω Minimum)
+
–
LEFT FRONT
SPEAKER
RIGHT FRONT
SPEAKER
+
–
LEFT FRONT
SPEAKER
RIGHT FRONT
SPEAKER
FRONT
REAR
–
+
–
+
SOURCE
SOURCE
AMP
2
OUTPUT
2R 2R
-
AMP
2
OUTPUT
2R 2R
-
2L
+
2L
-
+
2L
+
2L
-
+
RIGHT
1L
AMP
+
1L
-
1R
+
1R
-
ZRX
AMP
GAIN GAIN
1
AMP
2
RIGHT
LEFT
1L
AMP
+
1L
-
1R
+
1R
-
ZRX
AMP
GAIN GAIN
1
AMP
2
1
OUTPUT
BY-PASS
MODULE
1
OUTPUT
LEFT
BY-PASS
MODULE
AMP
1
AMP
2
OUTPUT
AMP
1
AMP
2
INPUT INPUT
OUTPUT
INPUT INPUT
INTERNAL
*
INTERNAL
*
CROSSOVER
BYPASSED
CROSSOVER
BYPASSED
+
–
+
–
LEFT REAR
SPEAKER
RIGHT REAR
SPEAKER
LEFT REAR
SPEAKER
RIGHT REAR
SPEAKER
–
+
–
+
Full Range Speakers
(1Ω Minimum)
Full Range Speakers
(1Ω Minimum)
BRIDGED TWO CHANNEL OPERATION STEREO
CAUTION: Up to 180W available to each channel's speaker load. The L+R inputs
for each channel will have the same information.
Example: Amp 1 L+R input get "Left" signal, Amp 2 L+R input get "Right" signal.
Full Range Speakers
(2Ω Minimum)
"Y" Cables
+
–
–
RIGHT
LEFT
+
SOURCE
RIGHT
LEFT
RIGHT
LEFT
-
-
-
-
1L+ 1L 1R+ 1R 2L+
2R+ 2R
AMP2L
2
OUTPUT
ZRX
AMP
GAIN GAIN
1
AMP
2
AMP
1
OUTPUT
BY-PASS
MODULE
AMP
1
AMP
2
OUTPUT
INPUT INPUT
INTERNAL
*
CROSSOVER
BYPASSED
BI AMP USING ZRX MODULE
Mid/High Range Speakers
(1Ω Minimum)
+
–
LEFT FRONT
SPEAKER
RIGHT FRONT
SPEAKER
–
+
SOURCE
AMP
2
OUTPUT
-
2L 2R 2R
-
2L
+
+
RIGHT
LEFT
-
-
1R
1L
AMP
+
1L
1R
+
ZRX
LOWPASS
MODULE
AMP
GAIN GAIN
1
AMP
2
1
OUTPUT
AMP
1
AMP
2
OUTPUT
INPUT INPUT
INTERNAL
*
CROSSOVER
HIGHPASS
+
–
KICKER Subwoofer
(2Ω Minimum)
7
BI AMP USING EXTERNAL SUB AMP AND ZRX MODULES
Full Range Speakers
(1Ω Minimum)
+
–
LEFT FRONT
SPEAKER
RIGHT FRONT
SPEAKER
FRONT
REAR
–
+
SOURCE
AMP
2
OUTPUT
-
2L+ 2L 2R+ 2R
-
OUTPUT
RIGHT
-
-
1L+ 1L 1R+ 1R
ZRX
AMP
GAIN GAIN
1
AMP
2
AMP
1
OUTPUT
HIGHPASS
MODULE
LEFT
AMP
1
AMP
2
INPUT INPUT
+
–
RIGHT REAR
SPEAKER
LEFT REAR
SPEAKER
–
+
Full Range Speakers
(1Ω Minimum)
AMP
2
OUTPUT
-
2L+ 2L 2R+ 2R
-
RIGHT
LEFT
ZRX
GAIN
LOWPASS
MODULE
OUTPUT INPUT
+
–
KICKER Subwoofer
(2Ω Minimum)
SETTING GAIN CONTROLS
Each channel pair on the ZX460 is equipped with a variable gain control. The gain control
is provided for level matching purposes; it does not give the amplifier any more power by
turning it up – its purpose is to adjust the sensitivity of the amplifier in relation to the
output level provided by the source.
Start with the amp gain set to minimum by turning the control counter-clockwise.
Turn the source level up until distortion is barely audible – this will be at about 75-80%
of full volume. Raise the amplifier gain until distortion is just audible. The gain is now set
correctly. Check the level with CD/tape and tuner to make sure the adjustment is correct
for all sources.
8
OPTIONAL ACTIVE SIGNAL PROCESSING MODULES
All KICKER amplifiers have a Module Docking Port, which allows the use of any KICKER
Module. These modules greatly increase your amplifier’s versatility, and cost very little
when compared to “stand alone” units with the same functions.
Active Crossover Modules:
These 2-way modules allow you to use separate amplifiers for your subwoofers, midbass
drivers, midranges, or tweeters. By doing this, especially on the subwoofer, a clean and
undistorted sound is available at much higher listening levels.
Each module offers a range of selectable crossover frequencies and 24dB/octave filtering.
• SWX – 60Hz, 80Hz, or 100Hz subwoofer/midbass or midrange crossover.
• MRX – 175Hz, 250Hz, or 350Hz midbass/midrange crossover.
• TWX – 3500Hz or 4500Hz midrange/tweeter crossover.
Specialty Modules:
• EEM (Electronic Enclosure Module) – When used with KICKER Freeair™ woofers,
this module simulates the response of KICKER Competition™ woofers in
a sealed enclosure.
• EQM (Equalization Module) – Frequency Enhancement and extension module
that equalizes frequencies in the low bass region as well as the upper
treble regions.
• CRM (Center/Rear Fill Module) – This module allows one amplifier to drive a
center channel and rear speakers independently at the same time.
• RGX (Remote Gain Module) – An ideal amplifier enhancement module that pro
vides a remote gain control function.
• PBM (Parametric Bass Module) is designed to meet the demand for a
remote-controllable bass EQ to enhance your bass listening pleasure and
to allow you to adjust the bass boost and center frequency from the comfort
of the driver’s seat.
• KEQ (KICKEQ) – adds adjustable Bass Boost (up to +18dB at 40Hz) and Treble
Boost (up to +12dB at 18kHz).
• MMDP (Multi-Module docking Port) – Allows the use of two KICKER Active Signal
Processing Modules in a single amplifier.
See your Authorized KICKER Dealer for more high performance Active Signal Processing
Modules - the secret behind the amazing flexibility of KICKER amplifiers.
9
TROUBLE SHOOTING
Note: It is normal for the yellow trouble LED to blink when the amplifier is turned on or off.
This is a function of the protection circuit looking for trouble.
ꢀRed LED power indicator off, yellow trouble indicator off.
With a Volt Ohm Meter (VOM):
• Check +12 Volt terminal
• Check Ground terminal
• Check for +12 Volts at remote turn-on terminal
ꢀRed LED power indicator on, yellow trouble indicator off:
• Make sure there is a module in place and the settings are correct
• Check RCA and speaker connections
• Test speaker outputs with a known good speaker
• Substitute a known good signal source
ꢀYellow trouble LED on, red power indicator off:
1. Amp is very hot - Thermal protection is engaged. Verify that speaker
load impedance is not below specified minimums. Check area
around amplifier for objects which may restrict air flow and proper
cooling. If this continues to be a problem, take vehicle to an
authorized Kicker dealer for evaluation.
2. Amp is not too hot - Overcurrent protection is engaged, red power LED
blinks every two seconds. This indicates that there is a short in the
speaker wiring. Locate short using a VOM by checking between
speaker positive and negative. If the amplifier is used in stereo, try
disconnecting one channel at a time to help isolate which channel is shorted.
3. Amp is not too hot - Voltage to amp is not within the 9-16 volt operating
range. If the vehicle’s charging system goes over 16 volts, the amp
will shut off. If the voltage gets too low, the amp will not operate.
Using a VOM identify the voltage problem and rectify.
ꢀ
Alternator noise (whistling sound that follows the engine RPM).
• Make sure that the amp case is not grounded.
• Make sure that the source has a good ground.
• Check routing of the RCA cable. Try substituting another RCA
cable routed in a different location in the vehicle.
• Check gain setting to make sure that it is not too high.
ꢀStereo image is unfocused and bass is reduced.
Check system phasing by turning the balance control from the left to
the right. If the bass is more prominent when turned to either side,
check speaker wiring for proper positive and negative connections.
Reverse connections on one channel if necessary.
CAUTION: When jump starting the vehicle, be sure that connections made with jumper
cables are correct. If improper connections are made, it can result in blown amplifier fuses
as well as failure in other systems in the vehicle.
More questions? See your Authorized KICKER Dealer or contact KICKER directly at
10
11
ELECTRONICS LIMITED WARRANTY
Stillwater Designs warrants this product to be free from defects in material and workmanship
under normal use for a period of three (3) years from date of original purchase when installed by
an Authorized KICKER Dealer or one (1) year from date of original purchase if not installed by
an Authorized KICKER Dealer. If this product is labeled “B Stock”, it is warranted for one (1) year
from date of purchase, regardless of place of installation. Should service be necessary under this war-
ranty for any reason due to manufacturing defect or malfunction during the warranty period,
Stillwater Designs will replace or repair (at its discretion) the defective merchandise with equivalent
merchandise at no charge. Warranty replacements on “B-Stock” merchandise may have cosmetic
scratches and blemishes. Discontinued products may be replaced with equivalent products.
This warranty is valid only for the original purchaser and is not extended to owners of the prod-
uct subsequent to the original purchaser. Any applicable implied warranties are limited in duration to a
period of the express warranty as provided herein beginning with the date of the original purchase at
retail, and no warranties, whether express or implied, shall apply to this product thereafter. Some
states do not allow limitations on implied warranties, therefore these exclusions may not apply to you.
This warranty gives you specific legal rights; however you may have other rights that vary from
state to state.
WHAT TO DO IF YOU NEED WARRANTY OR SERVICE
Defective merchandise must be returned to your local Authorized Stillwater Designs
(Kicker/Impulse) Dealer for warranty. Assistance in locating an Authorized Dealer can be obtained by
writing or calling Stillwater Designs direct. You can confirm that a dealer is authorized by asking to see
a current authorized dealer window decal.
If it becomes necessary for you to return defective merchandise, call the Kicker Customer Service
Department at (405)624-8510 for a Return Authorization (RA) number. Package all defective items in
the original container or in a package that will prevent shipping damage, and return to
Stillwater Designs, 5021 North Perkins Road, Stillwater, OK 74075
The RA number must be clearly marked on the outside of the package. Return only defective com-
ponents. Non-defective items received will be returned freight collect.
Include a dated proof-of-purchase from an Authorized Dealer. Warranty expiration on items
returned without proof-of-purchase will be determined from the manufacturing date code. Coverage
may be invalidated if this date is greater than one (1) year previous to the date item is sent in. Freight
must be prepaid; items received freight collect will be refused.
Failure to follow these steps may void your warranty. Any questions can be directed to the Kicker
Customer Service Department at (405)624-8510.
WHAT IS NOT COVERED?
This warranty is valid only if the product is used for the purpose for which it was designed. It
does not cover:
• Products purchased from an unauthorized dealer.
• Items previously repaired or modified by any
unauthorized repair facility.
• Damage due to improper installation
• Damage caused by exposure to water, excessive
heat, chemical cleaners, and/or UV radiation.
• Damage through negligence, misuse, accident or
abuse. Repeated returns for the same damage may
be considered abuse.
• Items returned from unauthorized individuals or
dealers.
• Return shipping on non-defective items.
• Products with tampered or missing barcode labels.
• Products returned without a Return Authorization
(RA) number.
• Freight damage.
• The cost of shipping product to Stillwater Designs.
HOW LONG WILL IT TAKE?
Stillwater Designs maintains a goal of 24-hour service for all returns. Delays may be incurred if lack of
replacement inventory or parts is encountered.
INTERNATIONAL WARRANTY
Contact your International Stillwater Designs dealer or distributor concerning specific procedures for your
country’s warranty policies
P.O. BOX 459 • STILLWATER, OKLAHOMA 74076 • 405 624-8510
.KICKER components are capable of producing sound levels that can permanently damage
your hearing! Turning up a system to a level that has audible distortion is more damaging
to your ears than listening to an undistorted system at the same volume level. The
threshold of pain is always an indicator that the sound level is too loud and may perma-
WARNING:
nently damage your hearing. Please use common sense when controlling volume!
FEBRUARY 2000
|