Fusion Electronics Car Amplifier FM 402 User Manual

User / Installation Manual  
Marine Amplifier  
FM-402  
Contents  
Feature Overview  
Feature Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg 3  
2 Ohm Stable MOSFET Amplifier Design  
Variable Bass Boost 0 - + 12dB  
Control Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg 4  
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg 6  
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg 6  
Inputs and Gain Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg 7  
2 Channel Installation / Trouble Shooting . . . . . . . . . . . . . . . . . . . . Pg 8  
3 Channel Installation / Power Cable Calculator. . . . . . . . . . . . . . . Pg 9  
4 Channel Installation / Specifications. . . . . . . . . . . . . . . . . . . . . . Pg 10  
Variable LP and HP Electronics X-OVER @ 12dB/octave  
FUSION Regulated Amplifier Technology (F.R.A.T.)  
FUSION Intercooled Semi-conductor Technology (F.I.S.T.)  
Gold Plated 4 Gauge Power and Ground Connections  
Gols Plated Audio Input and Output Connections  
FUTRANZ Efficient Heat Sink Transfer Technology  
Gold Plated RCA Output for multi-amp Installations  
What sets FUSION apart?  
The FUSION FM series amplifiers come complete with FRAT power supplies, FIST cooling system and FUTRANZ. Also  
all marine amplifiers use heat-tempered PCB’s for maximum product life and performance. Gold plated connectol-  
ogy, ensures your signal flows from the head unit through to the speakers with as little injected distortion and  
noise as possible. This results is a very clean and very powerful reproduction of the input signal. All these features  
make it easier to achieve sonic perfection in almost any installation.  
FUTRANZ  
RECORD YOUR PRODUCT DETAILS HERE:  
In developing extremely powerful amplifiers, it is essential to keep things cool so FUSION developed a heat sink  
that has a heat dissipation ability like never before. This was not an easy task but none the less it was achieved,  
another important factor is efficiently transferring the heat from the semi-conductors to the heatsink, conven-  
tional designs use a white paste as the interface between these devices and the heatsink, this is not a perfect  
solution when complete surface coupling is required. So all Marine Ampliers come equipped with a composite heat  
transferring tape. Core heat in semi-conductors causes distortion and poor component performance characteris-  
tics. Testing has shown a massive reduction in core heat has been achieved by using the FUTRANZ heat transfer-  
ring technology. In simplified terms this means excellent thermal stability and maximum component reliability.  
MODEL NUMBER  
DATE OF PURCHASE  
AFFIX RECEIPT HERE  
F.I.S.T (fusion intercooled semi-conductor technology)  
FIST is an innovative method of clamping down all internal power switching and audio output devices with an  
aluminium extrusion that has extremely low temperature co-efficiency. By using F.I.S.T it creates the perfect cool-  
ing solution, rapidly removing core heat from all associated semi-conductors from both sides of the device at once  
resulting in extremely low distortion an excellent thermal stability  
F.R.A.T (fusion intercooled semi-conductor technology)  
FRAT is a regulated amplifier design, FUSION regulated amplifiers allow an enormous amount of output power at  
the lowest voltage (12.6 Volts) and extreme output at 14.4 volts.  
2010 Version 1.0  
Set the crossover switch 2 to HP and turn this control to 65Hz or above when using speakers smaller than 6  
x 6”, this feature is designed to filter all low bass frequencies that only SUBWOOFERS should produce. NOTE:  
Failure to do so could result in speaker damage.  
Control Descriptions  
7
Bass Boost:  
This is a variable control to increase the bass boost at 45Hz from 0 -+18dB of gain, adjust to suit.  
8
9
Subsonic Filter:  
This is a variable control filters out all Sub Bass Frequencies below the set point at 18dB/octave.  
Level:  
This allows level adjustment of the input signal. Use this control to correctly match the head unit to the  
amplifier. To set this control correctly, turn the amplifier level to MIN and the head unit to 3/4 volume, with  
the BASS and TREBLE on zero , then slowly turn up this amplifier level control towards the MAX end of the  
control. NOTE: If the sound becomes distorted, turn this control down.  
1
2
3
4
5
6
7
8
9
10  
11  
10 RCA Input:  
Connect these RCA connectors to the rear LOW LEVEL output connection from the head unit.  
11 RCA Output:  
Use these RCA Output connectors to connect to a secondary amplifier. This output is a PASS-THRU connection  
derived from the RCA input connector so the signal level and frequency response are the same as the original  
input signal.  
14  
12  
13  
15  
16  
12 Ground Connection:  
Connect directly to a suitable ground point via a 4 gauge power cable. NOTE: This is to be the first wire to  
connect when wiring up amplifiers. Damage could result of this is not done.  
1
2
3
4
5
Bass Remote Selector  
13 +12V Connection:  
Use this switch to activate or deactivate the (optional) FP-BASS controller.  
Bass Remote Connector  
This must be connected to the battery positive (+) terminal via a 4 guage power cable and with an inline fuse  
or circuit breaker at the battery end. NOTE: This is to be the last wire to connect up during installation as  
damage could result.  
This port allows connections to the (optional) FP-BASS control.  
Power And Status LEDs:  
14 Remote Connection:  
This input is for turning the amplifier on and off. This requires a switched positive (+12V) to power ‘ON’ the  
amplifier, this can be found on the rear of the head unit in the form of an electric antenna output, or a remote  
on output. If not available you can wire to the ACC position on the key.  
this shows if the amplifier has been correctly powered up and if any faults are present.  
Crossover Selector:  
15 Fuses:  
Set the appropriate mode of operation. The 3 positions available are OFF, LP and HP. See points 5 and 6 below.  
Please ensure the correct type of fuse is fitted, as specified in this manual. PLEASE NOTE: the FM-402 has 1x  
25A fuses.  
Low Pass:  
Set the crossover switch 2 to LP when a subwoofer is connected. Ensure the crossover frequency is set at  
100Hz or below, this feature is designed to filter all mid to high frequencies that only FULL RANGE speakers  
should produce. NOTE: Failure to do so could result in speaker damage.  
16 Speaker Output:  
See 2/1 channel installation diagrams in this manual for correct speaker connection.  
6
High Pass:  
over the screw and bare metal to prevent rust. Now its time to connect the power and ground cables to the amplifier. Cut both  
cables to length. Crimp the yellow spade connectors supplied to the power and ground. Use a hex type screwdriver to loosen the  
+12V and the GND connections on the amplifier. Terminate the ground first, and then the +12V and please make sure that you  
terminate them into the correct terminals. Then tighten the screws down securely.  
Installation  
Mounting  
Appropriate mounting is very important for the prolonged life expectancy of any amplifier. Select a location that allows enough  
space so sufficient airflow is maintainable and a location that provides protection from moisture. Keep in mind that an amplifier  
should never be mounted upside down. Upside down mounting will compromise heat dissipation through the heatsink and  
could engage the thermal protection circuit. Excessive heat will shorten your amplifiers life. To maximise heat dissipation, be  
sure to leave at least 2.5” of clearance around the amplifier. If space is of the essense and the amplifier must be mounted in  
an enclosed or restricted area, a small 3 inch fan should be used in correspondence with a duct so the heat can flow past the  
FUTRANZ Heatsink. Try to avoid mounting any amplifier on a subwoofer enclosure, as extended exposure to vibration may cause  
malfunction of the amplifier.  
Speaker Load  
Keep in mind FUSION ‘FM’ series amplifiers are high power amplifiers and not high current amplifiers. In other words they require  
a minimum impedance of 2 ohms STEREO and 4 ohms bridged MONO to operate trouble free. Too low of an impedance could send  
your FUSION amplifier into protection mode and/or damage the amplifier.  
Remote Turn-on  
This terminal must be connected to a switched +12V source. Typically, remote turn-on leads are provided at the head unit which  
will turn on and off the amplifier in correspondence with the source. If the head unit does not have a remote turn-on lead, then  
a power antenna wire can be used. If neither of these leads are present on the head unit then a switched +12V supply must be  
used , like the ACC +12V.  
To avoid scratching your new FUSION amplifier, pre-drill the mounting holes with either a 3mm or 9/64” diameter drill bit and use  
the screws supplied in the accessory kit. Be sure to investigate your mounting area thoroughly to avoid electrical wires, vacuum  
lines and brake or fuel lines.  
Run a minimum of 18 gauge wire from the amplifier location to the source of the switched +12V lead. If possible, route this wire  
on the same side of the vehicle as your power cable. Connect the source remote output to the wire. Go back to the amplifier and  
cut the wire to length. Loosen the screw terminal marked REM on the amplifier using a hex type screwdriver. Slip the wire into  
the connector and tighten the screw securely.  
Installation Options  
The quality of installation will affect the performance and reliability of your FUSION amplifier. For maximum performance we  
recommend you have your new FUSION amplifier installed by an authorised FUSION dealer. Our highly skilled dealers have vast  
knowledge of our products and their installation techniques are necessary to unleash the high performance capabilities of your  
amplifier.  
Speaker Wiring  
Choose the correct speaker wire for your application. Most application will require a minimum of 16 gauge. Route these using the  
same precautions as you did when you ran the power cables. Terminate these wires at the speaker end using insulated speaker  
terminals (not supplied) or by soldering the connection. Make sure the speaker connections are positive to positive and negative  
to negative. At the amplifier end, use a #2 Phillips screwdriver to loosen the speaker terminals on the amplifier. Connect the  
speaker wires and tighten the screws securely. Check to make sure you’ve maintained proper polarity and balance.  
If you decide to connect the amplifier yourself, it is important that you read this manual carefully and throughout before start-  
ing. Once you have finished reading and you still have questions regarding installation, we recommend your FUSION dealer.  
Connection  
FUSION amplifiers are designed to work within a 10 to 16 volt DC range. Before any wires are connected, the vessel’s electrical  
system should be checked for correct voltage supply with the help of a voltmeter. First, check the voltage at the battery with the  
ignition in the OFF position. The voltmeter should read between 12 and 13.8 Volts. If your vehicle’s electrical system is not up to  
these specification, we recommend having it checked by an auto electrician before any further installation. Once the vessel is  
checked, make certain the correct cable size is used. We recommend using the following cables calculator diagram on page 8 to  
calculate the correct power cable for your application.  
Inputs & Gain Setup  
Low Level Inputs  
Be extra careful with your RCA interconnects. Hiss, engine noise, and fan noise can easily be picked up through RCA cables if run  
incorrectly. Avoid running your RCAs near large wire looms and electric fans if possible. Run your RCA cables on the opposite side  
of the power cable. Be sure to check for correct balance (Red is right and black or white is left)  
Power  
Level Control  
FUSION amplifiers should be wired directly to the battery using the appropriate sized cable. Start at the vehicle battery and run  
the power cable through to the amplifier. FUSION recommends the use of grommets when passing the power cable through any  
metal wall to avoid sharp corners or sharp body parts that may easily cut through the insulation on the cable.  
On the amplifier, is the LEVEL control, this control allows you to match the input level of the amplifier to the output level of your  
head unit. Matching the input can be accomplished in three simple steps:  
Avoid running the power cable over engine components and near heater cores. The use of an inline fuse or circuit breaker is  
a must, this will prevent the risk of a potential fire caused be a short in your power cable. Connect the fuse holder or circuit  
breaker as close to the battery positive terminal as possible. Use a fuse or circuit breaker of equal value as that found on the  
chassis of your FUSION amplifier. You may now connect the cable to the battery, but remember to leave the fuse out or circuit  
breaker off until all other cable connections are made.  
1. Turn the LEVEL control on the amplifier to minimum.  
2. Turn up the head unit and adjust to 2/3 maximum volume ensuring that the BASS and TREBLE are set to zero.  
3. Adjust the LEVEL control until the desired volume is achieved without audible distortion.  
Remember, the gain control is not a volume control. Ignoring the three steps above may leave you with damaged speakers and/  
or a damaged amplifier.  
Ground  
When grounding your FUSION amplifier, locate a metal area close to the amplifier that is a good source of ground. Once again,  
investigate the area you wish to use for electrical wires, vacuum lines, and brake or fuel lines. Use either a wire brush or sand-  
paper to eliminate unwanted paint. This will supply a better contact for your ground. Use the same gauge cable for ground as  
you did for the power. Secure the ground cable to the appropriate ground point using a bolt, star washer and nut. Spread silicon  
All  
1 Channel Installation  
2 Channel Installation  
FUSE  
FUSE  
PLEASE NOTE: The crossover selector positions  
PLEASE NOTE: The crossover selector positions  
Power Cable Calclator  
Trouble Shooting  
Total Amperage  
0-20  
0-4ft  
14  
12  
10  
8
4-7ft  
12  
10  
8
7-10ft  
10-13ft  
13-16ft  
16-19ft  
19-22ft  
22-28ft  
12  
8
10  
8
10  
6
8
6
4
4
2
2
0
0
8
6
4
4
2
2
0
0
8
4
4
2
0
0
0
0
Problem  
Cause  
Solution  
20-35  
Replace with correct fuse. Typically twice the rating of the fuse that  
is on the amplifier  
Fuse at battery blown or not installed  
35-50  
8
6
4
Power LED not ‘ON  
Check that the ground wire, power wire and the remote wires are  
connected to the correct terminal  
50-65  
8
6
4
4
Improper connections  
65-85  
6
6
4
4
2
Fuse or amplifier blown  
Amplifier too hot  
Replace with the correct AMP rated fuse  
85-105  
105-125  
125-150  
6
6
4
2
2
Move the amplifier into a more ventilated area  
4
4
4
2
0
Check that there are no speaker wires shorted to any other wire and  
also check if any wire is shorted to the vehicle chassis  
Status LED ‘ON’  
Speaker wires shorted  
Internal malfunction  
2
2
2
0
0
Disconnectallwiresexceptground, powerandremote. Thenturnthe  
amplifierON’, iftheprotectionlightisstillONthenreturnforservice  
The above chart shows cable gauges to be used, if no less than a 0.5 volt drop is acceptable. If aluminium wire or tinned wire is used, the gauges should be of an even larger  
size to compensate. Cable gauge size calculation takes into account terminal connection resistance. 1 Metre = 3.28 Feet  
Specifications  
Bandwidth  
Signal to Noise  
Separation  
10Hz - 40kHz  
>95dB  
>60dB  
12.6 Volt power output specification  
50 Watts RMS x 2 @ 4Ω 1% THD+N  
96 Watts RMS x 2 @ 2Ω 1% THD+N  
Input Sensitivity  
LP Variable Crossover  
HP Variable Crossover  
Variable Bass Boost  
Variable Subsonic Filter  
Input Impedance  
Damping factor  
T.H.D  
300mV - 8V  
160 Watts RMS x 1 @ 4Ω Bridged 1% THD+N  
40Hz - 160Hz @ 12dB/octave  
40Hz - 600Hz @ 12dB/octave  
0 - + 18dB @ 45Hz  
20Hz - 55Hz @ 18dB/octave  
20KW  
14.4 Volt power output specification  
65 Watts RMS x 2 @ 4Ω 1% THD+N  
100 Watts RMS x 2 @ 2Ω 1% THD+N  
200 Watts RMS x 1 @ 4Ω Bridged 1% THD+N  
>200  
0.05%  
Fuse Ratings  
1 x 25A  
Dimensions(mm)  
220 (W) x 260(L) x 57.5(H)  

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