ZXi200.

2
ZXi40.4 / ZXi80.4 / ZXi150.4
ZXi60.4+1K
 ZEUS HIGH PERFORMANCE AMPLIFIERS
The Zeus ZXi Series products have been designed to a very high level of performance, with features unavailable in
any other product. All of the amplifiers have variable crossovers built in, with added touches such as subsonic
filter, bass equalization and a remote Level control module(some models) that allows subwoofer Level control from
the drivers seat.

To ensure years of listening pleasure, all amplifiers have a built in diagnostic mode that will detect shorted speaker
leads, low impedance, dangerous high temperatures, DC shorts and will shut down the amp to prevent serious
damage.

INDEX PAGE
General Installation Procedure..........................................................................................................................................................................................1

Amplifier Feature Descriptions...........................................................................................................................................................................................2

ZXi200.2 2-CHANNEL AMPLIFIER APPLICATIONS.......................................................................................................................................................3

Full range stereo / mono

ZXi40.4 / ZXi80.4 / ZXi150.4 4-CHANNEL AMPLIFIER APPLICATIONS.......................................................................................................................4-5

4, 3 and 2 channel operation / front/rear high pass using a 2 channel model for mono sub bass

ZXi60.4+1K 5-CHANNEL AMPLIFIER APPLICATIONS.................................................................................................................................................. 6

5 channel discrete operation / single stereo RCA input with 5 channel output

Features and Specifications.............................................................................................................................................................................................. 7

Setting Up Systems After Installation For Best Performance.............................................................................................................................................. 8

Troubleshooting and Diagnostics.......................................................................................................................................................................................9

Product Warranty.............................................................................................................................................................................................................10

Check out our videos of new products,

events and technical tutorials at
www.youtube.com/maxxsonicsusainc

The contents of this manual may not be reproduced or copied with out the written consent of MAXXSONICS USA, Inc.
 GENERAL INSTALLATION PROCEDURE
System Design
The success of any car stereo system relies on several factors, such as the system design, execution of the installation, and system setup. Please
remember that any system is only as good as its weakest link.
Please remember that higher power systems are not necessarily useful purely for high sound pressure levels, but also to establish a headroom capability, to
reproduce musical peaks cleanly without distortion. Lower power amplifiers will clip earlier than their more powerful cousins, and cause loudspeaker failure when
overdriven, due to the harmonics generated by a clipped signal, thus overheating voice coils.

Amplifiers should be mounted with the fins running horizontally for best convection cooling, to minimize overheating. Purchase the best quality RCA cables you can
afford, for reliability and less engine noise interference in the audio system.

Installation

WOOD
It is highly recommended that the amplifier be mounted to a board of MDF or other solid
structure using the 4 mounting screws provided. Avoid mounting the
amplifier to metal as this can introduce noise and other unwanted issues. When mounting HF
the amplifier, ensure that it is mounted HORIZONTALLY, as shown in the diagram above, for
optimal heat dissipation. Mounting amplifiers to speaker enclosures is not recommended as
this can cause damage to the amplifier components. When choosing a location for
mounting the amplifier, ensure that you check for clearance from wires, gas tank, electrical
devices and brake lines etc.
General:
Run the wiring so that RCA cables are at least 18“ away from power and speaker cables. Keep RCA cables away from electrical devices in the vehicle that can cause
electrical noise, such as electric fuel pumps, emission control modules and other on-board electronic modules.

Power and ground connections(see the features matrix on page 7 for proper gauge cables per amplifier):
Use a sufficient gauge power cable and ground cable using the chart below as reference to what size wire you require. Zeus series amplifiers require at least 4 gauge
power wire. In a multi amplifier system, add the total value of the manufacture recommended fusing to get your total system amperage. Some applications may
require multiple runs of power wire to meet the system requirements. In multi amplifier systems it is advisable to mount a large enough fuse right at the battery, and
run one or multiple +12 volt power cables to a fused distribution block near the amplifiers. It is then a simple matter to connect the +12 volt terminal of each amplifier
to the distribution block. During this process, please ensure that the main power fuse is removed to avoid shorting the electrical system. The main fuse must be within
12” of the vehicles battery.

Ground each amplifier with as short a ground lead as possible directly to the vehicle chassis using at least 4 gauge wire or equivalent to the size of the amplifiers’
power wire. Use a ground distribution block, if you wish, but it is extremely important to keep the main ground lead from this distribution block to the chassis as short
as possible , not more than 12“. The ground connection integrity to the chassis is very important, and the best way to achieve a good, solid electrical and mechanical
contact is to use a large round crimp lug, crimped and soldered to the ground cable. The next step is to scrape the paint off the vehicle chassis , slightly larger than
the ground lug, at the connection point. Drill a clearance hole in the chassis, the same size as the lug hole, and use a bolt, spring washer and nut to securely fasten
the ground lug. Use petroleum jelly to coat the bolt/lug connection, to prevent oxidization with time.

TIP: Use the same approach when installing head units, equalizers or any audio equipment for that matter - run short individual grounds from each piece directly to
the vehicle chassis, to minimize ground loops and system noise. All power, ground and speaker connections should be crimped and soldered for reliability. Make sure
that none of the cable insulation can chafe against exposed metal in the vehicle, causing short circuits to the chassis.
WIRE LENGTH
SYSTEM
7-10 ft. 10-13 ft. 13-16 ft. 16-19 ft. 19-22 ft. 22-28 ft.
AMPERAGE
NOTE: This Matrix is a general rule
35-50 8 6 4 4 4 4
of thumb. Please refer to the
WIRE GAUGE

50-65 6 4 4 4 4 2
68-85 4 4 2 2 2 0
manufacturers specific
85-105 4 2 2 2 2 0 requirements. ZXi specifications
105-125 4 2 0 0 0 0 can be found on page 7.
125-150 2 0 0 0 0 0

Safe connection sequence:

After all cables are run, connect speaker wires to the speakers and amplifiers, then run and plug in RCA cables. Next, connect all power, ground, and remote turn on
leads. Now connect all +12 volt cables to the amplifier/s and distribution blocks and fuse holders. Finally, connect the main +12 volt cable to the battery, with the main
fuse removed, and we are almost ready to power up the system.

Power up the system:

The following procedure may seem like overkill, but there is nothing more frustrating when turning on a system for the first time, and it does not work properly
immediately.
First, make sure the head unit is off, and turn all level controls to minimum (counterclockwise), including the head unit volume control. Set all equalizers to 0 dB (no
boost), and all crossover frequency controls at approximate frequencies, as recommended by the loudspeaker manufacturer. Set all input selector and crossover
switches as required for the application. Remove all amplifier fuses, and insert the main fuse at the battery. If the fuse does not blow, you can insert the fuse in one of
the amplifiers, and we are ready to turn on the system. Turn the head unit on, insert a CD, or select a radio station, and increase the head unit volume control. If the
system sounds fine, turn off the head unit, and install fuses in the remaining amplifiers, one by one, till the complete system is powered up and functioning properly.
1
AMPLIFIER FEATURE DESCRIPTIONS
ZEUS ZXi AMPLIFIERS:
! Each model is capable of 4 & 2-Ohms stereo per channel, or 4-Ohms mono bridged operation ! CAUTION: DO NOT OPERATE ANY AMPLIFIER BELOW THE INTENDED IMPEDANCE. YOU
except the 5 channel which is capable of 1-Ohm on channel 5. WILL CAUSE DAMAGE TO THE AMPLIFIER THAT WILL NOT BE COVERED UNDER THE
! The input sensitivities for rated output powers are variable from 0.2 volts to 6 volts. WARRANTY PRINTED IN THE BACK OF THE MANUAL. 2 & 4 Channel amps are capable of 4
! All crossovers are fully variable in their respective ranges. and 2-Ohms wired stereo and 4-Ohms wired mono bridged. The 5 channel amp is capable of 4,
! Crossover filters are 12dB/Octave. 2 and 1-Ohm operation on the 5th channel ONLY.
! A POWER LED indicates the powered up and turned on condition.
! All Hifonics amplifiers feature a comprehensive diagnostic system, with speaker lead short circuit,
and amplifier DC faults indicated by the red “PROTECT” LED.

ZXi200.2 2-CHANNEL AMPLIFIERS

The X-OVER slide switch selects the internal crossover functions:
-The input signal is routed directly to the LINE OUT RCA jacks, regardless of the X-OVER setting LINE INPUT LINE OUT
simplifying daisy chaining of amplifiers. HI PASS X-OVER LOW PASS BASS EQ LEVEL POWER
-HP: Selects the built in HIGH PASS filter, variable from 10Hz to 15kHz. L L

-FULL: Bypasses all crossovers for full frequency range operation.

REMOTE 10Hz 15KHzHP FULL LP/BP 30Hz 150Hz 0dB 10dB 6V 0.2V PROTECT
-LP/BP: Selects the built in LOW PASS , variable from 30Hz to 150Hz.
R R
BASS EQ: Fixed 45Hz bass boost variable from 0dB to 10dB.
LINE INPUT: The line input accepts unbalanced (RCA) inputs from 0.2V to 6V.
LINE OUTPUT: The line output passes through signal from the line inputs which allows you to daisy
chain multiple amplifiers from one signal.
Note that the LOW PASS signal is MONO.
-In the LP/BP position, the HIGH PASS filter acts as a
subsonic filter.
-When the LP/BP mode is selected, a 0 to +10dB, at 45Hz,
BASS EQ is also switched in.

ZXi40.4 / ZXi80.4 / ZXi150.4 4-CHANNEL AMPLIFIERS

The 4 channel amps have the same features as the 2 channel models accept that there are 2 sets of
controls. LINE INPUT REMOTE HI PASS 1/2 CH
X-OVER
LOW PASS BASS EQ LEVEL POWER LINE OUT
CH1/2 CH3/4
1 set for channels 1 & 2 and 1 set for channels 3 & 4.
R R R
In addition, the 4 channel models have a Mode switch. Switch to 2 channel if you only have 1 set of 10Hz-15KHz HI FULL LP/BP 30Hz-150Hz 0dB-10dB 6V 0.2V PROTECT
RCA’s in CH 1/2 and the unit will automatically supply signal to channels 3/4. Select 4 channel if you HI PASS 3/4 CH
X-OVER
LOW PASS BASS EQ LEVEL

are providing RCA’s to channels 1/2 and 3/4. L L L

CH2-CH4
The X-OVER slide switch selects the internal crossover functions: MODE 10Hz-15KHz HI FULL LP/BP 30Hz-150Hz 0dB-10dB 6V 0.2V
-The input signal is routed directly to the LINE OUT RCA jacks, regardless of the X-OVER setting
simplifying daisy chaining of amplifiers.
-HP: Selects the built in HIGH PASS filter, variable from 10 Hz to 15kHz.
-FULL: Bypasses all crossovers for full frequency range operation. Note that the LOW PASS signal is MONO.
-LP/BP: Selects the built in LOW PASS , variable from 30 Hz to 150Hz. -In the LP/BP position, the HIGH PASS filter acts as a
BASS EQ: Fixed 45Hz bass boost variable from 0dB to 10dB. subsonic filter.
LINE INPUT: The line input accepts unbalanced (RCA) inputs from 0.2V to 6V.
LINE OUTPUT: The line output passes through signal from the line inputs which allows you to daisy -When the LP/BP mode is selected, a 0 to +10dB, at 45Hz,
chain multiple amplifiers from one signal. BASS EQ is also switched in.

The ZXi60.4+1K has three sets of inputs:

Line inputs on RCA jacks for channel pairs 1&2, 3&4, and MONO channel 5. These inputs can be used in
various combinations, to suit the application, depending on the settings of the INPUT MODE switch, and
ZXi60.4+1K 5-CHANNEL AMPLIFIERS
the X-OVER switches for channels 1&2, and channels 3&4, respectively.

INPUT MODE slide switch: LINE INPUT CH1/2

CH3/4
HI PASS LEVEL HI PASS X-OVER LOW PASS LEVEL
- In the CH2 position, ALL five amplifier inputs are selected from the CH1/CH2 RCA jacks. Channel 5 X-OVER
HI FULL
HI FULL BP

receives a mono mixed signal. CH1 CH3

10Hz 15Khz 6V 0.2V 10Hz 15Khz 30Hz 150Hz 6V 0.2V
- In the 4CH position, channel pair 1&2 receive input signal from RCA jacks CH1 and CH2, and channel POWER
5CH

pair 3&4 receive input signal from RCA jacks CH3 and CH4. A mono mixed signal from these four RCA
jacks are also fed to channel 5. CH2 CH4
REMOTE 30Hz 150Hz 0dB-10dB 6V 0.2V
LOW PASS BASS EQ LEVEL PROTECT
Ch2 Ch4 Ch5
MODE
- When 5CH DISCRETE is selected, each channel receives an input signal from its respective input RCA
jack. Channel 5 has two jacks on its LINE INPUT, which are summed together.
CH1/2 X-OVER slide switch:
- HI: Selects the HIGH PASS filter, variable from 10Hz to 15KHz.
- FULL: Sets this pair to full range operation.

CH3/4 X-OVER slide switch:

- HI: Selects the HIGH PASS filter, variable from 10Hz to 15KHz.
- FULL: Sets this pair to full range operation.
-LP/BP: Selects the built in LOW PASS , variable from 30 Hz to 150Hz.

CH 5:
- The channel 5 functions were chosen to be very specific to mono bass operation, and not switchable:
- The LOW PASS filter has a variable range from 30 Hz to 150 Hz.
- The BASS EQ gives a bass boost, 0 to +10 dB, at 45 Hz.

2
ZXi200.2 2-CHANNEL AMPLIFIER APPLICATIONS
FULL RANGE STEREO
This is the most basic application for the HFi Series 2 channel amplifiers. 4. Line Level:
Refer to the section “Setting up systems after installation for best performance”
1. Interconnect cable checklist:
Connect the LINE INPUTS to the Radio/CD with good quality RCA cables. NOTE: Minimum final loudspeaker impedances:
2. Crossover Switch: 4 & 2 Ohms stereo mode or 4-Ohms mono mode
The X-OVER switch must be in the FULL position. This amplifier will not do 1 Ohm stereo or 2/1 Ohm mono operation.
3. Crossover frequency control checklist:
N/A for full range operation.
FULL RANGE FULL RANGE
STEREO LINE INPUT SPEAKERS
LINE INPUT
R

- LEFT +
SPEAKER OUTPUT
REMOTE 10Hz 15KHzHP FULL LP/BP 30Hz 150Hz 0dB 10dB 6V 0.2V PROTECT

BRIDGED
- RIGHT +
HI PASS
X-OVER

FUSE
LOW PASS
BASS EQ

REM BATT+12V
TO BATTERY +12v
LEVEL

POWER INPUT
VIA FUSE
REMOTE TURN-ON
POWER

CHASSIS GROUND

GND
LINE OUT
R

MONO
This application illustrates the basic mono bridging method for all Hifonics Switch setting checklist:
amplifiers. - The AMPLIFIER X-OVER switch should be in the LP/BP position.

Interconnect cable checklist: Crossover frequency control setting checklist:

A MONO signal source is required, such as would be available from the mono LPF: 11 o’clock
sub bass output of an active crossover, whether stand alone, or built into a head
unit or equalizer. Important: Do not be tempted to connect the hot, or positive Minimum final loudspeaker impedance:
outputs, from any source together to obtain a mono signal, as this could very - 4 ohm mono.
well damage the output stage of that source.
It is necessary to feed the SAME signal to both left and right inputs via a Y-
adapter RCA cable. Connect the mono speaker positive terminal to the LEFT +,
and its negative terminal to RIGHT -.

MONO SPEAKER
or SUBWOOFER
LINE INPUT
R

- LEFT +
SPEAKER OUTPUT
REMOTE 10Hz 15KHzHP FULL LP/BP 30Hz 150Hz 0dB 10dB 6V 0.2V PROTECT

BRIDGED

FULL RANGE
MONO LINE INPUT
- RIGHT +
HI PASS

VIA Y-ADAPTER
FROM MONO SOURCE
X-OVER

FUSE
LOW PASS
BASS EQ

REM BATT+12V

TO BATTERY +12v
LEVEL

POWER INPUT

VIA FUSE
REMOTE TURN-ON
POWER

CHASSIS GROUND
GND
LINE OUT
R

3
ZXi40.4 / ZXi80.4 / ZXi150.4 4-CHANNEL AMPLIFIER APPLICATIONS
4 CHANNEL FULL RANGE SYSTEM
Here we show how to use the 4 channel amplifiers as straightforward discrete 4 - HI PASS: N/A
channel full range units. - LOW PASS: N/A

Interconnect cable checklist: Channels 3/4:

- Connect the four inputs of the amplifier to a Radio/CD with quality RCA cables. - HI PASS: N/A
- LOW PASS: N/A
Switch setting checklist:
- 1/2CH X-OVER: FULL Level control checklist:
- 3/4CH X-OVER: FULL - Refer to the section “Setting up systems after installation for best performance”

Crossover frequency control checklist: Minimum final loudspeaker impedances:

Channels 1/2: - 2 ohm per channel.

R
L

CH1/2 CH3/4
LINE INPUT

- LEFT +
BRIDGED
CH 1/2 SPEAKER OUTPUT CH 3/4
R
L

- RIGHT +
CH2-CH4

REMOTE
MODE10Hz-15KHz HI FULL LP/BP 30Hz-150Hz 0dB-10dB 6V 0.2V

10Hz-15KHz HI FULL LP/BP 30Hz-150Hz 0dB-10dB 6V 0.2V PROTECT

- LEFT +
HI PASS
HI PASS

BRIDGED
- RIGHT +
3/4 CH
X-OVER

X-OVER
1/2 CH LOW PASS
LOW PASS BASS EQ

FUSE
BASS EQ

REM BATT+12V
LEVEL
LEVEL

POWER INPUT
POWER LINE OUT

GND
R
L

2 or 3 CHANNEL SYSTEM
Here we show how to use the 4 channel amplifiers as a 3 channel unit by taking Switch setting checklist:
advantage of the mono bridging capability of all Hifonics amplifiers. - 1/2CH X-OVER: FULL
- 3/4CH X-OVER: LP/BP
The following example shows how to create a 3 channel system by mono
bridging channel pair 3 / 4. In order to create a 2 channel system, simply follow Crossover frequency control checklist:
the example to also mono bridge channel pair 1 / 2. Channels 1/2:
- HI PASS: N/A
Interconnect cable checklist: - LOW PASS: N/A
- Connect the inputs of channel pair 1/2 to a suitable stereo source, e.g. a head
unit with good quality RCA cables. Channels 3/4:
- A MONO signal source is required to bridge channel pair 3/4, such as would be - HI PASS: N/A
available from the mono sub bass output of an active crossover, whether - LPF: 11 o’clock
standalone, or built into a head unit or equalizer. If you only have 1 set of RCA
outputs from your headunit, you can simply connect those to the inputs for ch TIP: If you are using the mono sub bass output of an active crossover, there is
1/2 and switch the MODE to 2ch. The amplifier will auto sum the signal and nothing wrong with switching in the low pass filter in these amplifiers for a
provide mono output for bridged channels 3/4 once the X-OVER is switched to steeper low pass rolloff.
LP/BP.
Important: Do not be tempted to connect the hot, or positive outputs, from any Level control checklist:
source together to obtain a mono signal, as this could very well damage the - Refer to the section “Setting up systems after installation for best performance”
output stage of that source.
- It is necessary to feed the SAME signal to both left and right inputs via a Y- Minimum final loudspeaker impedances:
adapter RCA cable. - 2 ohm per channel in stereo mode.
- Connect the mono speaker positive terminal to the LEFT +, and its negative - 4 ohm mono bridged.
terminal to RIGHT - as shown.
STEREO LINE INPUT
R
L

CH1/2 CH3/4
LINE INPUT

- LEFT +

MONO LINE INPUT

BRIDGED
CH 1/2 SPEAKER OUTPUT CH 3/4

(Unless using procedure

R
L

- RIGHT +
CH2-CH4

REMOTE

listed above for 3ch)

MODE
10Hz-15KHz HI FULL LP/BP 30Hz-150Hz 0dB-10dB 6V 0.2V

10Hz-15KHz HI FULL LP/BP 30Hz-150Hz 0dB-10dB 6V 0.2V PROTECT

- LEFT +
HI PASS
HI PASS

BRIDGED
- RIGHT +
3/4 CH
X-OVER

X-OVER
1/2 CH
LOW PASS
LOW PASS BASS EQ

FUSE
BASS EQ

REM BATT+12V
LEVEL
LEVEL

POWER INPUT
POWER LINE OUT

GND
R
L

4
 ZXi40.4 / ZXi80.4 / ZXi150.4 4-CHANNEL AMPLIFIER APPLICATIONS
Front/Rear high pass, using a 2 channel amplifier for mono sub bass
The combination of a 2 and a 4 channel amplifier, utilizing their built in Channels 1/2:
crossovers, makes it a snap to put together a full system with front and rear - HI PASS: 100 Hz
highs, with mono sub bass. LOW PASS: N/A

Interconnect cable checklist: Channels 3/4:

- Using good quality RCA cables, feed the front and rear outputs of a head unit to - HI PASS: 100 Hz
the inputs of the 4 channel amplifier as shown. - LOW PASS: N/A
- Also connect the LINE OUT of the 4 channel amplifier to the LINE INPUT of the
2 channel amplifier as shown. 2 channel bass amplifier:
- HI PASS (Subsonic filter): 10 Hz to 40 Hz
Mono bass woofer wiring: - LOW PASS: 80 Hz
Connect the mono speaker positive terminal to the LEFT +, and its negative
terminal to RIGHT -. Please note that these frequency points are suggestions only. Refer to the
loudspeaker manufacturer specifications and the section “Setting up systems
Switch setting checklist: after installation for best performance”
4 channel highs amplifier:
- 1/2CH X-OVER: HI Level control checklist:
- 3/4CH X-OVER: HI - Refer to the section “Setting up systems after installation for best performance”

2 channel bass amplifier: Minimum final loudspeaker impedances:

- X-OVER switch: LP/BP - 2 ohm per channel in stereo mode.
- 4 ohm mono bridged.
Crossover frequency control checklist:
- 4 channel highs amplifier:
R
L

CH1/2 CH3/4
LINE INPUT

- LEFT +
BRIDGED
CH 1/2 SPEAKER OUTPUT CH 3/4
R
L

- RIGHT +
CH2-CH4

REMOTE
MODE
10Hz-15KHz HI FULL LP/BP 30Hz-150Hz 0dB-10dB 6V 0.2V

10Hz-15KHz HI FULL LP/BP 30Hz-150Hz 0dB-10dB 6V 0.2V PROTECT

- LEFT +
HI PASS
HI PASS

BRIDGED
- RIGHT +
3/4 CH
X-OVER

X-OVER
1/2 CH
LOW PASS
LOW PASS BASS EQ

FUSE
BASS EQ

REM BATT+12V
LEVEL
LEVEL

POWER INPUT
POWER LINE OUT

GND
R
L

STEREO
INTERCONNECT
RCA CABLE MONO SPEAKER
or SUBWOOFER
LINE INPUT
R

- LEFT +
SPEAKER OUTPUT
REMOTE 10Hz 15KHzHP FULL LP/BP 30Hz 150Hz 0dB 10dB 6V 0.2V PROTECT

BRIDGED
- RIGHT +
HI PASS
X-OVER

FUSE
LOW PASS
BASS EQ

REM BATT+12V

TO BATTERY +12v
LEVEL

POWER INPUT

VIA FUSE
REMOTE TURN-ON
POWER

CHASSIS GROUND
GND
LINE OUT
R

5
ZXi60.4+1K 5-CHANNEL AMPLIFIER APPLICATIONS
5 channel discrete, one being mono low pass
You can use this configuration simply as 4 discrete full range channels, with a 5th - CH 3 / 4 X-OVER: FULL
low pass channel. All of the crossovers are bypassed , except the LOW PASS on
channel 5. The 5 channels can also be utilized with an outboard active crossover, Crossover frequency control checklist:
or with crossovers in head units or equalizers. This setup is common when your - CH 1 / 2 HIGH PASS: N/A
headunit or crossover has 2 sets of full range RCA outputs and 1 set of mono - CH 3 / 4 HIGH PASS: N/A
subwoofer outputs. - CH 3 / 4 LOW PASS: N/A
- CH 5 LOW PASS: 80 Hz
Interconnect cable checklist:
Connect channel 1&2 inputs to the front output, channels 3&4 to the rear output, Please note that these frequency points are suggestions only. Refer to the
and channel 5 to the mono subwoofer output of a head unit or in dash equalizer. loudspeaker manufacturer specifications and the section “Setting up systems
The LOW PASS filter on channel 5 will be in tandem with that of the source. You after installation for best performance”
can either set it to the same frequency for a steeper rolloff, or set it to a higher
frequency to minimize it’s effect. By the same reasoning, you could switch Level control checklist:
channels 1,2,3&4 high pass crossovers in for steeper high pass slopes. - Refer to the section “Setting up systems after installation for best performance”

Switch setting checklist: Minimum final loudspeaker impedances:

INPUT MODE: 5CH DISCRETE - 2 Ohms per channel for channels 1-4
- CH 1 / 2 X-OVER: FULL
CH2

CH1

-
LINE INPUT

+ 5CH
CH4

CH3

+ 4CH -
HI FULL
REMOTE 30Hz 150Hz 0dB-10dB 6V 0.2V

X-OVER

BRIDGED
CH1/2

-
10Hz 15Khz 6V

3CH
LOW PASS BASS EQ

HI PASS

+
+ 2CH -
LEVEL

BRIDGED
0.2V 10Hz 15Khz
LEVEL

-
HI PASS

+ 1CH
HI FULL BP
PROTECT

POWER

X-OVER
CH3/4
Ch2 Ch4 Ch5

30Hz 150Hz 6V 0.2V

REM BATT+12V
LOW PASS
MODE

POWER INPUT
LEVEL

GND
5CH

Single Set of Stereo RCA’s

We will use the same basic setup on the speaker and subwoofer connections as
above to illustrate an installation that only has 1 set of stereo RCA’s to connect to Crossover frequency control checklist:
this amplifier. By switching the amplifier to 2CH on the INPUT MODE, you now - CH 1 / 2 HIGH PASS: N/A
provide signal to all channels on the amplifier. - CH 3 / 4 HIGH PASS: N/A
- CH 3 / 4 LOW PASS: N/A
Interconnect cable checklist: - CH 5 LOW PASS: 80 Hz
Connect Stereo Left and Right RCA’s from headunit to CH1&2 RCA Inputs.
Minimum final loudspeaker impedances:
Switch setting checklist: - 2 ohm per channel in stereo mode
INPUT MODE: 2CH - 4 ohm per mono bridged pair
- CH 1 / 2 X-OVER: FULL - 2 ohm on channel 5
- CH 3 / 4 X-OVER: FULL
CH2

CH1

-
LINE INPUT

+5CH
CH4

CH3

+ 4CH -
HI FULL
REMOTE 30Hz 150Hz 0dB-10dB 6V 0.2V

X-OVER

BRIDGED
CH1/2

-
10Hz 15Khz 6V

3CH
LOW PASS BASS EQ

HI PASS

+ 2CH - +
LEVEL

BRIDGED
0.2V 10Hz 15Khz
LEVEL

-
HI PASS

+1CH
HI FULL BP
PROTECT

POWER

X-OVER
CH3/4
Ch2 Ch4 Ch5

30Hz 150Hz 6V 0.2V

REM BATT+12V
LOW PASS
MODE

POWER INPUT
LEVEL

GND
5CH

6
7
SETTING UP SYSTEMS AFTER INSTALLATION FOR BEST PERFORMANCE
ZXi200.2 / ZXi40.4 / ZXi80.4 / ZXi150.4 / ZXi60.4+1K
General:
At this point you are ready to get more specific on the settings for your amplifier.

High Pass:
-When in Hi Pass operation, this setting acts as a low frequency cut off for your system reproduction. The point that you set it at cuts off any frequencies from reproduction beyond this
point. The 12 o’clock position is a great starting point. EXAMPLE: If you adjust the High Pass to 100Hz, the amplifier will not play frequencies below 100Hz but will play frequencies from
100Hz to the highest frequency the amplifier is capable of reproducing.
-When in Low Pass/Bandpass operation, this setting acts as a low frequency cut off for your system reproduction aka Subsonic Filter. The point that you set it at cuts off any frequencies
from reproduction beyond this point. The 12 o’clock position is a great starting point. EXAMPLE: If you adjust the High Pass to 60Hz, the amplifier will not play frequencies below 60Hz
but will play frequencies from 60Hz to the chosen Low Pass frequency.
-When in Flat/Full operation, the Low Pass crossover is bypassed.

Bass EQ:
This setting is a fixed bass boost at 45Hz that is variable from 0-10dB. This feature provides impact to your bass, but if not adjusted correctly, it can be over used and cause damage to
your speakers and amplifiers. It is best to slowly turn this setting clockwise until the desired punch is felt. It is not recommended to exceed the 12 o’clock position unless listening at a low
volume or a low recording quality as this can result in high distortion and possibly clipping.

Low Pass:
The Low Pass control acts as a ceiling and doesn’t allow frequencies to the right of the desired setting to be reproduced. Turning the potentiometer all the way to the right is a great
starting point. EXAMPLE: If you adjust the Low Pass to 120Hz, the amplifier will not play frequencies above 120Hz but will play frequencies from 120Hz to the chosen Hi Pass or
Subsonic frequency.
-When in Hi Pass operation, this setting is bypassed.

Level Control Setup:

Ensure that the Level is turned completely to the left prior to turning the system on. Next you should insert a CD or cassette that you are familiar with to use as a reference, and turn the
head unit volume control to about 80% of its full setting. The system sound level will of course be very low, and the following procedures will help you to match the amplifier input
sensitivities properly to the head unit output signal level.
It is important to match the amplifier LEVEL input sensitivity to the Radio/CD output sensitivity. This can be located in the Radio/CD manual.
If the Radio/CD output sensitivity is 2 volts, then adjust the amplifier LEVEL input to 2 volts.

If you are not sure what the Radio output sensitivity is, follow these general guide lines:
Turn the level control up slowly, till you hear distortion, then back off a few degrees on the control. If at any point your amplifier goes into protection, you will need to turn the Level to the
left a bit and then try again. If you reach a point where the output does not increase, stop turning the Level control to the right as the amplifier/speaker combo has reached its maxx
output in this application.

2 or 3 way active systems (all):

Always start with the bass, or low frequency amplifier as a reference, by turning its control up to the point where distortion is audible, and back it off some.
Now adjust the level control for the highs or tweeter channels in a 2 way active system, to balance the highs to lows.
In a 3 way active system, match the midrange level to the bass, and then the highs to the midrange and bass. It may be necessary to perform a few iterations of the midrange and highs level
control settings to achieve a satisfactory sound balance.

Channel 5 on the ZXi60.4+1K

General:
At this point you are ready to get more specific on the settings for your amplifier.

Bass EQ:
This setting is a fixed bass boost at 45Hz that is variable from 0-10dB. This feature provides impact to your bass, but if not adjusted correctly, it can be over used and cause damage to
your subwoofers and amplifiers. It is best to slowly turn this setting clockwise until the desired punch is felt. It is not recommended to exceed the 12 o’clock position unless listening at a
low volume or a low recording quality as this can result in high distortion and possibly clipping.

Low Pass:
The Low Pass control acts as a ceiling and doesn’t allow frequencies to the right of the desired setting to be reproduced. The 12 o’clock position is a great starting point. EXAMPLE: If you
adjust the Low Pass to 80Hz, the amplifier will not play frequencies above 80Hz but will play frequencies from 80Hz to the chosen Subsonic frequency.

Level Control Setup:

Ensure that the Level is turned completely to the left prior to turning the system on. Next you should insert a CD or cassette that you are familiar with to use as a reference, and turn the
head unit volume control to about 80% of its full setting. The system sound level will of course be very low, and the following procedures will help you to match the amplifier input
sensitivities properly to the head unit output signal level.
It is important to match the amplifier LEVEL input sensitivity to the Radio/CD output sensitivity. This can be located in the Radio/CD manual.
If the Radio/CD output sensitivity is 2 volts, then adjust the amplifier LEVEL input to 2 volts.

If you are not sure what the Radio output sensitivity is, follow these general guide lines:
Turn the level control up slowly, till you hear distortion, then back off a few degrees on the control. If at any point your amplifier goes into protection, you will need to turn the Level to the
left a bit and then try again. If you reach a point where the output does not increase, stop turning the Level control to the right as the amplifier/subwoofer combo has reached its maxx
output in this application.

Sit back and enjoy the music!

8
 TROUBLESHOOTING A SYSTEM
The key to finding the problem in a misbehaving sound system is to isolate parts of that system in a logical fashion to track down the fault.

Description of the PROTECT system built into all Hifonics amplifiers

The diagnostic system will shut down the amplifier, until reset by turning the head unit off, and back on. This state of affairs will be indicated by the front panel PROTECT
LED lighting up under the following conditions:
1 - A sort circuit on the loudspeaker leads.
2 - An internal amplifier fault that causes a DC offset on the loudspeaker output.

Should the amplifier go into protect mode, simply disconnect all RCA and speaker leads, while keeping +12 volt, power ground and remote leads connected.
1. Now turn the amplifier back on, and if the diagnostic LED lights, the amplifier has an internal fault.
2. If not, plug the RCA cables back, and reset the amplifier. If it goes into diagnostic now, the fault lies in the input, either with bad cables or source unit.
3. If the amplifier seems fine with RCA cables plugged in, connect the speakers, one at a time, and if one of the speakers or its wiring is faulty, it will activate the diagnostic
system.

Amplifier heatsink overheating

The amplifiers will shut down when the heatsink temperature reaches 80 degrees centigrade, and turn back on once the unit has cooled down below that point.
Causes of overheating:
1 - Inadequate cooling - relocate or remount to provide better natural airflow over the fins.
2 - Driving high power levels into low impedances - back off on the volume control, and/or make sure you are not loading the amplifier with less than the recommended
loudspeaker impedance.

Low output power

1 - Check that level controls have been set up properly.
2 - Make sure that the battery voltage, as measured at the amplifier’s +12 volt and ground terminals, is 11 volts or more.
3 - Check all +12 volt and ground connections.

Fuses blowing
1 - The use of loudspeaker impedances below the recommended minimums will draw more current - check.
2 - A short on the main +12 volt cable from the battery to the vehicle chassis will cause the main fuse to blow.
3 - If an amplifier fuse blows continually, with only +12 volt, ground and remote leads connected, the amplifier may be faulty.

System does not turn on

1 - Check all fuses.
2 - Check all connections.
3 - Measure the +12 volt and remote turn on voltages at the amplifier terminals. If these are non existent or low, take voltage measurements at fuse holders, distribution
blocks, the head unit’s +12 volt and remote leads to localize the problem.
Noise problems
System noise can be divided into two categories, hiss, and electrical interference.

Hiss, or white noise

1 - High levels of white noise usually occurs when amplifier level controls are turned up too high - readjust according to the procedures in section ”Setting up systems after
installation for best performance”
2 - Another major problem that can cause excessive hiss, is a noisy head unit - unplug the amplifier input RCA cables, and if the hiss level reduces, the source unit is at fault.

Electrical interference
The inside of an automobile is a very hostile electrical environment. The multitude of electrical systems, such as the ignition system, alternator, fuel pumps, air conditioners,
to mention just a few, create radiated electrical fields, as well as noise on the +12 volt supply and ground. Remember to isolate the problem - first unplug amplifier input RCA
cables, if the noise is still present, check the speaker leads, if not, plug the RCA’s back, and investigate the source driving the amplifier, one component at a time.

A ticking or whine that changes with engine RPM:

1 - This problem could be caused by radiation pickup of RCA cables too near to a fuel pump or a distributor, for instance, - relocate cables.
2 - Check that the head unit ground is connected straight to the vehicle chassis, and does not use factory wiring for ground.
3 - Try to supply the head unit with a clean +12 volt supply directly from the battery +, instead of using a supply from the in dash wiring/fusebox.

A constant whine:
This type of noise can be more difficult to pinpoint, but is usually caused by some kind of instability, causing oscillations in the system.
1 - Check all connections, especially for good grounds.
2 - Make sure that no speaker leads are shorting to exposed metal on the vehicle chassis.
3 -RCA cables are notorious for their problematic nature, so check that these are good, in particular the shield connections.

We have also provided several videos that will help you with your battery,
alternator and even Big 3 upgrades at www.youtube.com/maxxsonicsusainc .
9
 Maxxsonics Limited Warranty

As the manufacturer of Maxxsonics, MB Quart, Autotek, Crunch and Hifonics car audio
products, Maxxsonics USA Inc. Warrants to the original consumer purchaser the amplifier
to be free from defects in material and workmanship for one (1) Year from date of purchase.

All other parts and accessories of the system are warrantied to be free from defects in
material and workmanship for one (1) year from date of purchase. Maxxsonics will
repair or replace at it’s option and free of charge during the warranty period, any system
component that proves defective in materials and workmanship under normal installation,
use and service provided that the product is returned to the authorized Maxxsonics dealer
from where it was purchased. A photo copy of the original receipt must accompany the
product being returned.

Valid purchase receipts will contain the name and address of the authorized reseller.

Any damage to the product as a result of misuse, abuse, accident, incorrect wiring,
improper installation, alteration of date code or bar code labels, revolution, natural
disaster, or any sneaky stuff because someone messed up, repair or alteration out side
of our factory or authorized service centers and any thing else you have done that you
should not have done is not covered.

This warranty is limited to defective parts and specifically excludes any incidental
or consequential damages connected therewith. This warranty is not to be construed
as an insurance policy.

Warranty on installation labor, removal, re-installation and freight charges are not the
responsibility of Maxxsonics USA Inc.

Warranty products damaged as a result of insufficient or improper packing materials

are not covered by this limited warranty and such damaged product will be returned
“as is” at the expense of the owner.

10
 OEM Integration
Accessories
MX-1 Premium High To Low Level Converter MX-3 Bass Controller

* Converts High Level OEM speaker wires to Ultra Clean RCA

Low Level Outputs
* High Level Inputs: Accepts all types of High level Inputs
including floating ground and high voltages up to 30 volts. * Parametric Bass EQ: Provides a wide array of subwoofer output signal
* Audio Signal Sense / Hardwire Turn-On: Audio sense detects shaping controls to enhance bass response and sound quality including
music signals from the OEM wires and activates the MX-1. As Bass Boost, adjustable Bandwidth (wide and narrow), Low Pass and
an option, the module also offers a remote turn-on wire. Subsonic Filter.
* Parametric Bass EQ: Features Bass Boost, adjustable Band * Accepts a wide range of incoming music signal levels while
Width (wide & narrow), Low Pass and Subsonic Filter. accommodating all types of head units and signal processors and
* Clipping Indicators: Visually indicates audio signals Pre-Clip, controlling the output level to the amp to maximize a signal strength up to
Soft Clip and Hard Clip 9 volts.
* Balanced Line Output: Ultra clean DIN variable high voltage * Clipping Indicators: Visual clipping indicators provide indication of
output for driving mono amps. damaging clipped signals to help protect the subwoofer(s) and amplifier.
* Remote Output: Driver circuit to turn on amplifier when Includes pre-clip, soft-clip and full-clip indications.
module activates. * Music Shaping: Shapes the music signal to achieve deep bass notes as
* Bass Remote: Features for subwoofer Level control with built- low as 15Hz.
in clipping indicators. * Bass Remote: Included bas Remote features built-in clipping indicators
* Input & Output Level Control: Allows for gain matching both allows direct bass control from in-dask or under-dash.
radio and amplifier audio signals.

MX-2 Deluxe High To Low Level Converter MX-4 Add A Sub High To Low Level Converter

* Converts High Level OEM speaker wires to Ultra Clean RCA * Converts High Level OEM speaker wires to Ultra Clean RCA Low Level
Low Level Outputs Outputs
* High Level Inputs: Accepts all types of High level Inputs * High Level Inputs: Accepts all types of High level Inputs including
including floating ground and high voltages up to 30 volts. floating ground and high voltages up to 30 volts.
* Audio Signal Sense / Hardwire Turn-On: Audio sense detects * Audio Signal Sense / Hardwire Turn-On: Audio sense detects music
music signals from the OEM wires and activates the MX-2. As signals from the OEM wires and activates the MX-4. As an option, the
an option, the module also offers a remote turn-on wire. module also offers a remote turn-on wire.
* Remote Output: Driver circuit to turn on amplifier when module * Remote Output: Driver circuit to turn on amplifier when module activates.
activates.

11
PART#: A1209