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Shining a Light on Headlight Beam Patterns: What You Need to Know

Beam Pattern

Every fall, car stereo and automotive accessory shops install thousands of lighting upgrades. These days, the most common upgrade is a set of LED headlight bulbs that fit into the stock light locations. While seemingly simple, the resulting beam pattern can be negatively affected if the chosen bulbs are not designed specifically for the lens or projector application. Let’s take a close look at understanding headlight beam patterns.

What Is a Headlight Beam Pattern?

Let’s kick this off with a bit of a definition. A beam pattern describes how the light from the headlight assembly illuminates the road. A lot of science goes into designing the reflector and lens in a headlight to focus the light energy where it does the most good. Of equal importance, headlights are designed to minimize blinding oncoming drivers. If an approaching driver can’t see correctly because your headlights aren’t aimed or functioning properly, everyone on the road is at risk. Crazy, bright headlights that blind everyone aren’t just dangerous for other drivers; they likely don’t work well at long distances. This reduces your safety.

Beam Pattern
Reputable aftermarket lighting companies like Baja Designs offer clearly defined beam patterns from their upgrades.

Off-Road Versus On-Road Lighting

In an off-road application, the driver wants as much light coverage as possible. If the trees are lit up, that isn’t a significant problem. However, on the road, we need to control where all the light from the vehicle goes. The issue with this light is that the beam is still directed at the oncoming driver’s eyes. This is incredibly dangerous as it prevents them from seeing any obstacles in front of them, including your vehicle, the road, or animals.

Beam Pattern
Side-view of a typical cone-shaped beam pattern from an off-road spotlight.
Beam Pattern
Overhead view of a typical cone-shaped beam pattern from an off-road spotlight.

The solution might be to angle the lights down so the top of the beam is below horizontal. The problem with this method is that the hot spot in the middle of the light is no longer way out in front of the vehicle. Most of the light will illuminate an area about 50 feet away. We don’t need to see this part of the road as much as we need to see 100 feet and beyond. Further, with the foreground so bright, the iris in our eyes will close to reduce the total light we see. This reduces how much we can see objects in the shadows or long distances.

Beam Pattern
Aiming the lighting down so the top of the beam is below horizontal will help reduce glare.
Beam Pattern
Lighting aimed too low will illuminate the foreground too much, reducing visibility at long distances.

Proper Automotive Headlight Systems

Many new cars and trucks use LED projector headlights; although some models may use reflector-type headlights, HID lights, or halogen bulbs. In the case of projector light assemblies, a cut-off feature assists in creating a good beam pattern. The goal of the lighting system is to illuminate the road as far as possible without making the foreground too bright. This requires a well-focused hot spot in the middle of the light and a way to prevent oncoming drivers from being blinded.

Beam Pattern
A metal shutter is placed in the headlight assembly to prevent oncoming drivers from being blinded.

Looking at the image closely, you’ll see a metal plate in the middle of the light assembly. The plate has a notch in it. That plate is oriented so it bisects the hot spot of the light beam. If the vehicle is pointed at a wall, you will see the step down on the left side of the light and a hot spot in the middle of that step.

Beam Pattern
A photo of the headlight beam pattern from a new SUV with LED projector headlights.

Asymmetric Low Beam Pattern

The step in the shutter reduces the light that shines on the left side of the road. This allows the lane in front of you to be well-illuminated while reducing glare for oncoming drivers. This is called an Asymmetric Low Beam Pattern. Here’s an aerial image of the beam pattern from the SUV to show the effect on the ground.

Beam Pattern
An aerial photo of the beam pattern produced by the headlights illuminating the fence in the above image.

If you look closely at the pattern produced by the headlights, you can see a beam of light extending almost off the image’s right side. This light is in line with the vehicle’s direction of travel and will light the road far off into the distance.

Beam Pattern
This second photo of the beam pattern further accentuates how light is focused towards the right side of the road.

What to Know When Upgrading Headlights

If you plan on upgrading the lighting on your car, truck, or SUV, it’s paramount that the changes you make don’t negatively affect the beam pattern. First, the hot spot should remain in the center and not dramatically brighten the foreground. The cutoff must remain sharp so as not to blind oncoming drivers. Technically, any bulbs you install should comply with FMVSS and be marked accordingly to be legal for on-road use.

Something is wrong if the lights don’t seem as bright or there are streaks of light pointing off to the side or upward. Have the shop reinstall the original bulbs until you find a perfect solution.

This article is written and produced by the team at www.BestCarAudio.com. Reproduction or use of any kind is prohibited without the express written permission of 1sixty8 media.

Filed Under: ARTICLES, Lighting, RESOURCE LIBRARY

Product Spotlight: KICKER KEYLOC

KICKER KEYLOC

There are a dozen or so high-quality line output converters available to help your installer integrate an amplifier into a factory-installed audio system. That said, most of them are simple devices that do nothing more than adjust voltage gain and perhaps apply some equalization to the signal. KICKER’s KEYLOC is a unique solution because it features a built-in digital signal processor that undoes equalization, delays, and all-pass filters applied to the factory signal. The goal is to establish a clean signal that you can build on. Let’s check out the outstanding KICKER KEYLOC.

Basic Features of the KICKER KEYLOC

Let’s start with the basics. The KEYLOC is a two-channel line output converter that can accept up to 10 volts of signal in low-level mode and an impressive 40 volts in high-level mode. In low-level mode, the KEYLOC presents a 60-ohm load to the driving amplifier. Many factory-installed source units and amplifiers will go into protection mode without a proper load. External resistors are available from KICKER if needed for high-level operation. The maximum output of the KEYLOC is 10 volts.

The KEYLOC measures 5.5 by 2.75 inches in footprint and is 1.375 inches thick. A Molex connector on the left side includes two speaker input channels, power and ground connections, and remote turn-on and remote output wiring. The remote output activates automatically when the KEYLOC detects a DC offset voltage on the input speaker wires, enabling an aftermarket amplifier to turn on. There are a pair of RCA output jacks on the right side of the chassis to feed your new amplifier.

The top panel of the KEYLOC features two stereo potentiometers and a display with five LEDs. The pots are for adjusting input sensitivity and output voltage. The LEDs indicate power and are part of the signal testing and KEY processing features of the KEYLOC.

KICKER KEYLOC
The LED display on the front panel of the KEYLOC provides your installer with information about frequency response and correction processing.

Audio Analysis Tool

Depending on the design of your factory audio system, it might be difficult to find a full-range signal. The Low, Mid, and High LEDs on top of the KEYLOC can be used with the provided pink-noise test track to determine whether you have a full-range signal. The Low indicator illuminates when there is sufficient audio information in the 20 Hz to 200 Hz range. The Mid indicator monitors 200 Hz to 2 kHz, and the High LED monitors audio above 2 kHz. If you are missing low- or high-frequency information, the KEY processing will not produce a full-bandwidth signal for your new equipment.

The KEY to Audio Excellence

The KEYLOC uses KICKER’s patent-pending KEY algorithm to analyze a special audio test signal. The signal includes sine sweeps, pink noise, and impulses, which reveal frequency response, signal delay, and all-pass filter processing. Once measured, the KEYLOC applies its own signal processing to eliminate these attributes from the audio signal. The result is a flat frequency response signal that will allow new speakers, amplifiers, and processors to sound amazing. The process is fully automated and takes between two and 10 minutes to complete. Your installer can even temporarily bypass the correction to demonstrate how much the system has improved thanks to the KEYLOC.

KICKER KEYLOC
The KEYLOC is small enough to hide behind the radio in your dash, yet powerful enough to correct even the most complex audio signals.

Why You Need the KICKER KEYLOC

Factory-installed audio systems are typically designed to extract the best possible performance from inexpensive speakers. As such, radios and amplifiers include signal processing such as equalization, delays, and all-pass filters to create an optimized listening experience. Don’t be fooled: this processing is present even in simple “radio-only” systems and isn’t exclusive to premium systems with complex multi-channel amplifiers.

The goal of upgrading a car audio system is, of course, to make it sound better. As such, you are likely to add subwoofers and new speakers to the vehicle. The equalization that worked with the factory speakers is not likely to be ideal for the higher-performance options you’ve chosen. Eliminating factory processing with a product like the KICKER KEYLOC is crucial to achieving great sound in your car, truck, or SUV. The KEYLOC is also great for motorcycles, side-by-sides, and marine applications.

Visit a KICKER Dealer Today

When it’s time to make your vehicle’s stereo sound better, drop by an authorized KICKER retailer to find out whether the KEYLOC is needed to undo the signal processing built into your factory-installed audio system. You can find an authorized KICKER retailer near you using the Dealer Locator on the KICKER website.

Be sure to follow Kicker on Facebook, Instagram and YouTube to keep up with the latest product releases from our friends in Stillwater.

This article is written and produced by the team at www.BestCarAudio.com. Reproduction or use of any kind is prohibited without the express written permission of 1sixty8 media.

Filed Under: ARTICLES, Car Audio, PRODUCTS, RESOURCE LIBRARY Tagged With: KICKER

Managing Large Music Collections in Your Car

Music Collection

Having music playing while driving is not only entertaining, but it can be very relaxing. Enjoying your favorite songs while stuck in traffic or on a long drive can help time pass much quicker. We recently received a question from one of our readers about the best way to manage a large music collection. Specifically, they wanted to know what features different radios offer that make accessing a specific artist, album, or track easier. This is a great question, so let’s explore the answers.

Radio-Specific Storage Limits

So, what would be considered a large music collection? One BestCarAudio.com team member loves collecting music. He has over a terabyte of music on his home server, comprising almost 65,000 songs. That’s way more than would ever be reasonable to take on the road with you.

In fact, most modern car radios can’t handle that many tracks. The Sony XAV-9000ES, for example, allows up to 25,000 tracks to be read from a USB storage device. The folder structure itself limits other brands. For example, we looked at the specifications for a Kenwood radio, which allows for up to 999 files per folder, 9,999 folders, and a maximum folder depth of eight layers. We also checked the owner’s manual for an Alpine multimedia receiver. The particular unit we checked lists a limit of 10,000 files and folders, including the root folder. We’ve seen marine radios with a limit of 999 songs and a maximum of 255 folders.

The takeaway is that you must research this specific aspect of the radio you are considering before purchasing. Many consumers assume their radio will recognize all their tracks and play almost anything. If you forget to check, please don’t complain about it afterward. The manufacturers can’t change these limits; they are often based on the amount of memory connected to the radio’s microcontroller.

Modern Factory-Installed Infotainment Systems

For real-world testing, we copied 13 GB of music onto a 64 GB SanDisk USB memory stick. There are 27 folders containing 683 files. This wouldn’t be considered a massive amount of music, but it will help us determine how different source units handle finding a specific track.

We connected the memory stick to the infotainment system in a staff member’s 2025 Mazda CX-70 Turbo Signature, equivalent to the US Premium Plus model. The radio displayed an error message saying it didn’t support the connected device. It turns out that the radio in this brand-new vehicle can’t read USB memory sticks formatted with exFAT. Storage devices must be either FAT or FAT32.

Panasonic manufactures the “radio” in this vehicle, Automotive Systems. Bose provides the amplifier and speakers. This is referred to as a silver box solution. The radio itself has no integrated interface. Visteon manufactures the screen on the dash. The “radio” has the AM/FM tuner, satellite radio receiver, GPS receiver, and the inputs for the pair of USB-C ports in the center console. The radio sends a data stream to the Bose amp under the passenger seat, which then handles the signal processing and drives the speakers and subwoofer.

We tried again after searching for an old 8 GB stick and hunting down a USB-C to USB-A adapter. Now, the radio struggled with the file formats. It wouldn’t play 88.1 kHz, 24-bit FLAC audio files. Remember what we just said about ensuring the radio will play what you want? Yeah, we figured that out by trial and error. After a third trip back to the computer and some work in Adobe Audition, the content was finally working.

Mazda CX-70 Infotainment System

So, how does the Mazda handle navigating extensive music collections? You can search through folders pretty easily. It’s just a few presses on the control wheel in the center console to select the Folder option. If you want to search for a specific track alphabetically, you can choose the Library option, then select from Artists, Albums, Songs, Genres, Composers, or Playlists. From there, you will be presented with a list of options based on your chosen criteria. You can toggle to the right, scroll through the alphabet, and select a song. It’s a lot of button presses, but it works well.

Music Collection
A Panasonic-made Mazda CX-70 and CX-90 radio module.

Next, we tested a 2023 Nissan Rogue with Bose speakers and amplifier. Just for clarity, Bose doesn’t make radios. Robert Bosch GmbH manufactures this particular unit. We connected the SanDisk stick to no avail, so it was back to the old 8 GB stick. If you want to carry around a lot of music on a USB drive, support for a large drive will be the limiting factor.

Music Collection
Pressing the rotary controller displays a menu option to let you search for music.
Music Collection
Once you’ve selected how to sort your music, you can quickly navigate alphabetically.

With our little USB loaded with a few hundred songs, we set off to run some errands. We recalled seeing some voice recognition features outlined in the owner’s manual—yes, some of us read the manual. We pressed the voice button and asked the system to play a song. It informed us that it couldn’t because of how our smartphones were connected. If you connect your smartphone using Apple CarPlay or Android Auto, it appears to override the built-in voice commands.

Sadly, our USB listening experience took a turn for the worse. After about 30 minutes of driving, the radio encountered issues updating the screen. The results are shown below. It seemed to work fine the next day, but we didn’t play it for long.

Music Collection
After 30 minutes of listening to music from a USB stick, the Mazda radio encountered a display error.

Sony Radio Music Management

We checked with our Editor-in-Chief to see what he had on the test bench. He’d just unpacked a Sony XAV-AX3700 multimedia receiver, so we asked him to try the same test on that. With a large memory stick full of music, the Sony could display all the tracks he’d copied and had no problem reading the exFAT memory stick or playing the high-resolution FLAC audio files. Specifically, the XAV-AX3700 will play FLAC, ALAC, DSD, and WAV high-resolution audio files.

Sony makes it very easy to choose songs from different folders when it comes to finding songs. Navigating to the root folder and selecting sub-folders was straightforward. It would be wise to remember this when copying files to the drive. Putting 200+ random songs in a folder likely isn’t the best strategy. Sorting them by artist, album, or genre while copying will make finding what you want easier when driving.

Music Collection
The Sony XAV-AX3700 made it easy to pick folders from the large USB memory stick.
Music Collection
Picking a track is quick and easy once you’ve selected a folder.

Smartphone Music Storage

Now that we’ve examined a few radio behaviors regarding music stored on a USB memory stick, let’s consider using a smartphone as your music storage device. Apple’s Siri and CarPlay, Google Assistant, and Android Auto make it incredibly easy to access music stored on the phone.

Let’s say you have purchased eight Aerosmith albums. These will likely include Permanent Vacation and Pump. If you want to listen to “Dulcimer Stomp,” activate the voice recognition feature and say, “Play ‘Dulcimer Stomp’ by Aerosmith.” The system will find the track and start playing it automatically. You can also ask it to “play the album Pump by Aerosmith.”

Music Collection
If you have music stored on your smartphone, asking CarPlay or Android Auto to play it is incredibly intuitive.

Cloud-Based Streaming

If you don’t have the song stored on your phone, another option is to subscribe to a service like Spotify, YouTube Music, or Qobuz. For about USD 11.00 a month, you can access music from virtually every professional recording artist you want. These services also offer discounts for two users or even family plans that allow up to six users. Spotify and YouTube Music also provide discounts for students.

Is streaming as good as playing a FLAC or WAV file on a USB stick? If your service offers a high-quality stream, the tracks will sound very good over a wired connection between your phone and the radio. However, any compression will remove subtle details. You might hear the difference if your car’s audio system is good enough. With the basic audio quality settings in Spotify, for example, you can detect a loss in quality on a basic six-speaker factory-installed audio system.

Music Collection
Cloud-based streaming services provide instant access to almost any track you can think of. Just ask for it, and the music starts playing.

Test Your Music Collection Before Buying

What’s the takeaway from our testing? At first, the voice command capabilities of the Mazda seemed promising. Unfortunately, they didn’t work as expected. After that, the system required too many button presses and toggles to reach what we needed. In contrast, the Sony was simple, intuitive, and—best of all—worked seamlessly with our large memory stick and music files.

If you have an extensive music collection and want to enjoy it in your vehicle, always test the interface before making a purchase. This applies not only to aftermarket radios but also to new cars. Yes, we would absolutely avoid buying a vehicle if its infotainment system was difficult to use. You may recall that Ford CEO Jim Farley recently apologized for issues with their Sync infotainment system—this is the second time Ford has had to address these problems.

When shopping for a new car radio, visit a local specialty mobile enhancement retailer. Bring a USB memory stick or your phone and connect it to the radio you’re considering. Ensure it functions the way you want. If not, try a different model or even a different brand.

This article is written and produced by the team at www.BestCarAudio.com. Reproduction or use of any kind is prohibited without the express written permission of 1sixty8 media.

Filed Under: ARTICLES, Car Audio, RESOURCE LIBRARY

Stay Ahead of Thieves: The Power of GPS Tracking and Location Alerts!

Location Alert

Unfortunately, concern over car and truck theft continues to increase. Thieves seem to work tirelessly to conjure up methods of bypassing factory-installed security systems. Our experience has shown that while a GPS-based tracking system might not prevent vehicle theft, it is your only hope of recovering your vehicle. Let’s look at geofence and location-based alerts to understand how they can help with day-to-day vehicle use and during those times when criminals have dragged your pride and joy away with a tow truck.

What Is a GPS-Based Tracking System?

When discussing a tracking system, we refer to something more elaborate than an Apple AirTag, a Tile, a Samsung SmartTag, or a Chipolo. While these devices are great for finding your keys, tracking a package, an unplanned world tour, or your luggage, they aren’t the best solution for helping you find your vehicle.

A professional-grade tracking solution combines three essential parts. First, there is a cellular data radio. This is the part of your smartphone that lets you surf the Internet. It works like your cable modem at home to send data to the Internet. Instead of wires, it sends the information wirelessly to a cell tower. Data to and from the cell tower is connected to the Internet.

Location Alert
Vehicle tracking systems use cellular data communication to report location information.

Second, the tracking device will have a global navigation satellite system (GNSS) receiver. The Global Positioning System (GPS) is North America’s most commonly discussed system. However, other similar systems are in use. GLONASS, BeiDou, and Galileo are some of the different systems used worldwide. They all work the same way to allow the receiver to pinpoint a location, elevation, and even direction of travel.

Finally, a microcomputer chip takes data from the GNSS receiver and sends it to a data server using the cellular modem.

Location Alert
A look inside a modern vehicle tracking system module.

How Do Vehicle Tracking Systems Work?

Let’s say you’ve had a local specialty mobile enhancement retailer install a tracking system in your car or truck. If you want to know where your vehicle is, you’ll tap a button on a smartphone app or a website. That software will send a position request to the microcomputer in the tracking system over the Internet and cellular data network. The microcomputer will request the location information from the GNSS receiver and then send that back to the application you use. The application will display the vehicle’s location on a map service like Google Maps.

Some more elaborate tracking systems will have software that pushes information to your smartphone. For example, the Drone system from Firstech, the company that manufactures Compustar remote car starters, will notify the owner if the vehicle moves without the doors being unlocked. This could indicate someone attempting to tow the vehicle.

Location-Based Alerts

To this point, we’ve talked about the operation of tracking systems. However, the software these devices integrate with is crucial to the convenience and protection they offer. This leads us to a discussion of location-based alerts. For example, let’s say you are the parents of a teenager borrowing a family vehicle. If they can use the car to drive to school or work, you could use the tracking software to set up an alert around those geographic locations. You’ll receive an alert on your smartphone when the vehicle arrives at or leaves that area.

Location Alert
Here’s an example of an address-based geofence created around a school.

Location Alert Configuration Options

Depending on the brand of tracking system you are using, you may be able to define whether you receive an alert when the vehicle enters or exits a specific area. If you own, operate, or manage a fleet of vehicles and need to know when one is near a particular location, you can create a geofence around a parking lot. The image below shows a large parking lot outlined with a polygonal geofence. You could use this information to know when a driver left and returned in a company-owned vehicle.

Location Alert
Premium tracking solutions offer many options for defining location-based alerts.

A secondary benefit of a geofence, like what we’ve shown above, is the ability to monitor the operation of company-owned vehicles after work hours. For example, if you own a service company and your staff finishes work at 6 p.m., the vans should remain in your parking lot until at least 7:30 the following morning. If you’ve created a geofence around your facility, and a van leaves at 3 a.m., you’ll get a notification on your smartphone within a few seconds. There could be a legitimate emergency service call or someone stealing the vehicle.

Location Alert
All modern courier and delivery services use real-time location tracking on their fleet.

Advanced Safety Features

Tracking systems can provide more than location-based information for corporate applications. Large corporations spend significant amounts of money on insurance each year. Many studies have proven that employees drive better when they know they are being monitored. Modern tracking systems can record vehicle speed and send a warning if a threshold is exceeded. More advanced systems might include an accelerometer or software to monitor the vehicle for abrupt acceleration, braking, or even cornering too quickly.

Location Alert
Commercial-grade tracking systems offer a wide range of monitoring options.

Battery Backup for Premium Protection

Sadly, car thieves are clever these days. When they steal a car, they often park it in a public lot a few cities away. If the vehicle is still there after a few days, the chances of it having a tracking system are slim. This saves them the time and hassle of searching through the vehicle for a tracking system.

Another method they use is to disconnect the battery. This is common if the vehicle will be shipped out of the country or if the thieves want to tow it somewhere so they can look for tracking systems or program new keys. A tracking system usually won’t work when the battery is disconnected. However, many tracking systems include a built-in backup battery. Most of these systems send a notification when the battery is disconnected and continue to provide updates for at least three or four hours.

Location Alert
The Drone X1-Max includes a backup battery lasting up to four hours.

Protect Your Vehicle With a Premium Tracking System Today!

While it’s logical to worry about thieves stealing luxury models like Lexus, BMW, Audi, Mercedes-Benz, Range Rover, or Porsche, the reality is that an F-150, Silverado, Civic, CR-V, Ram 1500, Sonata, or Highlander are much more likely candidates for auto theft. Even if you’ve taken precautions like locking the vehicle in the garage and blocking it with a less tempting car, determined thieves always watch for opportunities to take your pride and joy.

A vehicle tracking system that’s appropriately integrated into the vehicle provides you with almost the only chance of recovering your car or truck. Even then, you need to act promptly and get the authorities involved. Drop by a local specialty mobile enhancement retailer today to find out what tracking solutions are available to keep tabs on and add convenience to your vehicle.

This article is written and produced by the team at www.BestCarAudio.com. Reproduction or use of any kind is prohibited without the express written permission of 1sixty8 media.

Filed Under: ARTICLES, Remote Car Starters, RESOURCE LIBRARY

Why Battery Voltage is Key to Your Car Audio Amp’s Performance

Battery Voltage

A short while ago, while testing an amplifier’s maximum power output, we observed how significantly the power increased with higher supply voltage. This observation made us realize that we’ve never thoroughly examined the relationship between a vehicle’s battery voltage and a car audio amplifier’s maximum power output. It’s time to address that.

Why Does Battery Voltage Matter to Amplifier Power Production?

Today, most car audio amplifiers use loosely or completely unregulated power supplies. As a result, the positive and negative voltages available to feed the output devices become a fixed multiple of the supply voltage. For instance, if the battery rests at 12.5 volts, an amp might generate 500 watts. However, if that voltage increases to 14.4 volts, the amp might produce 600 watts.

Maximum Supply Voltage Limits

To ensure product reliability, companies typically set a maximum voltage limit, which prevents the amp from producing excessive power. But why is this important? All car audio amplifiers convert some of the power they consume into heat. The heatsink and cooling system must dissipate a specific amount of heat energy to control the amp’s temperature. Notably, as the power level increases, the heat that needs to be expelled also rises because amplifier efficiency remains constant at maximum power.

For example, consider an amplifier that is 80% efficient and produces 500 watts of power; it converts 125 watts into heat. If provided with more supply voltage, the amp might produce 600 watts, requiring the heatsink to manage 150 watts of heat. This is likely manageable. Now, if the amp could produce 700 watts at 16 volts, it would have to manage 175 watts of heat—a significant increase from 125 watts. Unless the chassis is massive or there are numerous 0.3 watts, stepping from 14 to 15 volts increased the output by 56 watts.

Why does the power level increase more with each voltage jump? Power is proportional to the square of the voltage divided by the load resistance, according to the formula V^2 ÷ R. Thus, a slight increase in voltage results in a moderate power increase.

How Can You Maximize Voltage to Your Car Audio Amplifier?

Without resorting to unreliable aftermarket alternators or maintaining battery banks, the simplest way to ensure your amplifier receives all the power your battery and charging system produce is to have the technician working on the vehicle install a high-quality, all-copper power cable large enough for the amplifier’s current requirements.

In a car audio installation requiring about 15 feet of power wire, we suggest the following cable sizes: 10-AWG for loads up to 22 amps, 8-AWG for loads up to 35 amps, and 6-AWG (if you can still find it) for loads up to 56 amps. For loads up to 88 amps, a 4-AWG cable suffices. If you must pass 218 amps of current over 15 feet, a cooling fans, this difference means the amp won’t run as long before overheating.

Moreover, increased supply voltage presents another issue: the maximum voltage ratings on components. For example, most amplifiers include filtering capacitors on the power connections, which might be 16-volt, 1000 μF units. To accept more than 16 volts, the manufacturer might need to upgrade to 25-volt capacitors. These higher-voltage capacitors are larger and more expensive. Additionally, diodes and other protection circuitry components might need upgrades to handle higher operating voltages, further increasing costs with little performance gain under normal conditions.

Battery Voltage
High-quality car audio amplifiers will have capacitors on the power connections to reduce noise and store energy.

Testing Amplifier Maximum Power Output

We decided to test this further using a Rockford Fosgate Punch-Series P300X2 two-channel, full-range amplifier. Recently, we re-tested several amps with our new power supplies, and although this amp wasn’t on the schedule, we decided to test it anyway.

We set up the amp and connected it to a bank of 300-watt, low-inductance ceramic power resistors configured for a four-ohm load. Initially, we set the power supply to provide 16 volts to the amp, just under its maximum upper voltage limit. We then increased the signal to the amp until the output signal was within 1 to 1.05% THD+N. Afterward, we decreased the supply voltage and signal, measuring power output at 0.5-volt intervals until reaching the minimum power output of the power supplies. To comply with the ANSI/CTA-2006-D car audio amplifier power measurement standard, we measured power at 14.4 volts instead of 14.5 volts.

Battery Voltage

The difference in power output between 11.25 and 16 volts is substantial, as the chart shows. With an increase of 4.8 volts, the amp nearly doubled its power output. We simultaneously captured current draw measurements to calculate efficiency. This class-BD amplifier remained between 67% and 68% efficient throughout the entire range of measurements.

In our full Test Drive Review of the amplifier, our original maximum power rating was 360.1 watts at 14.15 volts. This time, we measured 398 watts at 14.4 volts. While you likely won’t hear the 38-watt difference, it’s worth noting that an amp rated to produce 300 watts made 400 watts. Rockford Fosgate fans already know they’re getting more than they paid for.

Plotting Amplifier Power vs. Battery Voltage

Let’s examine that chart as a graph.

Battery Voltage
Amplifier power output at 1% THD+N (+5, -0%) versus battery voltage.

Interestingly, while the relationship between the maximum power an amp can produce and the supply voltage appears linear, it’s not. The increase from roughly 12 to 13 volts yielded 48.3 more watts. The jump from 13 to 14 volts added 50-AWG power cable is necessary. For up to 289 amps, use a 2/0-AWG cable. Finally, if you have a massive amplifier or multiple smaller amps, 4/0-AWG cable over 15 feet is suitable for 422 amps. While these cables can undoubtedly pass more current, the voltage drop for these calculations is set not to exceed 0.35 volts over the entire length. Don’t forget to account for losses in the return path, which, if the cabling size and length are the same, would result in a 0.7-volt drop.

The Math on Power Output Versus Power Wire Size

To illustrate more clearly, for our 300-watt amplifier, losing 0.7 volts at the power terminals reduces the output by around 35 watts, roughly 10% of the rated power. If you think skimping on a power cable is a good idea, here’s the math to prove otherwise.

Consider this amp’s maximum theoretical power output with 15 feet of 10, 8, and 4-AWG cables for power and ground connections. Assuming the electrical system could maintain 14.4 volts at the battery, a 15-foot run of 10-AWG power and ground cable would reduce the voltage at the amp to 13.11 volts. With 8-AWG cables, the voltage would drop to 13.59 volts, while using 4-AWG cables reduces the drop to 14.08 volts. If you splurged on 0-AWG cable, the drop across the cable would result in the amp receiving 14.27 volts. You might have expected less drop across 30 feet of 0-AWG power wire, but that’s not the case.

If you’re curious why Rockford Fosgate overrates its amplifiers, it’s because most installations lack adequately large power and ground cables. If you waste a volt across the power wire, in the case of the Punch P300X2, the maximum power output drops by about 10%. You’ll still get all the power you paid for, but not as much as possible. Therefore, investing in larger power and ground cables is more cost-effective than buying the next-size car audio amplifier in a series.

Battery Voltage
Rockford Fosgate’s 1/0 AWG power wire is CTA-2015 and BC-5W2 compliant.
Battery Voltage
KICKER’s 1/0 power wire is 100% OFC and meets the full American Wire Gauge (AWG) size specification.
Battery Voltage
Audison Connection 1/0 power wire was one of the first super-flexible designs and is tinned for marine applications.

Don’t Starve Your Car Audio Amp for Voltage

Even after an average of three and a half decades in the mobile enhancement industry, none of our team members recall anyone publishing similar data. It may have happened, but we haven’t seen it. This data highlights the critical need for adequately sized power cables. If you’re considering upgrading your car audio system with high-power amplifiers, ensure the wiring is sufficient to maximize the power output from your chosen amp. Visit a local specialty mobile enhancement retailer today. Choose an amplifier that sounds great and is efficient, then ensure it is installed with the largest power and ground cables you can afford.

This article is written and produced by the team at www.BestCarAudio.com. Reproduction or use of any kind is prohibited without the express written permission of 1sixty8 media.

Filed Under: ARTICLES, Car Audio, RESOURCE LIBRARY

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