Orion Car Audio 2500D User Manual

INTRODUCTION  
Thank you for your purchase of Orion's 600D, 1200D, or 2500D power amplifier. Each Orion  
amplifier is designed to be the leader in its class offering the most power, advanced fea-  
tures, and extreme ease of use. In high-end sound systems or high SPL systems, Orion ampli-  
fiers will give you years of trouble-free performance.  
600D - 600 Watt single-channel Class D amplifier with built-in fully variable high-  
pass, low-pass, or band-pass crossover with INTELLi Q. Equipped with optional  
remote gain, the 600D is capable of one-channel operation with a maximum  
power of 600 Watts into 1W.  
1200D - 1200 Watt single-channel Class D amplifier with built-in fully variable  
high-pass, low-pass, or band-pass crossover with INTELLi Q. Equipped with option-  
al remote gain, the 1200D is capable of one-channel operation with a maximum  
power of 1200 Watts into 1W.  
2500D - 2500 Watt single-channel Class D amplifier with built-in fully variable  
high-pass, low-pass, or band-pass crossover with INTELLi Q. Equipped with option-  
al remote gain, the 2500D is capable of one-channel operation with a maximum  
power of 2500 Watts into 1W.  
The installation of all Orion components will determine the overall performance result.  
Improper installation will not only limit the performance of your Orion system but also  
potentially compromise the reliability of this amplifier. To ensure proper sonic results and  
component reliability, please refer to your authorized Orion dealer for installation assis-  
tance or advice. If you decide to perform the installation yourself, be sure to read the entire  
manual before beginning the installation.  
What’s in the Box  
(1) Amplifier  
(1) Spare fuse(s) (600D and 1200D only)  
(1) Allen wrench 2.5mm  
(1) Allen wrench 3mm  
(4) #8 self-tapping black Phillips head pan head screws  
(1) Amplifier installation and operation manual  
PRACTICE SAFE SOUND™  
Continuous exposure to sound pressure levels over 100dB may cause permanent hearing  
loss. High power automotive sound systems can generate sound pressure levels in excess of  
130dB. When playing your system at high levels, please use hearing protection and avoid  
long term exposure.  
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©2003 Directed Electronics, Inc.  
LIMITED TWO-YEAR CONSUMER WARRANTY  
Directed Electronics, Inc. promises to the original purchaser, to replace this product should  
it prove to be defective in workmanship or material under normal use, for a period of two  
years from the date of purchase by the dealer as indicated by the date code marking of the  
product PROVIDED the product was installed by an authorized Directed dealer. During this  
two year period, there will be no charge for this replacement PROVIDED the unit is  
returned to Directed, shipping pre-paid. If the unit was installed by anyone other than an  
authorized Directed dealer, the warranty period will be 1 year from date of purchase by the  
dealer as indicated by the date code marking of the product. During this 1 year period,  
there will be no charge for this replacement PROVIDED the unit is returned to Directed,  
shipping pre-paid. This warranty is non-transferable and does not apply to any unit that has  
been modified or used in a manner contrary to its intended purpose, and does not cover  
damage to the unit caused by installation or removal of the unit. This warranty is void if the  
product has been damaged by accident or unreasonable use, neglect, improper service or  
other causes not arising out of defects in materials or construction. ALL WARRANTIES  
INCLUDING BUT NOT LIMITED TO EXPRESS WARRANTY, IMPLIED WARRANTY, WAR-  
RANTY OF MERCHANTABILITY, FITNESS FOR PARTICULAR PURPOSE, AND WARRANTY  
OF NON-INFRINGEMENT OF INTELLECTUAL PROPERTY ARE EXPRESSLY EXCLUDED TO  
THE MAXIMUM EXTENT ALLOWED BY LAW, AND DIRECTED NEITHER ASSUMES NOR  
AUTHORIZES ANY PERSON TO ASSUME FOR IT ANY LIABILITY IN CONNECTION WITH  
THE SALE OF THE PRODUCT. DIRECTED HAS ABSOLUTELY NO LIABILITY FOR ANY AND  
ALL ACTS OF THIRD PARTIES INCLUDING ITS AUTHORIZED DEALERS OR INSTALLERS.  
Unit must be returned to Directed, postage pre-paid, with: consumer's name, telephone  
number, and address, authorized dealer's name and address, and product description. IN  
ORDER FOR THIS WARRANTY TO BE VALID, YOUR UNIT MUST BE SHIPPED WITH  
PROOF OF INSTALLATION BY AN AUTHORIZED DIRECTED DEALER. ALL UNITS  
RECEIVED BY DIRECTED FOR WARRANTY REPAIR WITHOUT PROOF OF DIRECTED  
DEALER INSTALLATION WILL BE COVERED BY THE LIMITED 1 YEAR PARTS AND  
LABOR WARRANTY. BY PURCHASING THIS PRODUCT, THE CONSUMER AGREES AND  
CONSENTS THAT ALL DISPUTES BETWEEN THE CONSUMER AND DIRECTED SHALL BE  
RESOLVED IN ACCORDANCE WITH CALIFORNIA LAWS IN SAN DIEGO COUNTY, CALI-  
FORNIA.  
NOTE:  
This warranty does not cover labor costs for the removal and reinstallation of the  
unit.  
Record Your Serial Number and Date  
Model:  
__________________________________________________  
Serial Number:  
__________________________________________________  
Date of Purchase: __________________________________________________  
Purchased from: __________________________________________________  
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©2003 Directed Electronics, Inc.  
SPECIFICATIONS  
Amplifier Section  
Orion 600D  
250 x 1  
400 x 1  
600 x 1  
Yes  
Orion 1200D  
425 x 1  
Orion 2500D  
1200 x 1  
1700 x 1  
2500 x 1  
No  
Power Output 4W (Watts)1  
Power Output 2W (Watts)2  
Power Output 1W (Watts)  
Externally Bridgeable  
Remote Gain Function  
725 x 1  
1200 x 1  
Yes  
Yes  
Yes  
Yes  
Distortion at Rated Power < 0.9% THD+N  
< 0.9% THD+N  
< 0.9% THD+N  
Frequency Response  
20Hz to 200Hz  
+0, -1dB  
20Hz to 200Hz  
+0, -1dB  
20Hz to 200Hz  
+0, -1dB  
Linear Bandwidth  
10Hz to 500Hz  
3dB  
10Hz to 500Hz  
3dB  
10Hz to 500Hz  
3dB  
Signal-to-Noise Ratio at  
Rated Power  
> 80dB  
> 80dB  
> 80dB  
Damping factor  
Input Sensitivity  
Input Impedance  
Fuse Type  
> 50  
200mV to 5V  
40kW  
> 50  
200mV to 5V  
40kW  
> 50  
200mV to 5V  
40kW  
(1) 50 Amp MAXI (3) 40 Amp ATC  
None  
Dimensions  
16.4"x10.5"x2.3" 18.7"x10.5"x2.3" 27.2"x10.5"x2.3"  
Weight  
13 lbs.  
16 lbs.  
24 lbs.  
Crossover Section  
Low Pass Crossover  
Continuously  
Variable  
Continuously  
Variable  
Continuously  
Variable  
2nd Order /  
4th Order  
2nd Order /  
4th Order  
2nd Order /  
4th Order  
Low Pass Frequency Range 30Hz to 250Hz  
30Hz to 250Hz  
30Hz to 250Hz  
High Pass Filter  
Continuously  
Variable  
Continuously  
Variable  
Continuously  
Variable  
2nd Order /  
4th Order  
2nd Order /  
4th Order  
2nd Order /  
4th Order  
High Pass Frequency  
INTELLi Q  
10Hz to 150Hz  
0 - 10dB boost  
10Hz to 150Hz  
0 - 10dB boost  
10Hz to 150Hz  
0 - 10dB boost  
1. Continuous 4W load 20Hz to 200Hz, < 0.05% THD, with input voltage at 13.8VDC.  
2. Continuous 2W load 20Hz to 200Hz, < 0.1% THD, with input voltage at 13.8VDC.  
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END PANEL LAYOUTS  
1. Power LED - when lit indicates that the amplifier is on.  
2. Gain Control - continuously adjusts from 200mV to 5V for full power output.  
3. Copy/Gain/Master Switch - determines the configuration of the RCA outputs.  
4. RCA Inputs - accepts RCA input from a source unit, preamplifier, or equalizer.  
5. RCA Outputs - provides easy connection to additional amplifiers.  
6. Low-Pass Crossover Switch - activates low pass crossover.  
7. Low-Pass Frequency Control - adjusts the frequency of the low-pass crossover.  
8. High-Pass Crossover Switch - activates high pass crossover.  
9. High-Pass Frequency Control - adjusts the frequency of the high-pass crossover.  
10. INTELLi Q Control - continuously adjusts the "Q" boost of the high-pass  
crossover from 0 to 10dB of boost.  
11. Phase Control Switch - Allows for adjustment of phase and makes bridging  
amplifiers possible.  
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12. Speaker Connections - accepts up to 12-gauge speaker wire.  
13. Remote Gain Jack - connects optional RGC-1 (remote gain control).  
14. 1 MAXI Fuse (600D) - protects the amplifier from over current situations.  
15 3 ATC Fuses (1200D) - protects the amplifier from over current situations.  
16. Power Connections - accepts up to 4 AWG power and ground cables.  
17. Additional Power Connectors (2500D) - accepts secondary power and ground  
cables.  
18. REM Remote Turn-on Input - turns on the amplifier when fed 12 V+.  
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©2003 Directed Electronics, Inc.  
AMPLIFIER SETTINGS  
Signal Input and Output Configurations  
The input section of the amplifier consists of a phase switch that sets the output configura-  
tion, gain controls, and RCA inputs. The input section makes it easy to adapt this amplifier  
to most system configurations.  
Input Gain  
The Orion 600D, 1200D, and 2500D amplifiers have level adjustments to allow for easy inte-  
gration with any source unit. The input sensitivity can be adjusted from 200mV to 5V. Refer  
to Testing the System and Adjusting the Sound of the System sections of this guide for  
detailed instructions on setting the gain.  
Phase Switches  
0° - leaves output unaffected. The output signal is in phase with the input signal.  
180° - inverts the output. The channel is 180° output of phase. This configuration  
is useful for inverting the phase of subwoofers to improve staging in a vehicle.  
This is also used when bridging two amplifiers into one speaker (600D and 1200D  
only).  
Auxiliary Output Configurations  
The auxiliary outputs on Orion amplifiers offer easy, unlimited system expansion. Routing  
signal from a source unit, pre-amplifier, or equalizer is a matter of connecting RCA's to the  
RCA Inputs and the RCA outputs to the next Orion amplifier in the signal chain. When the  
switch is in the COPY position, the RCA output is an identical copy of the input signal. The  
signal passes through a buffer stage so that several amplifiers can be daisy chained without  
signal loss or overloading of the source unit. This maximizes the signal output and mini-  
mizes the potential for system noise.  
When the switch is in the GAIN position, the RCA outputs are buffered through the gain  
stage of the amplifier. When the first amplifier in the signal chain is set this way, a remote  
gain controller (RGC-1) can be connected to the amplifier and act as a PRE-AMP controlling  
the overall level of the system. Following amplifiers are configured in the COPY mode with  
their gains set to zero as the GAIN amp is now controlling the gain level for all subsequent  
amps. This eliminates the need to gain match multiple amplifiers.  
When the switch is in the MASTER position, the RCA outputs are buffered through the gain  
stage of the amplifier and filtered through the crossover sections of the amplifier. When set  
this way, the amplifier's gain and crossover settings are sent to other amplifiers down the sig-  
nal chain. This can be useful for configuring multiple subwoofer amplifiers easily in a large  
SPL system. All subsequent amplifiers after the master amp will be in the COPY position and  
have their gains set to zero and all crossovers turned off. The master amplifier will control  
all the functions of the slave amps via the MASTER RCA output signal.  
Internal Crossover Configurations  
The crossover section of the Orion 600D, 1200D, and 2500D amplifiers is continuously vari-  
able and extremely flexible. There are different crossover configurations possible allowing  
high-pass, low-pass, and band-pass configurations. The high-pass crossover incorporates the  
INTELLi Q feature. This circuit is designed to optimize the performance of Orion subwoofers  
in all types of enclosures.  
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When using Orion loudspeakers, minor deviations from the recommended frequency  
ranges can provide superior results depending on your speaker locations and your vehicle  
acoustics. Setting crossover frequencies higher than recommended will not cause damage  
and may provide superior sonic results depending on your system's performance goals.  
Refer to your loudspeaker owner's manual for assistance in choosing the proper crossover  
frequencies for your system.  
WARNING! DO NOT set crossover frequencies lower than the speakers recommended  
operating range. This can cause driver failure that is not covered by the man-  
ufacturer's warranty.  
Low-Pass Crossover  
When the switch is to the left (OFF position), the low-pass crossover is bypassed. When the  
switch is in the middle (12 position), the low-pass crossover is active with a 2nd order (12dB  
per octave) slope. When the switch is to the right (24 position), the low-pass crossover is  
active with a 4th order (24dB per octave) slope. The low-pass crossover is continuously vari-  
able from 30Hz to 250Hz.  
High-Pass Crossover  
When the switch is to the left (OFF position), the high-pass crossover is bypassed. When the  
switch is to the right (ON position), the high-pass crossover is active with a 2nd order (12dB  
per octave) slope. The high-pass crossover is continuously variable from 10Hz to 150Hz and  
is optimized for use as a subsonic filter. Additionally, boost can be added at the high-pass  
crossover frequency for improved bass output while still protecting the woofer from exces-  
sive excursion. The INTELLi Q adjustment allows up to 10 dB of boost at the selected  
crossover frequency.  
WARNING! Exercise caution when setting INTELLi Q. Maximum boost can potentially  
cause woofer damage due to overexcursion.  
Fine Tuning the Crossovers  
The low-pass and high-pass crossover sections are each marked at four frequency points for  
ease of system adjustment. The low-pass crossover section is marked at 30Hz, 50Hz, 150Hz,  
and 250Hz. The high-pass crossover section is marked at 20Hz, 33Hz, 90Hz and 150Hz.  
Specific crossover points can be chosen based on the recommended operational bandwidth  
of your speakers.  
Adjusting INTELLi Q  
Incorporated in the high-pass crossover, INTELLi Q maximizes the performance of a sub-  
woofer. The high-pass subsonic filter removes unwanted bass output from the woofer,  
increasing the output of a subwoofer by as much as 3 dB due to the increased mechanical  
power handling. Depending on the enclosure, using INTELLi Q can increase the low fre-  
quency response by an additional 10dB! The type of enclosure used and the woofer's excur-  
sion capability determine acceptable boost levels. Listed below are recommended boost lev-  
els for different enclosure designs.  
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©2003 Directed Electronics, Inc.  
Enclosure Type  
Boost Levels  
0dB  
+3dB  
+6dB  
+10dB  
Not  
Infinite Baffle  
Tune above  
High X-Max  
Not  
Fs of woofer Drivers--Tune Recommended Recommended  
above Fs of  
woofer  
Sealed  
Tune above  
Tune above  
High X-Max  
Not  
Fs of woofer Fs of woofer  
Drivers--Tune Recommended  
above Fs of  
woofer  
Vented  
Tune to port Tune to port  
Tune to port High X-Max  
frequency  
frequency  
frequency  
Drivers--Tune to  
port frequency  
Sealed Band-pass  
Tune above  
Tune above  
High X-Max  
Not  
Fs of woofer Fs of woofer  
Drivers--Tune Recommended  
above Fs of  
woofer  
Vented Band-pass  
Aperiodic  
Tune to port Tune to port  
Tune to port High X-Max  
frequency  
frequency  
frequency  
Drivers--Tune to  
port frequency  
Set crossover Set crossover Set crossover Not  
to Fs of  
woofer  
to Fs of  
woofer  
to Fs of  
woofer  
Recommended  
Infinite Baffle Example High-Pass Set at 30Hz  
By removing low frequency signal that the woofer cannot produce, the woofer can play its  
capable range louder. The first example is an infinite baffle situation. The left graph displays  
the frequency response of a 12-inch woofer in an infinite baffle application without the  
high-pass filter, with the filter and with the filter and the INTELLi Q set to +3dB. As you can  
see, with +3dB of boost and the high pass filter set to 30Hz, the woofer has more output  
down to 25Hz and less overall excursion when compared to the non-high-pass response.  
Maximum physical excursion capability of the woofer is 15mm.  
NOTE:  
The left graph is the response; the right graph is the driver excursion. These des-  
ignations apply to the following graphs as well.  
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©2003 Directed Electronics, Inc.  
Sealed Example High-Pass Set at 20Hz  
This sealed example is the same 12-inch woofer in the recommended sealed enclosure. Up  
to 6 dB of boost is capable if 20 Hz was used. With +6dB of boost, the woofer has more out-  
put down to 15 Hz.  
Sealed Example High-Pass Set at 30Hz  
In this example, the frequency has been increased to 30 Hz. Up to 6 dB of boost is capable  
at this frequency. With +6dB of boost, the woofer has more output down to 23 Hz. The  
overall usable output is increased.  
Vented Example High-Pass Set at 30Hz  
Vented enclosures benefit most from the INTELLi Q. Up to 10 dB of boost is capable at the  
box tuning frequency of 30 Hz. With +10dB of boost, the woofer has more output down to  
22 Hz. The excursion below the tuning frequency has been greatly reduced.  
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©2003 Directed Electronics, Inc.  
Remote Gain Operation  
The remote gain port provides easy remote access to the internal gain structure of the HCCA  
power amplifier. The RGC-1 plugs into the amplifier via the 1/8" mini jack plug. The RGC-1  
can be installed in the front of the vehicle to control the amplifier gain level. The RGC-1 can  
be used as a bass level control when used on an amplifier dedicated to subwoofers.  
In addition, one RGC-1 can be used on multiple sub amplifiers. Plug the RGC-1 into the first  
amp that must have its RCA output selection switch in the MASTER position. The RGC-1  
information will now be sent to subsequent amps via the MASTER signal.  
AMPLIFIER WIRING  
Power Connections for the 600D and 1200D  
Orion 600D Fuse Size: 1 x 50 AMP MAXI  
Orion1200D Fuse Size: 3 x 40 AMP ATC  
Power connections accept up to 4 AWG wire.  
4 AWG power and ground wire recommended for optimal performance.  
Connect 12V+ to the battery through fuse holder. This connection provides +12V  
main power to the amplifier.  
Power wire must be fused no more than 18" from battery.  
Ground amplifier to a good chassis ground as close as possible to the amplifier.  
Connect REM terminal to remote turn-on lead from source unit. This connection  
provides +12V power to turn-on the amplifier.  
Add extra ground wire between the negative terminal of the battery and the  
chassis.  
Power Connections for the 2500D  
Power connections accept up to 4 AWG wire.  
Dual 4 AWG power and ground wire required for proper performance.  
Connect 12V+ to the battery through power distribution and fuse holder. This  
connection provides +12V main power to the amplifier.  
Power wires must be fused no more than 18" from battery.  
Terminate both grounds of the amplifier to a good chassis ground as close as pos-  
sible to the amplifier.  
Connect REM terminal to remote turn-on lead from source unit. This connection  
provides +12V power to turn-on the amplifier.  
Add an extra ground wire between the negative terminal of the battery and the  
chassis. Either dual 4 AWG or single 1/0 AWG is recommended.  
NOTE:  
The addition of a ground wire from the battery to the chassis of the vehicle  
improves the ability of the battery to supply power to the amplifier. This is recom-  
mended because the current delivery of the factory electrical system was designed  
only to accommodate electronics supplied by the auto manufacturer.  
WARNING! The Orion 2500D has two separate four-gauge power and ground inputs.  
Both pairs of connections must use 4 AWG power wire for proper operation.  
Failure to do this may damage the amplifier and is not covered under war-  
ranty. The 2500D cannot be operated in a bridge or strapped configuration,  
attempting to do so will damage the amplifier.  
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Speaker Connections  
The Orion 600D, 1200D, and 2500D amplifiers offer two positive and two negative output  
terminals for ease of connecting the speakers to the amplifier. Since these are mono ampli-  
fiers, the speaker connectors are paralleled internally. Each amplifier is stable to 1W.  
Bridging  
For bridging into a single speaker load, the Orion 600D and 1200D have the ability to be  
bridged with another amplifier of the same model. To do this you must utilize the  
COPY/GAIN/MASTER switch settings. For the MASTER amplifier, set the switch setting to  
MASTER. This will route the signal through RCA to the other (slave) amplifier. Refer to  
Auxiliary Output Configuration section of this guide. To set the PHASE switch on the (slave)  
amp, move the phase switch from 0 to 180, exactly opposite of the master amp. Refer to  
the Phase Switches section of this guide.  
On the (slave) amplifier be sure to turn off all crossovers. For the speaker connections, con-  
nect the positive (+) speaker lead from the speaker to the positive (+) speaker terminal of  
the master amplifier. On the negative (-) speaker connection, take the negative (-) speaker  
terminal of the master amplifier and connect it directly to the negative (-) speaker terminal  
of the (slave) amplifier. The remaining positive (+) speaker terminal of the (slave) amplifier  
must be connected to the negative (-) speaker lead from the speaker. The impedance of the  
speaker must not exceed 2W.  
NOTE:  
For best results, connect both negative speaker terminals on the master amp to  
both negative terminals on the slave amp using at least 12 AWG cable.  
WARNING! The Orion 2500D is not designed to work in a bridged or strapped configu-  
ration. Attempting to apply these configurations will damage the amplifier  
and will not be covered under warranty.  
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AMPLIFIER INSTALLATION  
Choosing Mounting Locations  
The location of your amplifier will depend on several important issues. Due to the low pro-  
file size of the Orion amplifiers, there are many possible installation locations that will yield  
satisfactory amplifier performance. Always mount the amplifier in a place that protects the  
amplifier from the elements. In addition, mount the amplifier on a stable, flat surface.  
NOTE:  
Mounting amplifiers upside down is not recommended and may cause premature  
thermal shutdown.  
WARNING! Do not mount any amplifier in the engine compartment. Amplifiers are not  
designed to endure the harsh environment of the exterior elements.  
Passenger Compartment  
If you are going to mount the amplifier in the passenger compartment, make sure you have  
adequate room for ventilation. The amplifiers have been designed to make under-seat  
mounting possible. When mounting your amplifier under a seat or similar area, keep a min-  
imum of 1" of clearance around the amplifier for adequate cooling.  
Trunk Compartment  
Mounting your amplifier in the trunk provides excellent performance as long as you do not  
restrict the airflow around the heatsink of the amplifier. For optimal results, mount the  
amplifier with as much clearance as possible. This type of mounting will yield the best cool-  
ing due to the convection effect of the amplifier chassis.  
General Precautions and Installation Tips  
WARNING! Be careful not to cut or drill into gas tanks, fuel lines, brake lines, hydraulic  
lines, vacuum lines, or electrical wiring when working on your vehicle.  
Disconnect the vehicle's ground wire at the battery before making or breaking connections  
to the audio system's power supply terminals.  
Do not use this amplifier unmounted. Failing to securely mount the amplifier can result in  
damage or injury, particularly in the event of an accident. An unmounted amplifier becomes  
a dangerous projectile in the event of a crash. Never mount the amplifier where it might  
get wet. Mount the amplifier so the wire connections will not be pulled. Route the wires  
where they will not be scraped, pinched or damaged in any fashion.  
The +12V power supply wire must be fused as close as possible to the battery terminal, ide-  
ally within 18". Use the recommended fuse size or circuit breaker listed in the Power  
Connections section of this manual.  
If you need to replace the fuse plugged into the side of the amplifier, replace the fuse with  
the same size ATC / MAXI type fuse that came with the amplifier. If you are not sure as to the  
correct value, refer to the Power Connections section of this manual for details. Using a high-  
er current fuse may result in damage to the amplifier that is not covered under warranty.  
NOTE:  
Make sure all the equipment in the system is turned off when making or break-  
ing connections to the input RCA's or speaker terminals. Turn on the system and  
slowly turn up the volume control only after double checking all wire connections.  
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©2003 Directed Electronics, Inc.  
Power for systems with a single amplifier can be supplied by most automotive electrical sys-  
tems. Systems with multiple amplifiers may require a higher capacity battery, alternator or  
the use of a storage capacitor. We strongly recommend the use of a Directed Audio  
Essentials power capacitor with an extra battery in larger stereo systems.  
Orion amplifiers generate a certain amount of heat as part of normal operation. Be sure the  
area around the amplifier is unobstructed to allow adequate air circulation. Remember,  
beach blankets, last week's laundry, school books and homework papers located on top of  
the amplifier do not improve air flow and may become damaged.  
Tools of the Trade  
Listed below are the majority of the tools required to perform an installation. Having the  
proper tools will make the installation that much easier. Some of these tools are necessities;  
some will just make the job easier.  
Allen Wrenches (2.5mm and 3mm)  
DMM or VOM  
Electric drill with assorted drill bits  
Grommets  
Heat shrink tubing  
Marking pen  
Nylon tie straps  
Phillips and flat blade screw drivers  
Pliers (standard and needle nose)  
Reference CD with 1 kHz Sine Wave at 0dB level (all bits high)  
RTA (real time analyzer)  
Soldering iron and solder  
Utility knife  
Wire brush or sandpaper for chassis grounding  
Wire crimper  
Wire cutters  
Wire strippers  
Step By Step Installation  
Step 1  
Step 2  
Step 3  
Determine the location for the amplifier. Refer to the Choosing Mounting  
Locations section of this guide for detailed information.  
Decide on the system configuration for your amplifier. For system sugges-  
tions, refer to the Speaker Connections section of this guide.  
Run all the wires from the amplifier location to the speakers, source unit, and  
battery. Do not connect the battery at this time. Be sure to run RCAs and  
power and speaker wires away from factory electrical wires and system as  
they pose a great potential for induced system noise.  
Step 4  
Step 5  
Pre-drill amplifier mounting holes. Be sure to "think before you drill". Gas  
tanks, fuel lines, and other obstructions have a nasty way of hiding them-  
selves. For best results use a marking pen to mark the mounting holes and  
pre-drill these holes with a standard 1/8" drill bit.  
Mount the amplifier. Make sure the amplifier is mounted on a flat surface. If  
this is not possible, do not over tighten the screws so that the chassis of the  
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©2003 Directed Electronics, Inc.  
amplifier is twisted or bent.  
Step 6  
Step 7  
Step 8  
Step 9  
Turn the vehicle's key switch to the off position.  
Disconnect the vehicle's battery ground terminal.  
Connect power wires to the amplifier (ground first, then 12 V(+) and REM).  
Connect the RCA and speaker wires to the amplifier. Check the quality of  
your speakers and signal connections. This will determine the ultimate per-  
formance of your Orion amplifier. Refer to the Signal Input and Output Level  
Controls and Speaker Connections sections of this guide for correct wiring  
instructions.  
Step 10 Reconnect the ground terminal to the battery after power, speaker, and RCA  
connections are completed.  
Step 11 Set crossovers. Refer to the Internal Crossover Configuration section of this  
manual for detailed instructions.  
Step 12 Once satisfied that all connections and settings are correct, install the fuse  
located near the vehicle's battery and proceed to the Testing the System sec-  
tion of this manual.  
WARNING! Never exceed the recommended fuse size of this amplifier. Failure to do so will  
result in the voiding of your warranty and possible damage to the amplifier.  
SET UP AND TROUBLESHOOTING  
Testing the System  
After you have completed the installation, you need to test the system. This will help ensure  
years of trouble-free operation. Please refer to the listed steps below when testing the  
sound of your Orion system.  
Step 1  
Step 2  
Check all the wiring connections to be sure they are correct and secure.  
Turn the signal source volume control all the way down. Set any tone con-  
trols to their flat or defeated positions. This includes the loudness control.  
Step 3  
Step 4  
Turn the level controls of the amplifier to their minimum positions.  
Turn the source unit on. Check to see if the power LED located on the con-  
nection side of the amplifier is on. If not, please refer to the Power  
Connections and the Troubleshooting Tips sections of this manual for instruc-  
tions.  
Step 5  
Step 6  
Step 7  
If using an aftermarket source unit, turn the level controls of the amplifier  
about one quarter of a turn. Slowly increase the volume level of the source  
unit to so that you can hear the output of the system. If no sound is heard or  
if the output is distorted, turn the system off immediately. Refer to the Power  
Connections and the Troubleshooting Tips sections of this manual to solve  
your installation problems.  
Check to make sure the output for each channel is correct. If the active  
crossovers are used, check to make sure that each output is correct from the  
amplifier. When using active crossovers on midrange and tweeters, do not  
use crossover frequencies lower than recommended. If the system is not con-  
figured properly, refer to the Internal Crossover Configuration section of this  
manual and take corrective action.  
If the output is clear and undistorted, continue to the Adjusting the Sound  
of the System section of this manual.  
15  
©2003 Directed Electronics, Inc.  
Adjusting the Sound of the System  
Once you have checked the system's operation, adjust the sound of the system. Adjusting  
the sound of the system is accomplished by setting the level controls and adjusting the  
internal crossovers.  
Step 1  
Turn the signal source volume control all the way down. Set any tone con-  
trols to their flat or defeated positions. This includes the loudness control.  
Step 2  
Step 3  
Turn the level controls of the amplifier to their minimum positions.  
Choose music with high dynamic content that you like, with which you are  
familiar, and will be used most often in the system.  
Step 4  
Step 5  
Turn the source unit's volume control up to its highest undistorted output  
level. If you lack test equipment, this point occurs between 3/4 to full volume  
depending on the quality of your source unit. Listen for any audible distor-  
tion. If any distortion is audible, reduce the volume of the source unit until  
you have an undistorted output. Leave the volume control at this position  
during your system tuning.  
While listening to your chosen dynamic music, turn up the level control cor-  
responding to the midrange output until you hear slight distortion and turn  
the level control back slightly for an undistorted output. Depending on your  
system, the midrange and tweeter output may be on the same output chan-  
nels.  
Step 6  
Step 7  
Turn up the level control corresponding to the tweeter output until you hear  
slight distortion and turn back the level control slightly for an undistorted  
output. Depending on your system the midrange and tweeter output may be  
on the same output channels.  
Fine-tune the output level between midrange and tweeters. Refer to the  
Internal Crossover Configuration section of this manual for detailed instruc-  
tions.  
Step 8  
Step 9  
Repeat Steps 5-7 for the rear speakers. If you do not have rear speakers con-  
tinue to Step 10.  
Set levels between the front and rear midrange and tweeters for optimum  
front/rear balance.  
Step 10 Turn up the level control corresponding to the woofer output until you hear  
slight distortion and turn back the level control slightly for an undistorted  
output.  
Step 11 Fine-tune the output level between satellite speakers and the woofers. Refer  
to the Internal Crossover Configuration section of this manual for detailed  
instructions. If using an RGC-1, adjust the level to the output of the woofer  
to match the sonic requirements of the system.  
Step 12 Enjoy your awesome Orion sound system.  
16  
©2003 Directed Electronics, Inc.  
Troubleshooting Tips  
Symptom  
Probable Cause  
Action To Take  
No output  
Low or no remote turn-on Check remote turn-on voltage  
at voltage amplifier and repair  
as needed.  
Fuse blown  
Check power wire's integrity  
and check for speaker shorts. Fix  
as needed and replace fuse.  
Power wires not connected Check power wire and ground  
connections and repair or  
replace as needed.  
Audio input not connected Check RCA connections and  
repair or replace as needed.  
Speaker wires not  
connected  
Check speaker wires and repair  
or replace as needed.  
Speakers are blown  
Check system with known work  
ing speaker and repair or  
replace speakers as needed.  
Audio cycles  
on and off  
Thermal protection engages Make sure there is proper venti  
when amplifier heatsink lation for amplifier and improve  
temperature exceeds 90°C ventilation as needed.  
(190°F)  
Loose or poor audio input Check RCA connections and  
repair or replace as needed.  
Loose power connections  
Check power wire and ground  
connections and repair or  
replace as needed.  
Distorted output  
Amplifier level sensitivity  
set too high exceeding  
maximum capability of  
amplifier  
Readjust gain. Refer to the  
Adjusting the Sound of the  
System section of this manual  
for detailed instructions.  
Impedance load to amplifier Check speaker impedance load,  
too low  
if below 1W, rewire the speakers  
to achieve higher impedance.  
Shorted speaker wires  
Check speaker wire connections  
and fix or replace as needed.  
Speaker not connected  
to amplifier properly  
Check speaker wiring and repair  
or replace as needed. Refer to  
the Speaker Connections section  
of this guide for detailed  
instructions.  
17  
©2003 Directed Electronics, Inc.  
Symptom  
Probable Cause  
Action To Take  
Distorted output  
Internal crossover not set  
properly for speakers  
Readjust crossovers. Refer to the  
Internal Crossover Configuration  
section of this guide for detailed  
instructions.  
Speakers are blown  
Check system with known work  
ing speakers and fix or replace  
as needed.  
Poor bass response  
Speakers wired with wrong Check speaker polarity and fix  
polarity causing cancellation as needed.  
at low frequencies  
Crossover set incorrectly  
Reset crossovers. Refer to the  
Internal Crossover Configuration  
section of this guide for detailed  
instructions.  
Impedance load at amplifier Check speaker impedance load,  
is too low  
if below 1W, rewire speakers to  
achieve higher impedance.  
Battery fuse  
blowing  
Short in power wire or  
incorrect wiring  
Check power and ground con  
nections and replace or repair as  
needed.  
Fuse used is smaller than  
recommended  
Replace with proper fuse size.  
Actual current exceeds fuse Check speaker impedance load.  
rating  
If below 1W, rewire speakers to  
achieve higher impedance.  
Amplifier fuse  
blowing  
Fuse used is smaller than  
recommended  
Replace with proper fuse size.  
Impedance load at  
amplifier too low  
Check speaker impedance load.  
If below 1W, rewire speakers to  
achieve higher impedance.  
Speaker is blown with  
shorted outputs  
Check system with known work  
ing speakers and fix or replace  
as needed.  
Actual current exceeds  
fuse rating  
Check speaker impedance load.  
If below 1W, rewire speakers to  
achieve higher impedance.  
18  
©2003 Directed Electronics, Inc.  
NOTES  
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19  
©2003 Directed Electronics, Inc.  
20  
©2003 Directed Electronics, Inc.  
Warranty  
LIMITED TWO YEAR CONSUMER WARRANTY:  
Directed Electronics, Inc. promises to the original purchaser, to replace this product should it prove  
to be defective in workmanship or material under normal use, for a period of two years from the  
date of purchase by the dealer as indicated by the date code marking of the product PROVIDED  
the product was installed by an authorized Directed dealer. During this two year period, there will  
be no charge for this replacement PROVIDED the unit is returned to Directed, shipping pre-paid.  
If the unit is installed by anyone other than an authorized Directed dealer, the warranty period will  
be 1 year from date of purchase by the dealer as indicated by the date code marking of the  
product. During this 1 year period, there will be no charge for this replacement PROVIDED the  
unit is returned to Directed, shipping pre-paid. This warranty is non-transferable and does not  
apply to any unit that has been modified or used in a manner contrary to its intended purpose,  
and does not cover damage to the unit caused by installation or removal of the unit. This warranty  
is void if the product has been damaged by accident or unreasonable use, neglect, improper service  
or other causes not arising out of defects in materials or construction. ALL WARRANTIES  
INCLUDING BUT NOT LIMITED TO EXPRESS WARRANTY, IMPLIED WARRANTY, WARRANTY  
OF MERCHANTABILITY, FITNESS FOR PARTICULAR PURPOSE, AND WARRANTY OF NON-  
INFRINGEMENT OF INTELLECTUAL PROPERTY ARE EXPRESSLY EXCLUDED TO THE  
MAXIMUM EXTENT ALLOWED BY LAW, AND DIRECTED NEITHER ASSUMES NOR  
AUTHORIZES ANY PERSON TO ASSUME FOR IT ANY LIABILITY IN CONNECTION WITH THE  
SALE OF THE PRODUCT. DIRECTED HAS ABSOLUTELY NO LIABILITY FOR ANY AND ALL ACTS  
OF THIRD PARTIES INCLUDING ITS AUTHORIZED DEALERS OR INSTALLERS. Unit must be  
returned to Directed, postage pre-paid, with: consumer's name, telephone number, and address,  
authorized dealer's name and address, and product description. IN ORDER FOR THIS WARRANTY  
TO BE VALID, YOUR UNIT MUST BE SHIPPED WITH PROOF OF INSTALLATION BY AN  
AUTHORIZED DIRECTED DEALER. ALL UNITS RECEIVED BY DIRECTED FOR WARRANTY  
REPAIR WITHOUT PROOF OF DIRECTED DEALER INSTALLATION WILL BE COVERED BY THE  
LIMITED 1 YEAR PARTS AND LABOR WARRANTY. Note: This warranty does not cover labor costs  
for the removal and reinstallation of the unit.  
BY PURCHASING THIS PRODUCT, THE CONSUMER AGREES AND CONSENTS THAT ALL  
DISPUTES BETWEEN THE CONSUMER AND DIRECTED SHALL BE RESOLVED IN ACCORDANCE  
WITH CALIFORNIA LAWS IN SAN DIEGO COUNTY, CALIFORNIA.  
© 2003 Directed Electronics, Inc. All rights reserved. G47400/05/10 2-03  

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