XTREME 200/400.4
OWNER’S MANUAL
HIGH PERFORMANCE CAR AUDIO
INTRODUCTION
Thank you for your purchase of ORION’s XTREME amplifier. Each ORION amplifier is designed to be the leader in its class offering the
most power, advanced features and ease of use. The ORION XTREME amplifiers are designed as the best “affordable high end” car
audio amplifier money can buy. Listed below are the features of the new ORION COBALT amplifiers.
• XTREME 200 – 50 watts per channel, 2-channel amplifier with built-in continuously variable high-pass or low-pass 12dB/octave
crossover from 45 to 5kHz. The XTREME 200 is capable of 3, 2, or 1 channel operation.
• XTREME 400.4 – 50 watts per channel, 4-channel amplifier with dual built-in continuously variable high-pass or low-pass 12dB/octave
crossover from 45 to 5kHz. The XTREME 400.4 is capable of 6, 5, 4, 3, or 2 channel operation.
NOTE: The installation of all ORION XTREME amplifiers 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 digital processor. To ensure
proper sonic results and component reliability, please refer to your Authorized ORION dealer for installation assistance or advice. If you
decide to perform the installation yourself, read the entire installation section of this manual before beginning the installation.
page 1
ABOUT THIS MANUAL
This manual is divided into different sections for different needs. Whether you are the owner, salesperson or installer, we have devoted
sections of this manual to answer your questions. If you just purchased this amplifier and have yet to decide on a system configuration,
refer to the System Planning section of this manual for awesome system ideas.
We, at ORION, strive to give you the latest up to date information about our products. What we cannot give you is personal installation
or technical experience. If you have questions regarding the installation or the set-up or tuning of this product, please refer to your
nearest Authorized ORION Dealer for assistance. Additionally, you can call ORION’s Technical Support Hotline at 1-800-315-2052 or 602-
705-5600 for assistance.
PRACTICE SAFE SOUND™
Continuous exposure to sound pressure levels over 100dB may cause permanent hearing loss. High powered 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.
RECORD YOUR SERIAL NUMBER AND DATE:
Model: __________________________________________________________
Serial Number: __________________________________________________________
Date of Purchase: __________________________________________________________
Company Purchased From: __________________________________________________________
page 2
WHAT’S IN THE BOX
(1) XTREME amplifier
(1) 8 gauge power and ground connector
(1) 14 gauge speaker and remote connector
(4) #8 self-tapping black Phillips pan head screws
(1) XTREME installation and operation manual
page 3
WARRANTY
ORION Industries Inc. warrants this product to be free from defects in material and workmanship under the following terms:
Parts and Labor are warranted for a period of 3 years IF:
a. The product is purchased from an Authorized ORION Dealer
b. The product is installed by an Authorized ORION Dealer
Parts and Labor are warranted for a period of 1 year IF:
a. The product is purchased from an Authorized ORION Dealer
b. The product is NOT installed by an Authorized ORION Dealer
Parts and Labor are warranted for a period of 90 days IF:
a. The product is NOT purchased from an Authorized ORION Dealer
If you are uncertain as to whether your dealer is authorized, please contact ORION at 1-800-775-7150 or 602-705-5600. In countries
other than the USA, each distributor warrants the ORION product it sells.
The following conditions and situations are NOT covered by this warranty:
Any product on which the serial number has been defaced, modified or removed. Damage or malfunction resulting from:
a. Accident, misuse, abuse, unauthorized modification or failure to follow the instructions provided with this product
b. Repair by anyone NOT authorized by ORION
c. Damage due to shipping (these claims must be presented to the freight carrier)
d. Removal or installation of this product
e. Any failure that has NOT been caused by a defect in material or workmanship
page 4
This warranty is in effect for the original purchaser only. ORION will pay for labor and material expense for covered items. ORION does
not cover removal or installation charges, payment of shipping charges to ORION, payment of OUT-OF-WARRANTY shipping charges, or
damage to other property caused by any defects in this product.
For IN-WARRANTY service, you must include a copy of the original, dated sales receipt, including serial number, from an Authorized
ORION Dealer. Please also provide your name, return street address (No P.O. Boxes) and a detailed description of the problem.
For out-of-warranty products, please include ORION E-Z Repair Form. These are available by contacting ORION Repair at 1-888-362-5283
or 602-705-5600 and ask for the Repair Department.
•
If you do not have the original packaging, the product must be packaged to prevent damage during shipment.
ORION Industries Inc.
ATTN: Repair Department
9235 South McKemy Street
Tempe, Arizona 85284 USA
Exclusion
1. This warranty is in lieu of all other warranties expressed or implied.
2. In no event will ORION be liable for any consequential damages resulting from the use of this product or any defect of this product.
This warranty gives you specific legal rights. You may also have other rights that vary from state to state.
page 5
SPECIFICATIONS
Amplifier Section
Power output 4Ω stereo (watts)1
XTREME 200
XTREME 400.4
50 x 4
50 x 2
50 x 2, 200 x 1
100 x 4
Power output 2Ω stereo (watts)2
Power output 4Ω mono (watts)1
Distortion all channels driven
(from 20Hz to 20kHz)
Frequency Response
100 x 2
200 x 1
200 x 2
<0.1% THD
<0.1% THD
20Hz to 20kHz ±0.25dB
6Hz to 50kHz ±3dB
>100dB
20Hz to 20kHz ±0.25dB
6Hz to 50kHz ±3dB
>100dB
Linear Bandwidth
Signal-to-noise ratio full bandwidth
@ rated output power
Damping factor @ output connector
@ full bandwidth
>400 at output connector
>400 at output connector
Slew Rate
Input Sensitivity3
>30Vµs
200 mV to 5 Vrms
20kΩ
>30Vµs
200 mV to 5 Vrms
20kΩ
Input Impedance
Fuse Type
30 Amp ATC
(2) 20 Amp ATC
page 6
Crossover Section3
Low-Pass Crossover
Low-Pass Frequency Range
High-Pass Crossover
High-Pass Freqency Range
General
XTREME 200
Continuously variable
45Hz to 5kHz
XTREME 400.4
Continuously variable
45Hz to 5kHz
Continuously variable
45Hz to 5kHz
Continuously variable
45Hz to 5kHz
Dimensions
8”L x 10.25”W x 2.25”H
13”L x 10.25”W x 2.25”H
(457mm x 260mm x 57mm)
(305mm x 260mm x 57mm)
1
2
3
4
All channels driven, continuous rated 4Ω load, 20Hz to 20,000Hz, >0.1% THD, per input voltage at 12.0VDC.
All channels driven, continuous rated 2Ω load, 20Hz to 20,000Hz, >0.1% THD, per input voltage at 12.0VDC.
XTREME amplifers are designed to accept full 9 Volts RMS input when set to the minimum gain position.
All crossovers are with a slope rate of 12dB/octave and a “Q” of .0707.
page 7
TECHNICAL DESIGN FEATURES
Complementary Matched
Bipolar Outputs
XTREME 200
Stereo/SUM/MONO Switch
Crosssover Selector
Crossover Frequency Control
Gain Control
and Remote
RCA Input
Power Supply Controller
PRS Power Supply
Ground
Power LED
Rectifier
Diodes
PRS Power supply
MOSFET switches
page 8
TECHNICAL DESIGN FEATURES
1. Power LED - when lit indicates that the amplifier is on
1
2
3
4
5
6
7
8
9
2. Front Output Configuration Switch - determines the output
configuration of the amplifier
3. Front Gain Control - continuously adjusts from 200mV to 5Vrms
for full power output
4. 2-Channel / 4-Channel Switch - configures the amplifier for two or
four RCA inputs
10 11
12
5. Front RCA inputs - accepts RCA input from a source unit,
preamplifier or equalizer
6. Rear RCA outputs - accepts RCA input from a source unit, preampli-
fier or equalizer
7. Rear Crossover Control - adjusts the frequency for the rear channels
8. Rear Crossover Switch - configures the rear channel for high-pass,
low-pass or full range operation
13
14
15
16
9. Rear Output Configuration Switch - determines the output
configuration fo the amplifier
10. Front Crossover Switch - configures the front channel for high-
pass, low-pass or full range operation
13. REM Remote Turn-on Input - turns on the amplifier when
fed 12 V+
11. Front Crossover Control - adjusts the frequency for the front
channels
14. Speaker Connections - allow up to 12 gauge speaker wire
15. Fuse - protects the amplifier from over current situations
12. Rear Gain Control - continuously adjusts from 200mV to 5Vrms
for full power output
16. Power Connections - allow up to 4 gauge power and
ground cables
page 9
SYSTEM PLANNING
SYSTEM 1
The easiest way to maximize the performance for your
ORION XTREME amplifier is to properly plan your sys-
tem. By planning your system, you can avoid situation
where the performance of the reliability of your system
is compromised. Your Authorized ORION dealer has been
trained by ORION Industries on how to maximize your
system’s sonic potential. Authorized ORION dealers are
a valuable resource in helping you with your system de-
sign and installation. If you wish to venture on with your
own system design, here are some systems designed by
ORION Industries.
System 1 is a simple 2-channel amplifier driving a pair
of satellites. This is a great start to an awesome sound-
ing system.
• Lowest recommended impedance is 2Ω per channel
• Amplifier can be configured for high-pass or full range
stereo operation
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page 10
SYSTEM PLANNING
SYSTEM 2
System 2 adds a subwoofer to system 1.
Amplifier 1 is configured high-pas for
the satellite speakers and Amplifier 2 is
configured low-pass for a single 4Ω sub-
woofer.
Amplifier 1
• Lowest recommended impedance is 2Ω
per channel
+
–
+
–
• Amplifier is configured high-pass for
satellite operation
+
–
–
+
• Amplifier is configured for stereo op-
eration
+
–
+
–
Amplifier 2
• Lowest recommended impedance is 4Ω
per channel
• Amplifier is configured for low-pass for
subwoofer operation
–
+
• Amplifier is configured for summed
bridged operation
page 11
SYSTEM PLANNING
SYSTEM 3
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page 12
SYSTEM PLANNING
SYSTEM 3
System 3 uses a 4-channel amplifier to drive an entire system. The front channels are configured high-pass operation for satellites. The rear channels
are configured low-pass for two dual voice coil subwoofers.
• Lowest recommended impedance for front channels is 2Ω per channel
• Front channels configured for high-pass operation
• Front channels configured for stereo operation
• Lowest recommended for rear channels is 2Ω per channel
• Rear channels configured for low-pass operation
• Rear channels configured for summed stereo operation
• Amplifier can be configured either for 2-channel or four-channel inputs
Note: when the amplifier is configured for 4-channel input the fader on the source unit can control the output level between the subwoofer and
satellites.
page 13
SYSTEM PLANNING
SYSTEM 4
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page 14
SYSTEM PLANNING
SYSTEM 4
System 4 uses a 4-channel amplifier to power the front satellites and a single 4Ω subwoofer and a 2-channel amplifier for the rear satellites.
Amplifier 1
• Lowest recommended impedance for the front channels is 2Ω per channel
• Front channels configured for high-pass operation
• Front channels configured for stereo operation
• Lowest recommended impedance for the rear channels is 2Ω
• Rear channels configured for low-pass operation
• Rear channels configured for summed stereo operation
• Amplifier is configured for 2-channel input
Amplifier 2
• Lowest recommended impedance is 2Ω per channel
• Amplifier is configured for high-pass or full range operation
• Amplifier configured for stereo operation
• Amplifier input received from the rear RCAs of Amplifier 1
page 15
SYSTEM PLANNING
SYSTEM 5
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page 16
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SYSTEM PLANNING SYSTEM 5
System 5 uses two 4-channel amplifiers for the front and rear satellites and two 2-channel amplifiers for two subwoofers. This system is designed
to really rock.
Amplifier 3
Amplifier 1
• Amplifier 1 is configured for 2-channel stereo operation
• Lowest recommended impedance is 4Ω mono
• Lowest recommended impedance is 4Ω per channel stereo
• Amplifier channels configured for low-pass operation
• Amplifier is configured for summed bridged operation
Amplifier 4
• Amplifier channels configured for high-pass operation
• Amplifier is configured for 2-channel input
Amplifier 2
• Lowest recommended impedance is 4Ω mono
• Amplifier 2 is configured for 2-channel stereo operation
• Amplifier channels configured for low-pass operation
• Amplifier is configured for summed bridged operation
• Lowest recommended impedance is 4Ω per channel stereo
• Amplifier channels configured for high-pass operation
• Amplifier is configured for 2-channel input
page 17
INSTALLATION
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 assistance or advice. IF you decide to perform the installation yourself, read the entire
installation section of this manual before beginning installation.
TOOLS OF THE TRADE
Listed are the majority of the tools required to perform the installation. Having the proper tools will make the installation much easier. Some of
these tools are necessities. Some make the job much easier.
•
•
•
•
•
•
•
marking pen
•
•
•
•
•
•
heat shrink tubing
nylon tie straps
volt-ohm meter (optional)
wire cutters
electric drill with assorted drill bits
utility knife
Phillips and flat blade screw drivers
pliers (standard and needle nose)
wire brush or sandpaper for chassis grounding
solder iron and solder
wire crimpers
wire strippers
page 18
POWER CONNECTIONS
• Minimum 8 gauge power and ground cable is recommended for acceptable performance
• Fuse power wire less than 18” from battery
• Ground amplifier to a good chassis ground as close as possible to the amplifier
• Add extra ground wire between the negative terminal of the battery and the chassis
TUNING 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 helps especially in newer vehicles, where the current delivery of the factory electrical system was
designed only to accommodate electronics supplied by the auto manufacturer.
Connect to remote turn-on
lead of source unit
Fuse less than 18"
from battery
6
100.1
FI
Amplifier
Fuse Size
+
–
XTREME 200
(2) 15 AMP
Vehicle Battery
XTREME 400.4 (2) 20 AMP
page 19
SPEAKER CONNECTIONS
• Lowest recommended impedance is 2Ω stereo
2-CHANNEL STEREO CONFIGURATION
• Output can be configured for high-pass, low-pass or full
range operation
• Output can be configured for either stereo operation or
summed for subwoofer applications.
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+
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page 20
SPEAKER CONNECTIONS
SINGLE BRIDGED CONFIGURATION
• Lowest recommended impedance is 4Ω bridged mono
• Output can be configured for high-pass, low-pass or
full range operation
• Output can be summed for subwoofer applications of
bridged mono for single input high power applica-
tions
–
+
page 21
SPEAKER CONNECTIONS
TRI-MODE 3-CHANNEL CONFIGURATION
• Lowest recommended impedance is 2Ω stereo and 4Ω
bridged mono
• Output must be set for full range operation
• Output must be configured for stereo operation
• Passive crossover frequencies must not overlap.
WARNING! Failure to do so may result in damage to the
amplifier
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4 Ohm Minimum
page 22
SPEAKER CONNECTIONS
4-CHANNEL STEREO CONFIGURATION
• Front and rear channel lowest recommended
impedance is 2Ω stereo
• Crossover, output and gain configurations
are independently adjustable between the
front and rear channels
• 2-channel or 4-channel input can be used for
this configuration. For source unit fading,
use the 4-channel input mode
• Front and rear outputs can be configured for
high-pass, low-pass or full range operation
• Front and rear outputs can be configured for
either stereo operation or summed for
subwoofer applications
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page 23
SPEAKER CONNECTIONS
3-CHANNEL STEREO/BRIDGED CONFIGURATION
• Front channels are configured for 2-channel stereo
operation
• Front channel lowest recommended impedance is 2Ω
stereo
• Rear channels are configured for a single channel
bridged output
• Rear channel lowest recommended impedance is 4Ω
• Crossover, output and gain configurations are indepen-
dently adjustable between the front and rear channels
• 2-channel or 4-channel input can be used for this
configuration. For source unit fading, use the 4-channel
input mode
• Front and rear outputs can be configured for high-pass,
low-pass or full range operation
• Front outputs can be configured for either stereo or
summed stereo operation
+
–
+
–
• Rear outputs can be configured for summed bridged or
single channel bridged operation for subwoofer
applications
+
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page 24
SPEAKER CONNECTIONS
TWO-CHANNEL BRIDGED CONFIGURATION
• Front and rear channels are configured for bridged 2-
channel operation
• Lowest recommended impedance for both front and rear
channels is 4Ω
• Crossover and gain configurations are independently
adjustable between the front and rear channels
• 2-channel operation is recommended for this operational
mode
• Front and rear outputs can be configured for high-pass,
low-pass or full range operation
• Front and rear outputs can be configured for stereo (front
channels will have right output, rear channels will have
left output or summed 2-channel operation
+
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+
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page 25
SPEAKER CONNECTIONS
TRI-MODE 6-CHANNEL CONFIGURATION
• Lowest recommended impedance is 2Ω stereo and 4Ω
bridged mono
• Front and rear outputs must be set for full range
operation
• Front and rear outputs must be configured for stereo
operation
• Passive crossover frequencies must not overlap.
WARNING! Failure to do so may result in damage to
the amplifier
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4 Ohm Minimum
4 Ohm Minimum
page 26
OUTPUT CONFIGURATIONS
Three position switches determine output configuration for the XTREME amplifiers. Each stereo pair of channels can be configured in either stereo,
summed-bridged and bridged-mono. The switch or switches are located on he outermost edge of the amplifier.
When the switch is in the left position, the output channels are configured for stereo operation.
When the switch is in the center position, the output channels are configured for summed mono operation by
mixing the left and right input signals together.
When the switch is in the right position, the output channels are configured for a single bridged output using a
single RCA input. To determine which RCA to use, refer to the marking in parenthesis. For the front outputs, the
Right RCA input is used. For the rear outputs, the Left RCA input is used.
page 27
4-CHANNEL AMPLIFIER INPUT CONFIGURATIONS
The 2-channel input / 4-channel input switch routes RCA input from the front RCA inputs to the rear section of the amplifier. This allows the
XTREME 4-channel amplifier to utilize a single set of RCAs to feed signal to both the front and rear channels of the amplifier.
When the switch is in engaged, signal from the front RCA input is routed to the rear RCA inputs.
NOTE: In this configuration, the rear RCA inputs can be routed to another amplifier. The signal leaving the amplifier
is a copy of the incoming signal.
When the switch is disengaged, front and rear RCA inputs are independent. This allows a source unit with an
internal fader to fade between the front and rear outputs.
INTERNAL CROSSOVER CONFIGURATION
The XTREME 200 and 400.4 amplifiers use multi-position switches to determine their crossover configurations. The multi-position switch (dual
switches on the XTREME 400.4) is located on the adjustment side of the amplifier. Listed below are the switch positions and their respective
crossover configurations. NOTE: On 4-channel amplifiers, the front and rear crossover settings are independently adjusted.
When the switch is in the “OFF” position, the crossover section of the amplifier is bypassed. Amplifier output is full
range.
When the switch is in the center position, the crossover is configured for high-pass operation.XTREME amplifiers
have a fixed frequency crossover set to 100Hz at 12dB/octave.
page 28
When the switch is in the right position, the crossover is configured for low-pass operation. XTREME amplifiers
have a fixed frequency crossover set to 100Hz at 12dB/octave.
FINE TUNING THE CROSSOVER
The crossover section is marked at four frequency points for ease of system adjustment. These points
are 45Hz, 175Hz, 600Hz and 5,000Hz. Specific crossover points can be chosen based on the recom-
mended operational bandwidth of your speakers.
2,500Hz
3,500Hz
There are three small dots on the frequency range dial. These dots represent commonly used ORION
crossover frequencies. These crossover frequencies are 85Hz, 2,500Hz and 3,500Hz respectively.
85Hz
SIGNAL INPUT AND OUTPUT LEVEL CONTROLS
XTREME amplifiers have separate front and
rear level adjustments. The input sensitivity
of these adjustments range from 200mv up
to 5Vrms on the RCA inputs. This allows easy
integration from any source unit either with
RCA outputs or speaker outputs. Refer to
the Testing the System and the Adjusting
the Sound of the System sections for
detailed instructions on setting up the level
controls.
page 29
CHOOSING MOUNTING LOCATIONS
The location of your XTREMEamplifier will depend on several important issues. Due to the low profile size of the XTREME 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 mounting surface. As with any amplifier, there are several
possible mounting locations and configurations that can be optimal. We will cover the most obvious of situations.
PASSENGER COMPARTMENT
If you are going to mount the amplifier in the passenger compartment, make sure you have
adequate room for ventilation. XTREME amplifiers have been designed to make possible under seat
mounting. When mounting your amplifier under a seat or similar area, keep a minimum of 1” of
clearance around the amplifier for adequate cooling.
1" Minimum
SPEAKER OUTPUTS
R
E
M
O
T
E
F
U
S
E
POWER
RIGHT
LEFT
R
E
M
B
R
I
D
G
E
D
REM
GAIN
1
2
V
+
G
N
D
TRUNK COMPARTMENT
Mounting XTREME amplifier in the trunk provides excellent performance as long as you do not
mount the amplifier upside down or restrict the airflow around the heatsink of the amplifier. For
optimal results, mount the amplifier with the cooling fins in the vertical position. This type of
mounting will yield the best cooling due to the convection effect of the amplifier chassis.
SPEAKER OUTPUTS
R
E
M
O
T
E
F
U
S
E
POWER
G A I N
R E M
1
2
V
+
G
N
D
RIGHT
LEFT
B R I D
R
G
E M D
E
R
E
M
B
R
I
D
G
E
D
REM
R I G H T
L E F T
1
2
V
+
G
N
D
GAIN
P O W E R
F U S E
R E M O T E
S P E A K E R O U T P U T S
ENGINE COMPARTMENT MOUNTING
Do not mount XTREME amplifier in the engine compartment. The amplifier was not designed to
endure the harsh environment of the exterior elements.
R
WE
PO
SE
FU
E
OT
EM
+
12V
G
ND
R
TS
PU
UT LEF
T
REM
N
GAI
E
R
O
T
K
G
H
EA
SP
RI
ED
BR
IDG
REM
page 30
GENERAL PRECAUTIONS AND INSTALLATION TIPS
Caution: 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 the XTREME amplifier unmounted. Failing to securely mount the amplifier can result in damage or injury, particularly in the event of
an accident. An unmounted amplifier acts like a heat-seeking missile in the event of a crash. Never mount a XTREME amplifier where it might
get wet. Mount the XTREME 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, ideally 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 XTREME amplifier, replace the fuse with the same size ATC 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 higher
current fuse may result in damage to the XTREME amplifier which is not covered under warranty.
NOTE: Make sure all the equipment in the system is turned off when making or breaking connections to the XTREMEinput RCAs or speakers
terminals. Turn on the system and slowly turn up the volume control only after double checking all wire connections.
Power for systems with a single XTREME amplifier can be supplied by most any automotive electrical system. Systems with multiple amplifiers
may require a higher capacity battery, alternator or the use of a storage capacitor. WE strongly recommend the use of both a Transient Storage
Capacitor and a MBR70 with an extra battery in larger stereo systems.
XTREME amplifiers generate a certain amount of heat as part of normal operation. Be sure the area around the cooling fins is unobstructed to
allow adequate air circulation. Remember, beach blankets, last weeks laundry, school books and homework papers located on top of the
amplifier, do not improve air flow.
page 31
STEP BY STEP INSTALLATION
Step 1
Step 2
Step 3
Determine the location for the amplifier. Refer to the Mounting Locations section in this manual for detailed information.
Decide on the system configuration for your amplifier. For system suggestions, refer to the System Planning section of this manual.
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, 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 themselves. 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 such that
the chassis of the amplifier is twisted or bent.
Step 6
Step 7
Step 8
Turn the vehicle’s key switch on the off position.
Disconnect the vehicle’s battery ground terminal.
Connect the RCA and speaker wires to the amplifier. Check the quality of your speakers and signal connections. This will determine the
ultimate performance of your ORION amplifier. Refer to the Input section of this manual for correct wiring instructions.
Step 9
Connect power wires to the amplifier. At this time do not connect the fuse at the main battery.
Step 10 Reconnect the ground terminal to the battery.
Step 11 Set crossovers. Refer to the Internal Crossover Sections of this manual for detailed instructions.
Step 12 Once satisfied that all connections and settings are correct, install the fuse at located near the vehicle’s battery and proceed to the testing
the system section of this manual.
WARNING! Never exceed the recommended fuse size of this amplifier. Failure to do so will result in the void of your warranty.
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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 XTREME system.
Step 1 Check all the wiring connections to be sure they are correct and secure.
Step 2 Turn the signal source volume control down all the way. Set any tone controls to their flat or defeated positions. This includes the
loudness control.
Step 3 Turn the level controls of the amplifier to their minimum positions.
Step 4 Turn the source unit on. Check to see if the remote power LED locate on the connection side of the amplifier is lit. If not, please refer
to the power connections section and the trouble shooting section of this manual for instructions.
Step 5 If using a 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 section and the trouble shooting section of this manual to solve your installation
problems.
Step 6 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 configured properly, refer to the internal crossover section of this manual and take corrective
action.
Step 7 If the output is clear and undistorted, continue to the adjusting the sound of the system section of this manual.
page 33
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 down all the way. Set any tone controls to their flat or defeated positions. This includes the
loudness control.
Step 2 Turn the level controls of the amplifier to their minimum positions.
Step 3 Choose music with high dynamic content that you like and that you are familiar with and will be most often used in the system.
Step 4 Turn the unit up to its highest undistorted output level. If you lack test equipment, this point occurs between 3/4 to full volume depend-
ing on the quality of your source unit. Listen for any audible distortion, 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.
Step 5 While listening to your chosen dynamic music, turn up the level control corresponding to the midrange 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.
Step 6 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.
Step 7 Fine tune crossover setting and output level between midrange and tweeters. Refer to the internal crossover section of this manual for
detailed instructions.
Step 8 Repeat Steps 5-7 for the rear speakers. If you do not have rear speakers continue to Step 10.
Step 9 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 crossover setting and output level between satellite speakers and the woofers. Refer to the internal crossover section of this
manual for detailed instructions. If using an RGC-1, adjust the level to match the output of the woofer to match the sonic requirements
of the system.
Step 12 Enjoy your awesome ORION sound system.
page 34
TROUBLESHOOTING TIPS
SYMPTOM
PROBABLE CAUSE
Low or no remote turn-on input
Fuse blown
ACTION TO TAKE
No output
Check remote turn-on voltage output at amplifier and fix as needed.
Check power wire integrity and check for speaker shorts.
Fix as needed and replace fuse.
Power wires not connected
Audio input not connected
Speaker wires not connected
Speakers are blown
Check power wire and ground connections and fix or replace as needed.
Check RCA connections and fix or replace as needed.
Check speaker wires and fix or replace as needed.
Check system with known working speaker and fix or replace
speakers as needed.
Audio cycles on
and off
Thermal protection engages when
amplifier heatsink temperature
exceeds 90°C (190°F)
Make sure there is proper ventilation for amplifier and improve
ventilation as needed
.
Loose or poor audio input
Loose power connections
Check RCA connections and fix or replace as needed.
Check power wire and ground connections and fix or replace as needed.
Distorted output
Amplifier level sensitivity set too high
Exceeding maximum capability
of amplifier
Readjust gain. Refer to Adjusting the Sound of the System
section of this manual for detailed instructions.
Impedance load to amplifier too low
Check speaker impedance load, if below 2Ω stereo or 4Ω mono.
rewire speakers to achieve a higher impedance.
Shorted speaker wires
Check speaker wires connections and fix or replace as needed.
Speaker not connected to
amplifier properly
Check speaker wiring and fix or replace as needed. Refer to the
Speaker Connections section of this manual for detailed instructions.
page 36
Distorted output
Internal crossover not set properly
for speakers
Readjust crossovers. Refer to the Internal Crossover section of this
manual for detailed instructions.
Speakers are blown
Check system with know working speakers and fix or replace as needed.
Check speaker polarity and fix as needed.
Poor bass response
Speakers wired with wrong polarity
causing cancellation at low frequency
Crossover set incorrectly
Reset crossovers. Refer to the Internal Crossover section of this manual
for detailed instructions.
Impedance load at amplifier is too low
Check speaker impedance load, if below 2Ω stereo or 4Ω mono
rewire speakers to achieve a higher impedance.
Battery fuse
blowing
Short in power wire or incorrect
power connections.
Check power and ground connections and fix or repair as needed.
Fuse used is smaller than recommended
Too much current being drawn
Replace with proper fuse size.
Check speaker impedance load, if below 2Ω stereo or 4Ω mono
rewire speakers to achieve a high impedance.
Check power and ground connections and fix or repair as needed.
Amplifier fuse
blowing
Too much current being drawn
Check speaker impedance load, if below 2Ω stereo or 4Ω mono rewire
speakers to achieve a high impedance and replace with recommended
size fuse.
Check power and ground connections and fix or repair as needed.
Replace with proper fuse size.
Fuse used is smaller than recommended
Impedance load at amplifier too low
Check speaker impedance load. If below 2Ω stereo or 4Ω mono, rewire
speakers to achieve a higher impedance.
Speaker is blown with shorted outputs
Check system with known working speakers and fix or replace as needed
page 37
AUTOSOUND 2000 TROUBLESHOOTING TIPS
QUICK CHECK FOR TROUBLESHOOTING CAR AUDIO SYSTEMS
Preface:
All audio systems exhibit noise; however, if the level of noise is low enough, and the signal level high enough, noise should
not be a problem. This means that it is very important that the signal level throughout the system be optimized BEFORE
dealing with your noise problem. Using a scope (or a small portable amplifier) and Track 99 (1kHz at all high bits) of
Autosound 2000’s CD #101, or tracks 24 through 29 of Autosound 200’s CD #102, adjust the system so that when the maximum
usable signal level of the deck is fed into the system, all the preamp level components clip at the same time. However, we
recommend up to as much as a 3:1 voltage overlap with the power amplifiers; i.e. an amplifier with a 2 volt minimum sensi-
tivity can be driven by up to 6 volts of signal.
Noise Overview:
Car audio electrical accessories are notorious for interfering with car audio systems. The interference commonly arises from
three areas:
1) Power line noise (5%), which can be attenuated with in-line noise filters,
2) Inadequate power supply isolation (45%), which can be cured with transformer signal coupling, additional isolated power
supplies, or changing out components, or
3) Inductive interference (45%) - Including loop area inductive noise picked up by the signal cables - which can be remedied
by relocating or rewiring components, rerouting signal cables, or using twisted cable or balanced transmission systems.
AUTOSOUND 2000 1-2-3 METHOD OF LOGICAL TROUBLESHOOTING
I.
MUTE THE AMP(S). Insert a muting plug (shorted male RCA connector) into each amplifier channel. Turn up the amp sensitivity. Start the car
and turn on the headlights, air conditioning, brake lights, etc. Listen for noise in each speaker. Be very picky here!
A. If still noisy, substitute a small test speaker with short leads for the speakers, crossovers, and speaker leads in the car. If still noisy,
substitute an isolated power supply (120 VAC to 13.8 VDC bench supply or a small motorcycle battery) for the car’s alternator. If the
amplifier is noisy with the test speaker, you have a BAD amp. Send it in. It really doesn’t matter if it is quiet or noisy while running on the
isolated supply because you have a BAD amp. Send it in for repair and if it was quiet on the isolated supply, indicate so on the repair tag.
page 38
B. If your muted amp is quiet, you’ve just joined 99.5% of car audio. Amps are usually very clean and do NOT pick up
unwanted noise! Continue on to Step II.
II. DECK TO AMP. Using a new set of signal cables, connect one channel from the output of the deck directly into one
channel of your clean amp. Run the cables outside the car and as far away as possible from the metal of the car. (For
noise purposes, consider a 2" thick cushion of electromagnetic energy emanating from every metal surface in the car.)
A. If still noisy, congratulations, in all probability your equalizer, electronic crossover, DSP whatchamacallit, are just fine.
This means that you can’t get your deck playing quiet with your amp, right? go to Step III.
B. If all is quiet, congratulations, in all probability your deck and amplifier(s) are fine - you obviously have a problem
with your equalizer, electronic crossover, DSP, etc. Skip on down to “Time for the Processors.”
III. MOVE THE DECK. If you’re at this step, it is time to turn your system into an “amplified deck” by temporarily relocating
the deck right ON TOP of the clean amplifier. Then using very, very short signal cables, connect the output of the deck
into the input of the amp and test for noise. Play a zero bit track - silence - and make sure all is completely quiet.
A. If still noisy, you’re in a heap of trouble, We suggest that you try another deck and give us a call so that we can put
your name into the ecord books. It’s a bad car audio day for you.
B. If the deck is quiet, then congratulations, you’re on your way to a successful installation. It is now time to slowly,
methodically, reinstall the deck back into its final position. Test for noise each step of the way. If the noise returns,
suspect the signal cables, forget shielding because it will have only a very, minimal effect within the audio band. We
highly suggest using twisted pair cables or a balanced transmission system for cable induced noise.
TIME FOR PROCESSORS
By the end of Step III, you should have the deck playing quietly with the amp, with the quiet cables quietly routed. So it’s
time to add the signal processors - one at a time - back into the system. Simply repeat Steps II and III with the equalizer, then
the electronic crossover, etc. However, before MOVING THE SIGNAL PROCESSORS to the amplifier, we highly suggest that
you supply power to the noisy processor from an isolated power supply rather than the car’s +12 volt DC and chassis ground.
Make sure to also connect the turn-on lead to the isolated power supply. If the processor is now quiet , then it is highly
page 39
probable that the component has inadequate isolation. Solutions include, changing components or permanently adding an
external isolated power supply (Call Autosound 2000 at 209-465-3450 for info on isolated power supplies).
SUMMATION
During the design stage of your vehicles, try to avoid using extra batteries and high output alternators. Extra batteries are
nothing but loads as soon as the engine is started and high output alternators usually make more noise than stock alterna-
tors. Also, extra batteries installed in the trunk of a car will ALWAYS force extra ripple current to flow over the car.
Install Transient Storage as close to the power supply input of your amplifier as possible. The big caps will feed the switching
power supplies of your amps and minimize the inductive losses in your power wiring. Plus, they will help your peak system
response.
In problem cases, we highly recommend the use of twisted pair cable rather than coaxial cable for RCA leads. This practice
will greatly minimize cable induced noise - especially in four channel amps!
Don’t forget that your system is only as good as its worst component. Do NOT use components with inadequate power supply
isolation or you will be asking for problems.
The best electrical ground on a car is the CHASSIS of the car. Do NOT run ground leads up to th
e case of the alternator or the negative battery post. Keep ALL ground leads as short as possible.
With properly isolated components, it does NOT matter where the component is grounded. With inadequately isolated
components, it matters! With poorly isolated components, different grounds can cause different noises.
The deck is the signal reference ground for the entire sound system. The deck usually has THREE connections to the car’s
chassis: The black ground lead, the base of the antenna, and the metal-to-metal bond between the case of the deck and the
chassis of the car. With three grounds, there is usually NO cause to worry about the ground of a deck.
Amplifiers are usually designed with adequate power supply isolation. This means that it should not matter where a deck is
grounded. (Decks are grounded three times and amps float. This is car audio!)
page 40
The more components installed on a signal path, the more chances for noise to enter a system. The more electrical accessories
on a car, the more noise will be produced by the alternator.
This information was compiled from more than 20 years of working in car audio. If you would like more information on this
topic, or any other technical aspect of car audio, please call 209-465-3450 and ask for a subscription to Autosound 2000 Tech
Briefs - the monthly magazine for the technically inclined.
page 41
HIGH PERFORMANCE CAR AUDIO
AMPLIFIERS, SIGNAL PROCESSORS
AND LOUDSPEAKERS
HIGH PERFORMANCE CAR AUDIO
©1998 Orion Industries, Incorporated
9235 S. McKemy St., Tempe, Arizona 85284
Phone: 602.705.5600 Fax: 602.705.5788
One of the ADST family of companies
Part#8900-0112 1/99
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