CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

What's In The Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Practice Safe Sound™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Record Your Serial Number and Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

End Panel Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Stereo / Mono Input Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Input Gain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Remote Gain Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Auxiliary Output Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Internal Crossover Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Low-Pass Crossover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

High-Pass Crossover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Fine Tuning the Crossovers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Adjusting INTELLi Q . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Infinite Baffle Example High-Pass Set at 30Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Sealed Example High-Pass Set at 20Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Sealed Example High-Pass Set at 30Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Vented Example High-Pass Set at 30Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Amplifier Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Speaker Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Amplifier Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Choosing Mounting Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Passenger Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Trunk Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

General Precautions and Installation Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Tools of the Trade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Step By Step Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Set Up and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Testing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Adjusting the Sound of the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Troubleshooting Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

©2003 Directed Electronics, Inc.

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INTRODUCTION

Thank you for your purchase of Orion's 8002 power amplifier. Each Orion amplifier is designed to be the leader in its class offering the most power, advanced features, and extreme ease of use. In high-end sound systems or high SPL systems, Orion amplifiers will give you years of trouble-free performance.

● 8002 - 200 Watt per channel two-channel high current amplifier with built-in fully variable high-pass, low-pass, or band-pass crossover with INTELLLi Q. Equipped with remote gain capability, the 8002 is capable of three, two, or one channel operation with a maximum power capability of 800 Watts into 4W mono.

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, be sure to read the entire manual before beginning the installation.

What's In The Box

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(1) Amplifier

(1) Extra fuse

(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.

©2003 Directed Electronics, Inc.

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: __________________________________________________

©2003 Directed Electronics, Inc.

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SPECIFICATIONS

Amplifier Section

Power Output 4W Stereo (Watts)1

Power Output 2W Stereo (Watts)2

Power Output 4W Mono (Watts)

Remote Gain

Distortion at Rated Power

Frequency Response

Linear Bandwidth

Signal-to-Noise Ratio at Rated Power

Damping Factor

Input Sensitivity

Input Impedance

Fuse Type

Dimensions

Weight

Crossover Section

Low Pass Crossover

200 x 2

400 x 2

800 x 1

Yes

< 0.1% THD+N

20Hz to 20kHz ±0.25dB

10Hz to 50kHz ±3dB

> 100dB

> 200

200mV to 5V

40kW

80 Amp MAXI

23.4" x 10.5" x 2.3"

10 lbs.

Low Pass Frequency Range

High Pass Filter

High Pass Frequency

INTELLi Q

Continuously Variable

2nd Order / 4th Order

20Hz to 3kHz

Continuously Variable

2nd Order

10Hz to 3kHz

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 13.8VD.

©2003 Directed Electronics, Inc.

END PANEL LAYOUT

1.

Power LED - when lit indicates that the amplifier is on.

2.

Stereo/Mono Switch - configures the amplifier for one or two inputs.

3.

Gain Control - continuously adjusts from 200mV to 5V for full power output.

4.

Copy/Gain/Master Switch - determines the output of the RCA outputs.

5.

RCA Inputs - accepts RCA input from a source unit, preamplifier, or equalizer.

6.

RCA Outputs - provides easy connection to additional amplifiers.

7.

Low-Pass Crossover Switch - activates 2nd or 4th order low-pass crossover.

8.

Low-Pass Frequency Control - adjusts the frequency of the low-pass crossover.

9.

High-Pass Crossover Switch - activates 2nd order high-pass crossover.

10. High-Pass Frequency Control - adjusts the frequency of the high-pass crossover.

11. INTELLi Q Control - continuously adjusts the "Q" boost of the high-pass crossover from 0 to 10dB of boost.

12. Speaker Connections - allow up to 12-gauge speaker wire.

13. Remote Gain Connector - allows the gain of the amplifier to be controlled remotely.

14. 1 MAXI Fuse - protects the amplifier from over current situations.

15. REM Remote Turn-on Input - turns on the amplifier when fed 12 V+.

16. Power Connections - allow up to four-gauge power and ground cables.

©2003 Directed Electronics, Inc.

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Stereo / Mono Input Configuration

The STEREO / MONO switch allows the Orion 8002 amplifier to use a single RCA or highlevel input to feed signal to both the right and left channels of the amplifier. When the switch is to the right (MONO position), signal from the left input is routed to the right channel. When the switch is to the left (STEREO position), right and left inputs are independent.

This allows a source unit with an internal balance to change the stereo imaging.

Input Gain

The Orion 8002 amplifier has separate front and rear level gain adjustments. The input sensitivity of these adjustments range from 200mV up to 5V. This allows easy integration from any source unit. Refer to the Testing the System and the Adjusting the Sound of the System sections for detailed instructions on setting up the level controls.

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. It can be installed in the front of the vehicle to control the amplifier gain level, and 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 amplifiers. Plug the RGC-1 into the first amp.

The first amp must have its RCA output selection switch in the MASTER or GAIN position.

The RGC-1 information will now be sent to subsequent amps via the MASTER signal.

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 minimizes 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 signal 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.

©2003 Directed Electronics, Inc.

Internal Crossover Configurations

The crossover section of the Orion 8002 amplifier is continuously variable 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.

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 manufacturer'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 variable 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 excessive 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 subwoofer. 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 frequency response by an additional 10dB! The type of enclosure used and the woofer's excursion capability determine acceptable boost levels. Listed below are recommended boost levels for different enclosure designs.

©2003 Directed Electronics, Inc.

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Enclosure Type

Infinite Baffle

0dB +3dB

Boost Levels

+6dB +10dB

Tune above High X-Max Not 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 Tune to port Tune to port Tune to port High X-Max frequency frequency frequency Drivers--Tune to port frequency

Aperiodic Set crossover Set crossover Set crossover Not to Fs of to Fs of to Fs of Recommended woofer woofer woofer

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.

8

NOTE: The left graph is the response; the right graph is the driver excursion. These designations apply to the following graphs as well.

©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 output 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.

©2003 Directed Electronics, Inc.

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AMPLIFIER WIRING

Power Connections

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8002 Fuse Size: 1 x 80 AMP MAXI

Power connections accept up to four-gauge wire.

Four-gauge 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.

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.

Speaker Connections

Two Channel Stereo Configuration

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Lowest recommended impedance is 2W stereo.

Stereo input should be used for this configuration.

Outputs can be configured for high-pass, low-pass, or full range operation.

©2003 Directed Electronics, Inc.

Summed Bridged Configuration

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Lowest recommended impedance is 4W bridged mono.

Mono or stereo input can be used for this configuration.

Outputs can be configured for high-pass, low-pass, or full range operation.

Output is configured as summed bridged which is ideal for subwoofer applications.

Single Channel Bridged Configuration

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Lowest recommended impedance is 4W mono.

Mono input must be used for this configuration. Only the Left input is used.

Outputs can be configured for high-pass, low-pass, or full range operation.

Outputs are configured for single channel bridged operation which is ideal for separate left or right channel subwoofer applications.

©2003 Directed Electronics, Inc.

11

Tri-Mode Three Channel Configuration

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Lowest recommended impedance is 2W stereo and 4W bridged mono.

Stereo operation must be used.

Outputs must be configured for full range operation.

Output is configured stereo and summed bridged.

Passive crossover frequencies must not overlap.

WARNING!

Failure to do so may result in damage to the amplifier.

12

©2003 Directed Electronics, Inc.

AMPLIFIER INSTALLATION

Choosing Mounting Locations

The location of your amplifier will depend on several important issues. Due to the low profile 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 minimum 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 cooling 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, 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 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 higher 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 breaking 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.

©2003 Directed Electronics, Inc.

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Power for systems with a single amplifier can be supplied by most automotive electrical systems. 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.

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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

14

Step By Step Installation

Step 1 Determine the location for the amplifier. Refer to the Choosing Mounting

Locations section of this guide for detailed information.

Step 2 Decide on the system configuration for your amplifier. For system suggestions, refer to the Speaker Connections section of this guide.

Step 3 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 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.

Step 5 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 amplifier is twisted or bent.

Step 6 Turn the vehicle's key switch to the off position.

©2003 Directed Electronics, Inc.

Step 7 Disconnect the vehicle's battery ground terminal.

Step 8 Connect power wires to the amplifier (ground first, then 12 V(+) and RGC).

Step 9 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 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 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 section 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 Check all the wiring connections to be sure they are correct and secure.

Step 2 Turn the signal source volume control all the way down. 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 power LED located on the connection side of the amplifier is on. If not, please refer to the Power

Connections and the Troubleshooting Tips sections of this manual for instructions.

Step 5 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.

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 Configuration 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.

©2003 Directed Electronics, Inc.

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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 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, with which you are familiar, and will be used most often in the system.

Step 4 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 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 the level control back 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 the output level between midrange and tweeters. Refer to the

Internal Crossover Configuration 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 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.

©2003 Directed Electronics, Inc.

Troubleshooting Tips

Symptom

No output

Probable Cause Action To Take

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

Speakers are blown

Check speaker wires and repair or replace as needed.

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 Readjust gain. Refer to the set too high exceeding Adjusting the Sound of the maximum capability of amplifier

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.

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Symptom Probable Cause Action To Take

Distorted output

Internal crossover not set Readjust crossovers. Refer to the properly for speakers 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 Replace with proper fuse size.

recommended

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 Replace with proper fuse size.

recommended

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

Actual current exceeds fuse rating

Check system with known work ing speakers and fix or replace as needed.

Check speaker impedance load.

If below 1W, rewire speakers to achieve higher impedance.

©2003 Directed Electronics, Inc.

NOTES

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©2003 Directed Electronics, Inc.

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©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. G47435 2-03