Orion Car Audio 800.4-2 Stereo Amplifier User Manual

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TABLE OF CONTENTS
INTRODUCTION o © 4
WARRANTY a 7
SPECIFICATIONS | _ В 9
END PANEL LAYOUT | 11
INPUT CONIFURATIONS | 12
4-CHANNEL INPUT CONFIGURATION - 12
RCA INPUT/COPY 1+2 ns I 13
INTERNAL CROSSOVER CONFIGURATION 13
INTELLI Q | 17
REMOTE GAIN OPERATION 19
INPUT GAIN 19
POWER CONNECTIONS | 20
SPEAKER CONNECTIONS | 21
INSTALLATION | 25:
TESTING THE SYSTEM a во
ADJUSTING THE SOUND OF THE SYSTEM 31
TROUBLESHOOTING TIPS | 32
AUTOSOUND 2000 TROUBLESHOOTING TIPS | | | | | a. 34
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 car audio amplifier money can
buy. Listed below are the features of the XTREME 800.4.
* XTREME 800.4 — 93.75 watts per channel, 4-channel amplifier with fully variable low-pass crossovers from 45Hz to 5khz. The high-
pass crossover is continuously variable from 10Hz to 10kHz. The XTREME 800.4 has the INTELLIQ subwoofer optimizing circuitry and
dual remote gain capability. The XTREME 600.4 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 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 the installation.
page 4
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.
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 setup 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 (480)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 5
WHAT’S IN THE BOX
(1). XTREME amplifier
(1) 4 gauge power and ground connector
(1) 12 gauge speaker and remote connector
(4) +8 self-tapping black Phillips pan head screws
(1) XTREME installation and operation manual
NOTE: The XTR amplifier handies are an optional accessory available at your local authorized ORION dealer.
Ln
WARRANTY
ORION Industries Inc. warrants this product to be free from defects in material and workmanship under the following terms:
page 6
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 (480) 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. |
¢. 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.
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. a
page 7
For all warranty and non-warranty service issues, please refer to your nearest Authorized ORION Dealer for assistance. If you require
additional information or assistance regarding service repair issues, please call (480) 705-5600. |
Exclusion
1. This warranty is in lieu of all other warranties expressed of 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 and you may also have other rights which vary from state to state.
SAVE YOUR RECIEPT!
ММММММИ
SPECIFICATIONS
Amplifier | XTREME 800.4 Front Channels | XTREME 800.4 Rear Channels
Power output 4 Q stereo (watts)' 100 x 2 100 x 2
100 x 2, 400 x 1 100 х 2, 400 х 1.
Роууег output 2 Q stereo (watts)? 200 x 2 200 x 2
Power output 4 Q mono (watts)! 400 x 1 400 x 1
Distortion all channels driven - <0.1% THD <0.1% THD
(from 20Hz to 20kHz)
Frequency Response
20Hz to 20kHz +0.25dB
20Hz to 20kHz +0.25dB
Linear Bandwidth
6HZ to 50kHz +3dB
6Hz to 50kHz +3dB
Signal-to-noise ratio full bandwidth
@ rated output power
>100dB
>100dB
Damping factor @ output connector
@ full bandwidth
>400 at output connector
>400 at output connector
Slew Rate >30Vus >30Vus
Input Sensitivity? 200 mV to 5 Vrms 200 mV to 5 Vrms
Input Impedance 20 k ohm 20 k ohm
Fuse Type
(3) 20 Amp ATC
(3) 20 Amp ATC
page 9
Crossover?
XTREME 800.4 Front Channels
XTREME 800.4 Rear Channels
Low-Pass Crossover
Continuously variable
Continuously variable
Low-Pass Frequency Range
45Hz to 5kHz
45Hz to 5kHz
High-Pass Crossover
~ Continuously variable
Continuously variable
High-Pass Frequency Range
10Hz to 10kHz
45Hz to 5kHz _
High-Pass INTELLIQ Range OdB to 10dB of Boost n/a
General
Dimensions 18”L x 10.25" W x 2.25” H 18”L x 10.25” W x 2.25" H
(457mm x 260mm x 57mm)
(457mm x 260mm x 57mm)
& WON =
All channels driven, continuous rated 4Q load, 20Hz to 20,000Hz, >0.1% THD, per input voltage at 13.8VDC.
All channels driven, continuous rated 2Q load, 20Hz to 20,000Hz, >0.1% THD, per input voltage at 13.8VDC.
XTREME amplifiers 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.
END PANEL LAYOUT
1.
10.
11.
12.
13.
14.
15.
16.
Power LED - lights up when the amplifier is on
Low-pass crossover frequency control-adjusts the front channel
low-pass crossover frequency (page 14)
Low-pass crossover switch-activates the front channel low-pass
crossover (page 14)
INTELLIQ gain-adjusts the level of INTELLIQ from OdB to 10dB of
boost (page 17)
High-pass crossover “x10” switch-changes the high- pass crossover
freguency range (page 15)
High-pass crossover frequency control-adjusts the front channel
high-pass crossover frequency (page 15)
High-pass crossover switch-activates the front channel high-pass
crossover (page 15) |
Front Gain Control - continuously adjusts from 200mV to 5Vrms
for full power output (page 19)
Front Input Configuration Switch - determines the input
configuration for the front channels (page 12)
Front RCA Inputs- accepts RCA input from a source unit, pream-
plifier or equalizer for the front channels
Rear RCA Inputs- accepts RCA input from a source unit, preampli-
fier or equalizer for the rear channels
2 RCA IN / 4 RCA IN Switch - configures the amplifier for two or
four RCA inputs (page 12)
Rear Output Configuration Switch - determines the output
configuration for the rear channels (page 12)
Rear Crossover Control - adjusts the frequency for the rear
channels (page 14)
RCA INPUT / COPY 1+2 button configures rear channels for direct
input or output of front channel crossover and gain (page 13)
Rear Gain Control - continuously adjusts from 200mV to 5Vrms
for full power output (page 19)
page 10
, E E E я A Ls A. и : ” E > «я E и Е
o SPEAKER OUTPUTS
RIGHT LEFT
REM + BRIDGED — — BRIDGED
FR REAR
SPEAKERS SPEAKERS
17.
18.
19.
20.
21.
22.
23.
18 19 20 21 | 23 |
Rear Crossover Switch - configures the rear channel for high-
pass, low-pass or full range operation (page 13)
REM Remote Turn-on Input - turns on the amplifier when fed
12 V+ (page 20)
Front speaker output- allows up to 12 gauge speaker wire (page
21) |
Rear speaker output- allows up to 12 gauge speaker wire (page
21) |
Remote Gain-allows dashboard control of the amplifier output
level (page 19)
Fuse - protects the amplifier from over current situations
Power Connections - allow up to 4 gauge power and ground
cables (page 20)
page 11
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.
ma
sr/ / mono my When the switch is in the left position, the output channels are configured for stereo operation.
SUM (L+R)
When the switch is in the center position, the output channels are configured for summed mono operation by
sr /[ Imono (Fa) mixing the left and right input signals together. Use this setting when using a pair of RCA inputs.
SUM (L+R)
(Cm When the switch is in the right position, the output channels are configured for a single bridged output using a
sr/ / [mono (п) single RCA input. To determine which RCA to use, refer to the marking in parenthesis. For the front outputs, the
SUM (Ler) Left RCA input is used. For the rear outputs, the Right RCA input is used.
4-CHANNEL AMPLIFIER INPUT CONFIGURATIONS
The 2 RCA IN / 4 RCA IN switch routes RCA input from the front RCA inputs to the rear section of the amplifier. This allows the
O XTREME 4-channel amplifier to utilize a single set of RCAs to feed signal to both the front and rear channels of the amplifier.
2 RCA IN = When the switch is in disengaged, signal from the front RCA input is routed to the rear RCA inputs.
4 RCA IN № |
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. |
O - 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. |
2 RCA IN =
ARCAIN Ml
page 12
RCA INPUT / COPY 1+2-
The RCA Input / COPY 1+2 push button switch configures the input for Channels 3 & 4. The feature allows the more
advanced crossover features of the front channels to be routed to both the front and rear channels. Configured in |
this manner, INTELLIQ is now available on all channels of the amplifier as well as bandpass crossovers for midbass and —
en @ midrange speakers.
# RCA м В oo bo |
ACA INPUT 4 SUM +8) When the switch is disengaged, the REAR INPUT RCA input feeds channels 3+4.
СОРУ 1+2 №
When the switch is engaged, channels 3 & 4 receive input signal from the output of channels 1 & 2 after the crossover
output. When the switch is in engaged, signal from the front RCA input is routed to the rear RCA inputs. The front
gain control controls the level of the entire amplifier. The rear gain controls are deactiviated.
4 ECA wm UE
RCAINPUT оО НЮ
СОРУ 1+2 №
REAR INTERNAL CROSSOVER CONFIGURATION
The XTREME 600.4 use multi-position switches to determine the rear crossover configuration. The multi-position switch is located on the
adjustment side of the amplifier. Listed below are the switch positions and their respective crossover configurations.
4 > XK fd >
mJ When the switch is in the “OFF”
position, the crossover section of the amplifier is bypassed. Amplifier output is
OFF HP LP full range.
600Hz 5kHz
Хан [ № | When the switch is in the center position, the crossover is configured for high-pass operation. The rear channels
| | 1 of the XTREME 600.4 are continuously variable from 45Hz to 5kHz.
OFF HP LP |
175Hz 45Hz
page 13
REAR INTERNAL CROSSOVER CONFIGURATION
600Hz 5kHz
me LC
| When the switch is in the right position, the crossover is configured for low-pass operation. The rear channels of
the XTREME 600.4 are continuously variable from 45Hz to 5kHz. |
| |
J] OFF HP LP
7
175Hz 45Hz
FRONT INTERNAL CROSSOVER CONFIGURATION
The front channels of the XTREME 600.4 can be configured for either high-pass, low-pass or bandpass operation. INTELLIQ is a feature of the
amplifier that maximizes the performance of any subwoofer system. INTELLIQ is the one feature that seperates ORION \ amplifiers from the
compitition.
FRONT CHANNEL ADJUSTMENTS
600Hz 5kHz E |
Nt
When the puch button switch is in the “off” position, the low-pass crossover is bypassed.
Am
175Hz 45Hz
LP ON vom НР СНЫ HE Gi ;
LP OFF El HPA TZ TA HIP CEP E :
FRONT CHANNEL ADJUSTMENTS
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600Hz 5kHz _ |
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When the push button switch is in the “on” position, the low-pass crossover is activated. The
crosso ver frequency range is from 45Hz to 5kHz. There are additional reference points at
85Hz, 2.5kHz and 3.5kHz respectively.
| В5Нх
7.
175HZ TOS À
8 E
ВР х НИНЕ вия HP OM em 3
LP ON w= :
HP x THT I MP ONES |
LP OFF |
‚ раде 14
FRONT INTERNAL CROSSOVER CONFIGURATION
FRONT CHANNEL ADJUSTMENTS
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Va $ * O O
175Hz AS | |3dB - Od8 | 35Hz 10Hz
482 038 vue
LP FF ВВ
~ When the puch button switch is in the “off” position, the high-pass crossover is bypassed.
HP x 10HZ = НР ОМ ка
HP x 1HZ [1 HP OFFEJ
Be
| When the push button switch is in the “on” position and the “x10” button is on the on
LEONI CHANNEL ADJUSTMENTS position, the high-pass crossover is activated in the “high” range. The crosso ver frequency
range is from 100Hz to10kHz. There are four corner frequencies at 100Hz, 350Hz, 1,200Hz and
10kHz. This range is usefull when used with smaller diameter midrange and tweeter speakers.
TZ Ghz 648 1008 120Hz 1kHz
of / Мать”
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17547 ASHE 3de ddB | 35Hz 10Hz
LP OR vus
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HP x 10HZ ea HP ON ==
HPx 1HZ DO - HPOFFO
2.
FRONT CHANNEL ADJUSTMENTS
When the push button switch is in the “on” position and the “x10” button is on the off
position, the high-pass crossover is activated. The crossover frequency range is from 10Hz
tolkHz. There are four corner frequencies at 10Hz, 35Hz, 120Hz and 1kHz. This range is
usefull when used with larger diameter midrange and midbass speakers. Additionally, this can
also be used as a “subsonic filter” to prevent potentially damaging low-frequency from
getting to your subwoofer (See INTELLi Q section on page 16.)
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af y EN / \ 7
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HPx 1H7 CC HP OFF]
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page 15
FINE TUNING INTERNAL CROSSOVER
2,500Hz
600HZ 5kHZ
Low Pass Crossover
N 3 500 Hz The low-pass crossover on the front channels and the rear crossover is continuously adjustable
’
7 7
175HZ «#52
85Hz
from 45Hz tro 5kHz. There are three markings surrounding the crossover pot that designate
85Hz 2,500Hz and 3,500Hz respectively.
High Pass Crossover
1,2 00 Hz 10 k Hz When the high-pass crossover push button switch is in the “on” position and the “x10” button
120Hz 1kHZz is on the on position, the high-pass crossover is activated in the “high” range. The crossover
N / frequency range is from 100Hz to10kHz. There are four corner frequencies at 100Hz, 350Hz,
1,200Hz and 10kHz. This range is usefull when used with smaller diameter midrange and
tweeter speakers.
/ N When the high-pass crossover push button switch is in the “on” position and the “x10” button
35Hz ТОНг is on the off position, the high-pass crossover is activated. The crossover frequency range is
350 Hz
INTELLI Q
100 Hz from 10Hz to1kHz. There are four corner frequencies at 10Hz, 35Hz, 120Hz and 1kHz. This
range is usefull when used with larger diameter midrange and midbass speakers. Additionally,
this can also be used as a “subsonic filter” to prevent potentially damaging low-frequency
from getting to your subwoofer.
page 16
FRONT CHANNEL ADJUSTMENTS
SOBRZ Skhz 120Hz 1kHz
PE \ DD
TER AH Зав 085 | 35Hz ТОНЕ
LiF ORY вт HP x 10HZ == HP ON eu
HPx1H7 © НР ОР
In the world of “me too features,” Orion has developed the INTELLi Q circuit that makes : a real differ-
ence in your automotive listening experience.
INTELLi Q (INTELLigently integrated Q adjustment) is actually an infinitely variable “Q” adjustment
found on the high-pass crossover of new XTREME and HCCA “Type R” power amplifiers. By changing the
“Q" of the high-pass from the industry standard 0.707 to any “Q” value between 0.707 and 3.5 (Figure
1), the high-pass filters essentially becomes two filters: a single band parametric equalizer and a subsonic
filter.
By increasing the “Q” value from 0.707 to 3.5, the output is boosted up to 10dB at the high-pass
crossover frequency. The end-panel display is clearly marked in 3dB boost steps. Unlike other manufac-
turers "subsonic filters,” adjusting the INTELLi Q's high-pass crossover frequency easily performed
turning the crossover pot located directly to the right of the “Q" adjustment (Figure 2). The high-pass
crossover is continuously variable from 10Hz to 1kHz or 100Hz to 10kHz via a x10 frequency selector. By
correctly using the INTELLi Q, you can increase low frequency output by as much as 10dB!
Boosting the lower bass frequency does not come without trade-offs. As anyone knows, one of the
greatest potentials for woofer damage is caused by over excursion. Excursion is the forward and
backward movement of a woofer. When the signal to the woofer is incorrectly boosted, the woofer is
required to move more than is capable. For reference, a 6dB of boost requires a woofer to quadruple its
excursion to match the input signal. Ordinary bass boost equalizers boost without protection. Without
any protection, potential for damage is high. | .
The difference of INTELL О
What makes the INTELLI Q different from all other equalizers or sub-sonic filters is that it can boost
lower frequencies the woofer can produce by 10dB while preventing over excursion that can damage the
woofer. The result is your woofer with the loudest low bass it can produce reliably. Here's how to use
it. |
раде 17
INTELLI Q
Setting up and using INTELLi Q
1. The first step to using the INTELLI Q is to install the amplifier. Seriously, basic installation techniques for new XTREME amplifiers remain
unchanged. Set the low-pass crossover as you would in “normal” installations. (Normal Orion of course.)
2. Determine which type of enclosure you are using. Refer to the table below for tuning assistance. For example: for vented enclosures, set
the high-pass crossover to the tuning frequency (port frequency) of the enclosure. If you have a woofer such as the new HCCA woofers up
to 10dB of boost can be used. For woofers of lesser excursion capability, it is recommended to use up to 6dB of boost only.
3. For RTA tuning, start the INTELL Q boost setting at OdB. Using pink noise, slowly increase the Q adjustment until the desired frequency
response is achieved.
. a similar desired effect. | |
4. For tuning by ear, start the INTELLi Q boost setting at 0dB. Using music the high-energy low frequency content, slowly increase the Q
adjustment until the desired sonic performance in achieved.
can lower the crossover frequency to get a similar desired effect
In situations where you are require more boost than is recommended, you can lower the crossover frequency to get
In situations where you are require more boost than is recommended, you
Boost Levels
дав
+3dB
+6dB
. +70dB
Enclosure Type :
Infinite Baffle
Acceptable No Problems Tune
above Fs of woofer
High X-Max Drivers Tune
labove Fs of woofer
Not Recommended
Not Recommended
Sealed Acceptable No Problems Tune [Acceptable No Problems High X-Max Drivers Tune Not Recommended
above Fs of woofer Tune above Fs of woofer above Fs of woofer
Vented Acceptable No Problems Tune [Acceptable No Problems Acceptable No Problems High X-Max Drivers Tune to
to port frequency
Tune to port frequency
Tune to port frequency
port frequency
Sealed Bandpass
Acceptable No Problems Tune
above Fs of woofer
| Acceptable No Problems
Tune above Fs of woofer
High X-Max Drivers Tune
above Fs of woofer
Not Recommended
Vented Bandpass
Acceptable No Problems Tune
to port frequency
Acceptable No Problems
Tune to port frequency
Acceptable No Problems
Tune to port frequency
High X-Max Drivers Tune to
| port frequency
Aperiodic
Set crossover to Fs of
woofer
Set crossover to Fs of
woofer
Set crossover to Fs of
woofer
Not Recommended
REMOTE GAIN
REMOTE
The remote gain port allows remote, user control over the output of the amplifier. When used on a
subwoofer amplifier, the remote gain allows you to change the bass level for different music styles,
driving conditions, or sonic preferences. Unlike other designs, Orion allows remote access to the level of
the amplifier via a digital micro-controller and electronic volume that does not interfere with the sonic
signal chain. The result is a clean clear control of the level of the amplifier that is unaffected by noise.
The XTREME 600.4 has two remote gain ports. This allows for individual control of either the front or
rear channels. One RGC-1 can be used to control the level of the front channels and another RGC-1 can
be used to control the output level of the rear channels. An example benefit of this is having the front
channels in bandpass mode for midbass and the rear channels in low-pass mode for subwoofers. Using
two RGC-1 would give the driver the ability to control the level of both the midbass and subwoofers for
easy optimal tuning. To utilize this function simply plug-in a RGC-1into either the front or rear gain
ports. The RGC-1 is available from your authorized ORION dealer.
© ©
REM
GAIN
REM
GAIN
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 7 еее - \_ > Lan” |
to 5Vrms on the RCA inputs. This allows
easy integration from any source unit |
either with RCA outputs or speaker сло 5
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. 2
FRONT REAR LB
INPUT
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o Ка us
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u. A М
GAIN A aa
ST 1 MONO}
SEA {LA
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OCH
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COPY 117 BE
page 19
POWER CONNECTIONS
* Minimum 8 gauge power and ground cable is recommended for acceptable performance
* 4 gauge power and ground cable is recommended for optimal 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.
O SPEANRER OUTPUTS
RIGHT LEFT RIGHT LEFT
+ =
Connect to remote turn-on
lead of source unit
Fuse less than 18"
from battery
Amplifier Fuse Size
XTREME 800.4 (3) 20 AMP
Vic AIM dT
SPEAKER CONNECTIONS —A-CHANNEL STEREO CONFIGURATION
* Front and rear channel lowest recom-
mended impedance is 2 Ohms 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 (page
11)
* Front outputs can be configured for high-
pass, low-pass or bandpass operation (page
13)
* Front channels equipped with INTELLIQ
subwoofer optimization circuitry (page 16)
* Rear outputs can be configured for high-
pass, low-pass or full range operation(page
13)
* Front and rear outputs can be configured
for either stereo operation or summed for
subwoofer applications (page 11)
2 Ohm Minimum 2 Ohm Minimum
page 21
SPEAKER CONNECTIONS | 3-CHANNEL STEREO/BRIDGED CONFIGURATION
* Front channels are configured for 2-channel stereo
operation (page 11)
o
um
e Front channel lowest recommended impedance is 2 |
Ohms stereo
e Rear channels are configured for a single channel
bridged output (page 11)
* Rear channel lowest recommended impedance is 4
Ohms
* Crossover, output and gain configurations are indepen-
dently adjustable between the front and rear channels
жен, Pr |
e 2-channel or 4-channel input can be used for this
configuration. For source unit fading, use the 4-channel
input mode (page 11)
e Front and rear outputs can be configured for high-pass,
low-pass or full range operation (page 12)
* Front outputs can be configured for either stereo or
summed stereo operation (page 11)
* Rear outputs can be configured for summed bridged or
single channel bridged operation for subwoofer
applications (page 11)
4 Ohm Minimum 2 Ohm Minimum
page 22
SPEAKER CONNECTIONS TWO-CHANNEL BRIDGED CONFIGURATION
* Front and rear channels are configured for bridged 2- | | | | o
channel operation a | | - oo — MEE
* Lowest recommended impedance for both front and rear | | |
channels is 4 Ohms | | o ==
* Crossover and gain configurations are independently
adjustable between the front and rear channels
REAR BEAR CHANNEL A
INPUT
e 2-channel operation is recommended for this operational
mode |
208
OIE 0 si
"29 @ > a,
* Front and rear outputs can be configured for high-pass,
low-pass or full range operation (page 12) =
e 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 (page 11)
Fe
RIGHT LEFT RIGHT LÉFT
+ = + = + = +
© GND
2 Ohm Minimum 2 Ohm Minimum
page 23
SPEAKER CONNECTIONS
* Lowest recommended impedance is 2 Ohm stereo and
4 Ohm bridged mono
* Front and rear outputs must be set for full range
operation (page 12)
* Front and rear outputs must be configured for stereo
operation (page 11)
* Passive crossover frequencies must not overlap.
WARNING! Failure to do so may result in damage to
the amplifier
TRI-MODE 6-CHANNEL CONFIGURATION
INSTALLATION TIPS
4 Ohm Minimum 4 Ohm Minimum
The installation of all ORION components will determine the overall performance result. Improper installation will not only limit the perfor-
mance 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. |
e marking pen
e electric drill with assorted drill bits
* utility knife
° Phillips and flat blade screw drivers
e pliers (standard and needle nose)
* wire brush or sandpaper for chassis grounding
e solder iron and solder
e heat shrink tubing
* nylon tie straps
е volt-ohm meter (optional)
* wire cutters
* wire crimpers
e wire strippers
page 25
MOUNTING THE XTR AMPLIFIER
The XTR amplifiers have a unique mounting system that can be con-
figured for different install situations. By placing the removable
mounting rails in the "in" or "out" positions the look of the amplifier
mounting can be changed to suit personal tastes or installation re-
quirements. In the "in" position, you will not see the amplifier
mounting screws and the amp will "float" above the mounting
screws. The amp can also be mounted in a "standard" manner using
the "out" position. |
FIGURE A | FIGURE A: This figure shows the mounting feet of
- the amplifier in the "in" position. To mount the am-
plifier in this manner you must mount just the two
feet to the mounting surface before screwing them
to the amp. The distance needed between the verti-
cal sides of each foot is noted in the figure to the
| left. Simply measure the distance, mount the feet,
then mount the amplifier to the feet.
XTR800.4 - 13" (457mm) —
FIGURE B
FIGURE B: This figure shows the mounting feet in the
"out" postion. This method can be accomplished by
using the same procedure as above or by simply
mounting the feet to the amplifier and mounting
| | the amplifier to the surface as you would a "nor-
XTR800.4 - 18"(457mm) mal" amp. |
раде 26
CHOOSING MOUNTING LOCATIONS
The location of your XTREME amplifier 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.
2221" Minimum
- 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.
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.
page 27
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 XTREME input 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 amplifi-
ers 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. |
STEP BY STEP INSTALLATION
Step 1 Determine the location for the amplifier. Refer to the Mounting Locations section in this manual for detailed information.
Step 2 Decide on the system configuration for your amplifier. For system suggestions, refer to the System Planning section of this manual.
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, 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. Ве 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 such that
the chassis of the amplifier is twisted or bent.
Step 6 Turn the vehicle's key switch on the off position.
Step 7 Disconnect the vehicle's battery ground terminal.
Step 8 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. o
WARNING! Never exceed the recommended fuse size of this amplifier. Failure to do so will result in the void of your warranty.
page 29
6
t.
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
Step 2
Check all the wiring connections to be sure they are correct and secure.
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
Step 4
Step 5
Step 6
Step 7
Turn the level controls of the amplifier to their minimum positions.
Turn the source unit on. Check to see if the remote power LED located on the connection side of the amplifier is on. If not, please
refer to the power connections section and the trouble shooting section of this manual for instructions.
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 section and the trouble shooting section 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 configured properly, refer to the internal crossover 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.
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
Step 2
Step 3
Step 4
Step 5
Step 6
Step 7
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. |
Turn the level controls of the amplifier to their minimum positions.
Choose music with high dynamic content that you like and that you are familiar with and will be most often used in the system.
Turn the unit 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.
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.
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 crossover setting and output level between midrange and tweeters. Refer to the internal crossover configuration section of
— this manual for detailed instructions.
Step 8
Step 9
Step 10
Step 11
Step 12
Repeat Steps 5-7 for the rear speakers. If you do not have rear speakers continue to Step 10.
Set levels between the front and rear midrange and tweeters for optimum front/rear balance.
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.
Fine tune crossover setting and 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 match the output of the woofer to the sonic
requirements of the system.
Enjoy your awesome ORION sound system.
page 31
TROUBLESHOOTING TIPS
SYMPTOM
PROBABLE CAUSE
ACTION TO TAKE
No output
Low or no remote turn-on input
Check remote turn-on voltage output at amplifier and fix as needed.
Fuse blown
Check power wire integrity and check for speaker shorts.
Fix as needed and replace fuse.
Power wires not connected
Check power wire and ground connections and fix or replace as needed.
Audio input not connected
Check RCA connections and fix or replace as needed.
Speaker wires not connected
Check speaker wires and fix or replace as needed.
Speakers are blown
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
Check RCA connections and fix or replace as needed.
Loose power connections
Check power wire and ground connections and fix or replace as needed.
Distorted output
Amplifier level sensitivity set too high
of amplifier
Readjust gain. Refer to Adjusting the Sound of the System
Exceeding maximum capability section of this manual for detailed
instructions.
Impedance load to amplifier too low
Check speaker impedance load, if below 2Q stereo or 4Q 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 32
Distorted output
section
Internal crossover not set properly
Readjust crossovers. Refer to the Internal Crossover configuration
— Of this manual for detailed instructions.
Speakers are blown
Poor bass response
Speakers wired with wrong polarity
causing cancellation at low frequency
Check system with know working speakers and fix or replace as needed.
Check speaker polarity and fix as needed.
Crossover set incorrectly
Reset crossovers. Refer to the Internal Crossover Configuration section
of this manual for detailed instructions.
Impedance load at amplifier is too low
Check speaker impedance load, if below 2 Ohm stereo or 4 Ohm 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
Replace with proper fuse size.
Too much current being drawn
Check speaker impedance load, if below 2 Ohm stereo or 4 Ohm 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 2Q stereo or 49 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.
Fuse used is smaller than recommended
Replace with proper fuse size.
Impedance load at amplifier too low
Check speaker impedance load. If below 2 Ohm stereo or 4 Ohm mono,
rewir 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 33
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 200s 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 sensitivity 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
|. 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.
‚раде 34
B. If your muted amp is quiet, you've just joined 99. 5% of car audio. Amps are e usually very clean and do NOT pick up
unwanted noise! Continue on to Step Il. |
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 IH. |
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.”
i. 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 record 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,
methodicaliy, 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 lil, 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 il 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 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).
page 35
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 alternators.
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 inadeguate 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 compo-
nents, 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!) |
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 36
NOTES: