CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Practice Safe SoundTM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Limited Two-Year Consumer Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Record Your Serial Number and Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 End Panel Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Stereo / Mono Input Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Input Gain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 INTELLi Bass Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Internal Crossover Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Low-Pass Crossover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 High-Pass Crossover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 High-Pass Woofers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Fine Tuning the Crossover Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Auxiliary Output Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Amplifier Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Speaker Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Amplifier Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Choosing Mounting Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Passenger Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Trunk Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 General Precautions and Installation Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Tools of the Trade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Step By Step Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Set Up and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Testing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Adjusting the Sound of the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Troubleshooting Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 ©2003 Directed Electronics, Inc. 1 INTRODUCTION Thank you for your purchase of Orion's 4002 or 6002 amplifier. Each Orion amplifier is designed to be the leader in its class offering the most power, advanced features, and ease of use. Orion amplifiers are designed as the best affordable high end car audio amplifier money can buy. Listed below are the features of the new Orion 4002 and 6002. 4002 - 100 Watts per channel, two-channel amplifier with dual built-in fully variable high-pass, low-pass, and band-pass 12dB/octave crossovers and INTELLi Bass. The 4002 is capable of 3, 2, or 1 channel operation with a maximum power capability of 400 Watts into 4W mono. 6002 - 150 Watts per channel, two-channel amplifier with dual built-in fully variable high-pass, low-pass, and band-pass 12dB/octave crossovers and INTELLi Bass. The 6002 is capable of 3, 2, or 1 channel operation with a maximum power capability of 600 Watts into 4W mono. The installation of all Orion 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 the 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 (1) Amplifier (1) Extra Fuse (1) Allen Wrench 2.5mm (1) Allen Wrench 3mm (4) #8 self-tapping black Phillips pan head screws (1) Amplifier installation and operation manual PRACTICE SAFE SOUNDTM 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. 2 ©2003 Directed Electronics, Inc. LIMITED TWO-YEAR CONSUMER WARRANTY Directed Electronics, Inc. promises to the original purchaser, to replace this product should it prove to be defective in workmanship or material under normal use, for a period of two years from the date of purchase by the dealer as indicated by the date code marking of the product PROVIDED the product was installed by an authorized Directed dealer. During this two year period, there will be no charge for this replacement PROVIDED the unit is returned to Directed, shipping pre-paid. If the unit was installed by anyone other than an authorized Directed dealer, the warranty period will be 1 year from date of purchase by the dealer as indicated by the date code marking of the product. During this 1 year period, there will be no charge for this replacement PROVIDED the unit is returned to Directed, shipping pre-paid. This warranty is non-transferable and does not apply to any unit that has been modified or used in a manner contrary to its intended purpose, and does not cover damage to the unit caused by installation or removal of the unit. This warranty is void if the product has been damaged by accident or unreasonable use, neglect, improper service or other causes not arising out of defects in materials or construction. ALL WARRANTIES INCLUDING BUT NOT LIMITED TO EXPRESS WARRANTY, IMPLIED WARRANTY, 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. 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. 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: Purchased from: __________________________________________________ __________________________________________________ __________________________________________________ Date of Purchase: __________________________________________________ ©2003 Directed Electronics, Inc. 3 SPECIFICATIONS Amplifier Section Power Output 4W Stereo (Watts)1 Power Output 2W Stereo (Watts)2 Power Output 4W Mono (Watts) Distortion with all channels driven at rated power (20Hz to 20kHz) Frequency Response Linear Bandwidth Signal-to-Noise Ratio at Rated Power Damping Factor Slew Rate Input Sensitivity Input Impedance Fuse Type Dimensions Weight Crossover Section Low Pass Crossover Continuously Variable 2nd Order (12dB per octave) 20Hz to 3kHz Continuously Variable 2nd Order (12dB per octave) 20Hz to 3kHz 10dB boost 45Hz Continuously Variable 2nd Order (12dB per octave) 20Hz to 3kHz Continuously Variable 2nd Order (12dB per octave) 20Hz to 3kHz 10dB boost 45Hz Orion 4002 100 x 2 200 x 2 400 x 1 < 0.1% THD+N 20Hz to 20kHZ ±0.25dB 10Hz to 50kHz ±3dB > 100dB > 200 > 20V per usec 200mV to 5V 40kW (2) 20 Amp ATC 18.4" x 10.5" x 2.3" 11 lbs. Orion 6002 150 x 2 300 x 2 600 x 1 < 0.1% THD+N 20Hz to 20kHZ ±0.25dB 10Hz to 50kHz ±3dB > 100dB > 200 > 20V per msec 200mV to 5V 40kW (1) 60 Amp MAXI 22.4" x 10.5" x 2.3" 12.5 lbs. Low Pass Frequency Range High Pass Filter High Pass Frequency INTELLi Bass INTELLi Bass Center Frequency 1. All channels driven, continuous 4W load 20Hz to 20kHz, < 0.05% THD, with input voltage at 13.8VDC. 2. All channels driven, continuous 2W load 20Hz to 20kHz, < 0.1% THD, with input voltage at 13.8VDC. 4 ©2003 Directed Electronics, Inc. END PANEL LAYOUT 1. 2. 3. 4. 5. 6. 7. 8. 9. Power LED - when lit indicates that the amplifier is on. Stereo/Mono Switch - configures the amplifier for one or two inputs. Gain Control - continuously adjusts from 200mV to 5V for full power output. Copy/Master Switch - Determines the output of the RCA outputs. RCA Inputs - accepts RCA input from a source unit, preamplifier, or equalizer. RCA Outputs - provides easy connection to additional amplifiers. Low-Pass Crossover Switch - activates 2nd order low pass crossover. Low-Pass Frequency Control - adjusts the frequency of the low-pass crossover. 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 Bass Control - continuously adjusts from 0 to 10dB of boost. 12. Speaker Connections - allow up to 12-gauge speaker wire. 13. (2) ATC Fuse - protects the amplifier from over current situations. 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. 5 Stereo / Mono Input Configuration The STEREO / MONO switch routes input from the front inputs to the rear section of the amplifier. This allows the Orion 4002 and 6002 amplifiers to utilize 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 4002 and 6002 amplifiers have gain adjustments with an input sensitivity 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. INTELLi Bass Control INTELLi Bass maximizes the performance of a subwoofer and allows for continuous adjustment of low frequency boost. INTELLi Bass can be adjusted from 0dB to 10dB of boost centered at 45Hz. Initially the Q is very low (wide). As INTELLi Bass is added, the Q rises (narrows). This allows the Orion 4002 and 6002 to overcome acoustic deficiencies in your vehicle. The type of enclosure used, the sub-woofer's excursion capability, personal preference, and attitude determine acceptable boost levels. WARNING! Exercise caution when setting INTELLi Bass. Maximum boost can potentially cause woofer damage due to overexcursion. Internal Crossover Configuration The crossover section of Orion 4002 and 6002 amplifiers is continuously variable and extremely flexible. There are eight different crossover configurations possible allowing high-pass, low-pass, and band-pass operation. This circuit is designed to optimize the performance of subwoofers in all types of enclosures. When using Orion loudspeakers, minor deviations from ...