CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 What's In The Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Practice Safe SoundTM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Limited Two-Year Consumer Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Record Your Serial Number and Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Amplifier Controls and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Amplifier Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Four-Channel Amplifier Input Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Internal Crossover Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Low-Pass Crossover (Front and Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 High-Pass Crossover (Front and Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 INTELLi Bass Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Amplifier Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Speaker Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Amplifier installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Choosing Mounting Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Passenger Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Trunk Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 General Precautions and Installation Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Tools of the Trade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Step By Step Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Set Up and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Testing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Adjusting the Sound of the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Troubleshooting Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 ©2004 Directed Electronics, Inc. 1 INTRODUCTION Thank you for your purchase of Orion's 4004 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 4004. 4004 - 50 Watts per channel, four-channel amplifier with dual built-in high-pass and low-pass 12dB/octave crossover centered at 100Hz and INTELLi Bass. The 4004 is capable of 6, 5, 4, 3, or 2 channel operation with a maximum power capability of 400 Watts into 4W stereo (front and rear channels bridged.) 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 Fuses (2) High Level Input Harness (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 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 ©2004 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: __________________________________________________ ©2004 Directed Electronics, Inc. 3 SPECIFICATIONS Amplifier Section Power Output 4W Stereo (Watts)1 Power Output 2W Stereo (Watts)2 Power Output 4W Mono (Watts)3 Distortion - all channels driven at rated power (20Hz to 20kHz) Frequency Response Linear Bandwidth Signal-to-Noise Ratio at Rated Power Damping Factor Slew Rate RCA Input Sensitivity High Level 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 16dB boost 45Hz 50 x 4 100 x 4 200 x 2 < 0.1% THD+N 20Hz to 20kHZ ±0.25dB 10Hz to 50kHz ±3dB > 100dB > 200 > 20V per msec 200mV to 5V 1V to 10V 10kW (2) 30 Amp ATC 15.9" x 10.5" x 2.4" 11 lbs Low Pass Frequency Range High Pass Crossover High Pass Frequency Range 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. 3. All channels driven, continuous 4W load 20Hz to 20kHz, < 0.1% THD, with input voltage at 13.8VDC. 4 ©2004 Directed Electronics, Inc. AMPLIFIER CONTROLS AND CONNECTIONS 1 2 3 4 5 6 7 8 13 12 11 10 14 9 17 16 15 1. 2. 3. 4. 5. 6. 7. 8. 9. Power LED - when lit indicates that the amplifier is on. Front Gain Control - continuously adjusts from 200mV to 5V for full power output. Front High-Level Input Connector - accepts input from head unit's speaker output. Front RCA Inputs - accepts RCA input from a source unit, preamplifier, or equalizer. Rear RCA Inputs - accepts RCA input from a source unit, preamplifier, or equalizer. Rear High-Level Input Connector - accepts input from head unit's speaker output. 4 CH / 2 CH Switch - configures the amplifier for two or four inputs. Rear Gain Control - continuously adjusts from 200mV to 5V for full power output. INTELLI Bass Control - continuously adjusts from 0 to 16dB of boost centered at 45Hz on the rear channels. 10. Rear Frequency Control - continuously adjusts the frequency of the rear crossover. 11. Rear Crossover Switch - controls the type of filter for the onboard active rear crossover. Full does not attenuate any frequencies and is for full range speaker systems. High attenuates low frequencies and is used for mid-range speakers and tweeters. Low attenuates high frequencies and is used for subwoofer speakers. 12. Front Frequency Control - continuously adjusts the frequency of the front crossover. 13. Front Crossover Switch - controls the type of filter for the onboard active rear crossover. Full does not attenuate any frequencies and is for full range speaker systems. High attenuates low frequencies and is used for mid-range speakers and tweeters. Low attenuates high frequencies and is used for subwoofer speakers. 14. REM Remote Turn-On Input - turns on the amplifier when fed 12 V+. ©2004 Directed Electronics, Inc. 5 15. Power Connections - accepts greater than eight-gauge power and ground cables. 16. 2 x 30A ATC Fuses - protect the amplifier from over current situations. 17. Speaker Connections - accepts up to 12-gauge speaker wire. AMPLIFIER SETTINGS Four-Channel Amplifier Input Configuration The 4CH / 2 CH switch routes input from the front inputs to the rear section of the amplifier. This allows the Orion 4004 channel amplifier to utilize a single set of RCA's or high-level inputs to feed signal to both the front and rear channels of the amplifier. When the switch is to the right (2 CH position), signal from the front inputs is routed to the rear channels. When the switch is to the left (4 CH position), front and rear inputs are independent. This allows a source unit with an internal fader to fade between the front and rear outputs. Internal Crossover Configuration The crossover section of Orion 4004 amplifiers are continuously variable and extremely flexible. The internal crossovers in your Orion 4004 amplifier are continuously variable and extremely flexible. The separate front and rear controls with variable frequency and selectable high-pass, low-pass, or full-range settings allow you to configure the amplifier to drive many different speaker and subwoofer system configurations. 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 manufacturer's warranty. Low-Pass Crossover (Front and Rear) When the switch is to the left (FULL position), the low-pass crossover is bypassed. When the swit ...