CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 What's in the Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Practice Safe SoundTM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Record Your Serial Number and Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Amplifier Controls and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Amplifier Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Signal Input and Output Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Four-Channel Amplifier Input Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Internal Crossover Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Low-Pass Crossover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 High-Pass Crossover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 High-Pass Woofers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Fine Tuning the Crossover Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Remote Gain Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Auxiliary Output Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Amplifier Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Set Up and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Testing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Adjusting the Sound of the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Troubleshooting Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 ©2004 Directed Electronics, Inc. 1 INTRODUCTION Thank you for your purchase of Orion's 8004 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 8004. 8004 - 100 Watts per channel, four-channel amplifier with dual built-in fully variable high-pass, low-pass, and band-pass 12dB/octave crossovers with INTELLi Bass. The 8004 is capable of six, five, four, three, or two channel operation with a maximum power capability of 800 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 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 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. 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) Power Output 2W Stereo (Watts) Power Output 4W Mono (Watts) Remote Gain Capable 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 RCA Input Sensitivity Input Impedance Fuse Type Dimensions Weight Crossover Section Low Pass Crossover Low Pass Frequency Range High Pass Crossover High Pass Frequency Range INTELLi Bass 2nd Order (12dB per octave) 20Hz to 3kHz 2nd Order (12dB per octave) 20Hz to 3kHz 16dB boost 100 x 4 200 x 4 400 x 2 Yes < 0.1% THD+N 20Hz to 20kHz ±0.25dB 10Hz to 50kHz ±3dB > 100dB > 200 > 20V per msec 200mV to 5V 20kW (1) 100 Amp MAXI 23.9" x 10.5" x 2.4" 10 lbs. 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 ©2004 Directed Electronics, Inc. AMPLIFIER CONTROLS AND CONNECTIONS 1 2 3 4 5 6 7 8 9 10 11 12 17 16 15 14 13 18 22 21 20 19 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Power LED - when lit indicates that the amplifier is on. Front Low-Pass Crossover Switch - activates 2nd order low-pass crossover. Front Low-Pass Frequency Control - adjusts the frequency of the low-pass crossover. Front Gain Control - continuously adjusts from 200mV to 5V for full power 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. RCA Outputs - provides easy connection to additional amplifiers. 4 CH / 2 CH Switch - configures the amplifier for one or two sets of inputs. Rear Gain Control - continuously adjusts from 200mV to 5V for full power output. Copy/Master/Gain Switch - determines the output of the RCA outputs. Rear Low-Pass Crossover Switch - activates 2nd order low-pass crossover. Rear Low-Pass Frequency Control - adjusts the frequency of the low-pass crossover. INTELLi Bass Control - continuously adjusts from 0 to 16dB of boost on the rear channels. Rear High-Pass Frequency Control - adjusts the frequency of the high-pass crossover. Rear High-Pass Crossover Switch - activates 2nd order high pass crossover. Front High-Pass Frequency Control - adjusts the frequency of the high-pass crossover. Front High-Pass Crossover Switch - activates 2nd order high-pass crossover. REM Remote Turn-on Input - turns on the amplifier when fed 12 V+. Power Connections - allow greater than eight-gauge power and ground cables. 1 x 100A MAXI Fuse - protect the amplifier from over current situations. Remote Gain Connector - allows the gain of the amplifier to be controlled remotely. Speaker Connections - allow up to 12 gauge speaker wire. ©2004 Directed Electronics, Inc. 5 AMPLIFIER SETTINGS Signal Input and Output Configurations The input section of the amplifier consists of a phase switch that sets the output configuration, gain controls, and RCA inputs. The input section makes it easy to adapt this amplifier to most system configurations. Four-Channel Amplifier Input Configuration The 4CH / 2CH switch routes input from the front inputs to the rear section of the amplifier. This allows the Orion 8004 channel amplifier to utilize a single set of RCA's to feed signal to the front and rear channels of the amplifier. When the switch is to the right (2CH position), signal from the front inputs is routed to the rear channels.When the switch is to the left (4CH 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 8004 amplifiers is continuously variable and extremely flexible. There are eight different crossover configurations possible allowing high-pass, lowpass, and band-pass operation. This circuit is designed to optimize the performance of subwoofers in all types of enclosures. When using 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 cro ...