Orion COBALT Series User manual

INSTALLATION MANUAL
COBALT Series
POWER AMPLIFIERS
•ORION

CONTENTS
Introduction.I
Descriptions.2
Input Connections and Controls.3
Manning Your Car Audio System.5
Power Connections and Safeguards.12
Speaker Connections.14
Installation.16
Amplifier Wiring.20
Setting Up Your Cobalt Amplifier.23
System Adjustments.24
Troubleshooting Guide.25
Specifications.26
Warranty Information.27

DESIGN
All Orion amplifiers are designed on our
sophisticated CAD system, utilizing the
latest technology available.
/
■ : K
PRODUCTION
All Orion amplifiers are Made in The USA,
with high-quality double-sided PC
boards containing superior-grade com¬
ponents.
PRODUCT USE
The Cobalt Series sets new standards for
performance and reliability.
They can attain Sound Pressure Levels well
in excess of 110 dB Use common sense
and wear hearing protection when
appropriate.

INTRODUCTION
You have purchased the finest car audio power amplifier available on the market today. Your
Cobalt amplifier (Model CO 230, CO 260, CO 430, CO 2100) incorporates the latest technological
advancements to exceed current measurement standards of performance, craftsmanship, and
reliability.
All our amplifiers contain the following built-in features:
• \Wi(ie Bandwidth, MOSFET, Class AB Output for full, clean reproduction of all frequencies, without any compromise of
deep bass sound
• Localized Feedback Design for extremely fast Transient Response and reduction of Harmonic and Intermodulation
Distortion
• Dynamic Current Limiting, to protea theamplifier by reducing its power supply voltage when minimum load
impedances are exceeded on either channel
• A Smart MOSFfT Power Supply with second-order RFI (noise) filtering that is energy efficient, reliable, and can artually
sensea variety of interconnect problems like shorted speaker leads, power ground problems, audio grou/Kl problems,
and low electrical system voltage
• Bridging Capabilities for Mono and Mixed Mono Installations
• A single Variable Input Sensitivity control for precise level matching of Control Head Unit outputs to amplifier inputs
• FET switched 40 dB audio attenuator to reduce turn.on/turnoff "thump"
•Aluminum Heat Sinks for efficient dissipation and refledion of heat
In addition, all our amplifiers are made in the USA with high-quality, double-sided printed circuit
boards, containing superior-grade components. Be assured that befcxeyou bought this superbly-built
amplifier, it was thoroughly tested and is now ready for the most demanding of situations. This
amplifier has passed an extensive five-step quality control inspection, culmination in a two-hour
'bum-in" under actual operating conditions. If it had failed, it wouldn't be in the box!
To aid you in enjoying this premium product, please take a few moments to read through this
manual before installing the amplifier in your new or existing system. Once the amplifier is carefully
installed and you listen to it for the first time, you will be astonished at its sound quality and power.
From that moment on, your Cobalt amplifier will provide you with years of pure sonic enjoyment!
Please fill out and send in the warranty card that is packed with your amplifier. For future refer¬
ence, also fill in the information requested in the blanks below.
MODEL:_
SERIAL NO:_
DATE OF PURCHASE:

DESCRIPTIONS
The CO 230 ,CO 430, and CO 260 are car stereo amplifiers that provide 30 and 60 watts rms power
per channel into a 4 ohm load, respectively. The CO 430 is a special model for four<hannet applica¬
tions. The CO 2100 is a car stereo amplifier that provides 100 watts rms per channel into a 4 ohm
load, or 200 watts rms per channel into a 2 ohm load in stereo. In mixed mono or summed it can
alternatively provide 350 watts rms into a 4 ohm load and may be used for subwoofer systems. The
CO 2100 features a continual low pass filter that ranges between 35 Hz and 200 Hz. Other than
power rating and physical size, these four models, shown in Fig. 1, have several features in
common, and similar electrical specifications {see Specifications on page 26).
Fig.1. CO230,CO260,CO430 and2100carstereoamplifiers.
Depending on your audio system requirements, any model Is an excellent choice for full-range
sound that will exhibit smooth highs and rich, tight bass. Or any model can be put to work a part of a
system that will drive satellite speaker sets (e g., tweeters and mid-range speakers) of sub-woofers.

INPUT CONNECTIONS AND CONTROLS
As shown if Fig. 2, and Fig. 3, the CO 230, CO 260 and CO 430 input connections contain LEFT
INPUT and RIGHT INPUT connectors, GAIN Control, and a POWER indicator.
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Fig. 2. Front panel layout for 230 and 260 amplifiers.
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Fig. 3. Front panel layout for the 430 (4channe!) amplifier.
3

INPUl^ CONNECTIONS AND CONTROLS
As snown in Hg. iA, the LU ^lUU input conneaions contain a mONO/STEREO button. The LEFT
INPUT and RIGHT INPUT connector functions are standard when the MONO/STEREO button is set on
STEREO. When the MONO/STEREO button is set on MONO the LEFT INPUT channel is full range
mono, and the RIGHT INPUT channel is low pass only mono.
.\\\\\ ////////.
Fig. 3A. Front panel layout for the 2t00 amplifier.
The LEFT INPUT and RIGHT INPUT connectors are gold-plated, ground isolated RCA jacks. Amplifier
input impedance is rated at 10k ohms.
NOTE. The GAIN Control is not a Volume Control! It enables you to adjust the amplifier's nominal
operating level for proper level match from any brand control head unit or radio.
A POWER indicator lights whenever DC power reaches and activates the internal amplifier circuits.

INPUl^ CONNECTIONS AND CONTROLS
As snown in Hg. iA, the LU ^lUU input conneaions contain a mONO/STEREO button. The LEFT
INPUT and RIGHT INPUT connector functions are standard when the MONO/STEREO button is set on
STEREO. When the MONO/STEREO button is set on MONO the LEFT INPUT channel is full range
mono, and the RIGHT INPUT channel is low pass only mono.
.\\\\\ ////////.
Fig. 3A. Front panel layout for the 2t00 amplifier.
The LEFT INPUT and RIGHT INPUT connectors are gold-plated, ground isolated RCA jacks. Amplifier
input impedance is rated at 10k ohms.
NOTE. The GAIN Control is not a Volume Control! It enables you to adjust the amplifier's nominal
operating level for proper level match from any brand control head unit or radio.
A POWER indicator lights whenever DC power reaches and activates the internal amplifier circuits.

PLANNING YOUR CAR AUDIO SYSTEM
Before starting the installation, you need to consider the type of car audio system you want, so
that you can purchase any needed components. For example, will your system be a brand new instal¬
lation, or will it be an upgrade to an existing system? Do you want a basic single-amplifier design that
uses existing full-range speakers, or a high-powered multi-amplifier system that drives a host of satel¬
lite speakers and sub-woofers. Will your system be stereo or mixed mono?
This section deals with these topics and more, Several example systems are presented here in a
building block approach. You can start with a simple system and then, at a later date, add more
amplifiers, speakers, and accessories to come up with a system of your own design. After you've fin¬
ished reading this section, proceed to the Installation chapter.
NEW BASIC SYSTEM
An ideal basic stereo system can be designed with a control head unit a CO 230 amplifier, and a
pair of full-range loudspeakers. If you want more power, then choose the CO 260, or CO 2100 ampli¬
fier to drive your system.
Fig, 4. An example of upgrading a basic factory system (no fader control) by using a CO 260 amplifier.

If you want more low end punch, add one or more sub-woofers and then reconfigure the CO 230,
CO 260, or CO 2100 amplifier wiring for Mixed-Mono Bridged operation, as shown in Fig. 4. For opti¬
mum sound, add an equalizer like the 300 PHD between the control head unit and amplifier, to tailor
the sound output for your car's environment.
UPGRADING A BASIC FACTORY SYSTEM
Many new cars come equipped with a factory-installed AM/FM cassette radio that drives two sets
of speakers, usually located in the front dashboard and rear deck plate. You can vastly improve the
sound of the factory installation by adding a CO 230 amplifier between the radio and speakers, as
shown in Fig. 5. For more power, choose the CO 260, or CO 2100 to drive your system.
If your radio has RCA jacks on the back, then the connection to the amplifier is a straight run with
a pair of high-quality RCA cables from the radio to the amplifier's left and right inputs.
Fig, 5. An example of a new basic system using a CO 230 amplifier. No Fader Control is possible with
this system configuration.

MULTI-AMPLIFIER SYSTEMS
For precise staging and raw power, you can implement a more sophisticated system by using two
amplifiers with satellite speakers, as shown in Fig. 6.
The pre-amp outputs form the control head unit actively split into two frequency bands by using a
aossover like the 200 SPX.
Stereo pairs of tweeters
and mid-range speakers are
driven by a CO 230 ampli¬
fier, fed by the crossover's
high output. Sub-woofers
are driven by a CO 260
amplifier in stereo or
Summed Mono Bridged
configuration, with the
feed from the crossover's
low output.
NOTE: As an alternative,
you can purchase XTREME
Dual l/orce-co// sub¬
woofers.
For greater sound con¬
touring, add a 300 PHD
equalizer between the
control head unit and 200
SPX active crossover.
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Fig. 6. An example of a multi-amplifier system, using a CO 230 amplifier to drive stereo pairs of full
range speakers, and a CO 260 amplifier to drive a pair of sub-woofers.

MULTI-CHANNEL AMPLIFIER
We designed the CO 430 to be more than just a standard 4<hannel amplifier. Depending on the
speaker wiring, you can configure the CO 430 as a 2-,3-,4-, 5-, or even a &-channel ampi if ier, as shown
in Fig. 7Aand Fig. 7B.
NOTE: The examples in Fig. 7Aand Fig. 7B are only a few of the audio systems possible with the CO
430 amplifier.
For a high-powered 2'{harrnel amplifier, connect a pair of full-range speakers in a bridged wiring scheme to obtain 120
watts rms (at 4 ohms) at each speaker.
For 3<hannel operation, connect full-range speakers to the CO 430 front stereo outputs, and add a sub-woofer with an
Orion Connection CSX-TI4 passive crossover to the rear connections in a Mixed-Mono Bridged configuration.
For a 4channet amplifier, use the CO 430 as Front and Rear stereo amplifiers. Connert fulkange or component-type
speakers with Orion Connection passive crossovers in this configuration.
FronlOunn«l Output
2- Channel
full-range speakers
8
Fig. 7A. 2 channel configurations for the CO 430

REAR
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L :J L :
Orion Connwtion
Fuse Holder
4- Channel
full-range speakers
front/rear
Fig. 7B. 2 and 3 channel configurations for the CO 430

CO 2100 SAMPLE SYSTEMS
We designed the CO 2100 to be more than just a standard amplifier. The CO 2100 shares ail
of the standard features available with the CO 230 and the CO 260. In addition, the CO 2100's
Stereo/Mono button allows flexibility in system design. The CO 2100 performs similarly to the
CO 230 and CO 260 when set to stereo.
COSND
CO MID AND
TWEETER SET
COIND
Fig. 88 and Fig. 9B show
the input connections of the
CO 2100 up close to clarify
how it is used in each system.
FULL RANGE SYSTEM
Fig. 8A. An example of CO
2100 amplifiers configured
for right and left channel
mono bridging (button in.)
Each amplifier feeds a Cobalt
Mid and Tweeter Set, and a
CO 10.
Fig. SB. View of the CO 2100 front panel as used
in diagram BA.The highlighted left channel (full
range mode) is In use, along with the button in
mono mode-
10

Depending on the Stereo/Mono button setting, the CO 2100 can be configured in a variety of
systems. The following system designs show examples of CO 2100 uses in systems with its
button in mono setting. The system shown in Fig. 8A, the mono button is in and the left input
is in use (full range mono mode). In the system shown in Fig. 9A, the mono button is in and the
right input is in use (crossover mode, low pass only). Using more than one CO 2100 amplifier in
your system will allow greater flexibility in it's design.
SUB ONLY SYSTEM
Fig. 9A. An example of CO 2100 amplifiers, configured for sub input (button in). Each
amplifier feeds a CO 10 sub-woofer.
11

POWER CONNECTIONS AND SAFEGUARDS
As shown in Fig, 10 and Fig. 11, the rear face-plate projects short wires for DC power connections
and a female plug that contains speaker and Remote Turn-On connections. The 12 gauge solder-
tinned red wire (with built-in fuse holder) goes to your car's positive battery connection, while the 12
gauge black wire with lug is bolted to metal chassis for power ground (see Installation, starting page
16).
NOTE: The (+) power wire on each amplifier must be connected directly to the positive battery terminal.
Fig. 11. Rear panel layout for the Cobalt 430 amplifiers

Each amplifier uses a DC switching circuit to multiply the incoming 12 VDC to the higher DC volt¬
ages needed for a high-power design. The switching time is optimized for efficient energy conversion
and minimum radiation of RFI (Radio Frequency Interference). A second-order filter is included in the
design to further reduce any potential interference artifacts.
The amplifier is turned on remotely via the connection on the male plug that inserts into the end
of the amplifier. When properly installed (see Installation, starting on page 16), you'll hear a gradual
level change when you power on the control head unit. Within two seconds, the amplifier will be at
the level you've set on the volume control. With this feature, you have time to judge and adjust the
loudness level without having to experience an immediate sonic blast.
Built into each amplifier are two additional fail-safe features. A thermal protection circuit senses
the temperature of the heat sink and will turn off the amplifier if the unit becomes too hot (see
Trouble-shooting Guide, on page 25). Once the amplifier has cooled down, the thermal protection
circuit will automatically turn the amplifier on again. An external fast-blow fuse, installed in-line with
the positive DCIine (red wire), protects the amplifier from any catastrophic system failures.
Each amplifier also includes a soft-start feature, to minimize turn-on "thump". Protective monitor
circuits in the output stages will shut down the amplifier in case of a speaker failure or a short circuit
in speaker wiring.
13

SPEAKER CONNECTIONS
On the CO 230, CO 260, and CO 2100 amplifiers, the male plug (see Fig.10 on page 12) provides
Left and Right speaker connections. Speaker wire is not included. We recommend 16 GA or bigger,
size of XTREME speaker cable. On the CO 430 (4<hannel) amplifier, the male plug includes additional
connections for the rear channels.
In addition, each amplifier model can be configured for Summed-Mono Bridging or Mixed-Mono
Bridging (see Planning Your Car Audio System, starting on page 5).
Since low frequencies are non-directional (i.e., you feel the sound rather than locate it), and more
power is needed to reproduce bass sounds, sub-woofers can be driven in a mono configuration. The
higher, more directional sounds (e.g., vocals and solo instruments) don't require as much power for
loud reproduction; therefore, these signals can be reproduced in stereo, which provides the listener
with essential positions for accurate sound staging.
Summed-Mono Bridging provides more power (than a stereo channel) to one or more sub-woofer
speakers, as shown in Fig. 12 on page 15. The stereo signal, coming from a Control Head Unit, is
routed to the (left and right) inputs of an aaive crossover. The crossover's low (left and right) outputs
are summed to mono via an RCA "Y" cable enroute to the amplifier (left and right) inputs. One or
more loudspeakers is then connected (in parallel) to the amplifier's Left(-)/Right(+), while the Left(+)
and Right(-) are not used. The woofers must be connected so that the impedance is 4 ohms or above.
NOTE: Summed-Mono Bridging is used exclusiveiy to drive sub-woofer systems. M/ben planning this
configuration, make sure the totai nominal sub-woofer impedance is not less than four ohms. Use a
series wiring scheme for connecting two four-ohm sub-woofers, as the total nominal impedance of
eight ohms will not significantly change the sound output in the Summed-Mono Bridging mode.
Mixed-Mono Bridging is implemented by connecting one or more pairs of tweeters and mid-range
speakers to the stereo signals, whi le one or more sub-woofers receives the mono signal. Uni ike
Summed-Mono Bridging, all speaker wire connections are used to realize this system.
NOTE: For the CO 230 or CO 260, a front-to-rear Fader Control is not available with Mixed-Mono
Bridging, because only a single 2<hannel amplifier drives both satellite and sub-woofer speakers.
However, Fader Control is possible for the CO 430 amplifier, since this model provides four channels
Refer to page 9 for more details

Fig. 12. An example of a CO 260 amplifier, configured for Summed-Mono Bridging, feeding a pair
of DVC sub-woofers. NOTE; Only the LOW outputs from the 200 SPX Active Crossover are shown.
15

INSTALLATION
This section details Mechanical and Electrical procedures you'll need to perform to install Cobalt
amplifiers. Take a moment to look over the list of tools and additional parts needed to successfully
complete the job.
REQUIRED TOOLS
• Electric DrilVDrill Bits
• Utility Knife
• Phillips and Flathead Screwdrivers
• Pliers (standard and needle nose)
• WireCutters/Strippers
• Wire Crimping Tool
• Wire Brush and Emery Sandpaper (for metal)
• Rubber Grommets
• Heat Shrink Tubing
• Soldering Iron and Solder
• Nylon Tie Wraps
• VoltfDhm Meter (VOM or DVM)
• Fell-tip Pen or Spring Loaded Center Punch Tool
REQUIRED PARTS
The following parts are packed with Cobalt amplifiers:
• Male Speaker Plug Pigtail Harness
• External Fuse Pigtail Assembly
• Fast-blow Fuse
• Butt Spike
• 4 Metal Self-tapping Phillips Screws
The following parts are not included in the packaging:
• 15-20 ft. 10 Gauge Orion Connection Power cable.
• 15-20 ft. Turn on lead.
• Fuse-holder and fuse for connection at battery.
• No, 10 Self tap Metal Screw, or Large Carriage Boll (to attadi
amplifier ground wire to chassis)
• 16 Gauge or Larger Orion Connection Xbeme Speaker Cable
• Orion Connection High Quality RCA Cables
OPTIONAL PARTS
The Orion Connection carries everything you need to complete your car audio system. Visit your
Orion dealer and check out genuine Orion Connection Installation Accessories.
• MBR 70 Multiple Battery Regulator • Audio Interlink Cables (RCA)
• Modular Power Distribution (POWER BLOCKS)
• Modular fuse Holders (POWER BLOCKS)
• XTREME Speaker Cable
• Power Cable, Ground Cable
• Battery Terminals
• Passive Crossovers
• Raw Crossover Components
• Automotive Carpet Vinyl & Grill Cloth
• Damping Material
• Cosmetic Integration Accessories
16