Orion Xtreme Series User manual

XTREME SERIES
POWER AMPLIFIERS
INSTALLATION MANUAL
TABLE OF CONTENTS
INTRODUCTION
DESCRIPTION & FEATURES
2-3
SYSTEM PLANNING
4-TO
SETTING SIGNAL JUNIPERS
11-16
INSTALLATION
17-25
SYSTEM ADJUSTMENTS
26
TROUBLESHOOTING
27
SPECIFICATIONS
28
WARRANTY INFORMATION
29

DESIGN
All ORION amplifiers are designed
on our sophisticated CAD system,
utilizing the latest technology
available.
PRODUCTION
All ORION amplifiers are made in
the USA, with high-quality, double¬
sided PC boards containing superior-
grade components.
INTRODUCTION
Congratulations! You have purchased the finest Car Audio
Amplifier available in the market today. The new XTR series of
Amplifiers are the result of many years of research and development
and ORION'S expertise in building high quality, high performance
amplifiers. Each ORION amplifier is hand built and thoroughly tested
to ensure that it will perform under the most demanding conditions.
Our five step quality control process and a two hour "burn-in" help
us produce the best sounding, most reliable amps on the planet.
These new amplifiers offer the improved sound quality and raw
power you expect from ORION, but as an added bonus we have
added two Module Slots. The slots can accept our new (crossovers,
and other signal processors that will be introduced in the future.)
These new amplifiers are compatible with any speaker system and can
be used with existing amplifiers to upgrade your system. This means
you don't have to purchase external crossovers.
In the "System Planning Diagram" section we have outlined some
killer systems that have been built and tested by our Technical
Support Team Each system has diagrams and pictures of the
configuration jumpers to make setting up the inputs and crossovers
easy. If you have any question about your new amplifier or need help
designing your system call our Technical Support Department at 1-
602-730-8200.
PRODUCT USE
The ORION XTR Series sets new
standards for performance and
reliability. They can attain sound
pressure levels well in excess of 130
dB- Use common sense, and wear
hearing protection when
appropriate.

DESCRIPTION AND FEATURES
PRS MOSFET POWER SUPPLY (PULSE REGULATED
SUPPLY)
A very large regulated power supply improves sound quality and
amplifier damping, so that large bass transients are reproduced
accurately. ORIONs power supplies are very stable and perform under
the most demanding conditions.
LARGE EFFICIENT HIGH EFFICIENCY
HEAT SINK
Large C n'C machined high efficient anodized alluminum heat sink
incorporating a large surface area allowing components to run cooler
and more efficiant for maximum heat dissapation.
MIXED/MONO OPERATION
One amplifier can power an entire speaker system using passive
crossovers. Left and right speakers run in stereo with a woofer
bridged mono. This is a very popular configuration for low cost entry
level system.
PARALLEL 8 PIN DIN AND RCA INPUTS/OUTPUTS
Amplifiers can be linked together using DIN or RCA connectors for
easy connection in multi-amp systems. These new eight pin DIN
connectors are fully compatible with previous ORION amplifiers,
crossovers and pre-amps.
TWO BUILT IN MODULE SLOTS
Two internal module slots are wired in series for unlimited system
flexibility. Use one crossover module for a 12dB per octave slope or
add an additional module to create a bandpass or 24dB per octave
crossover. Other types of modules for signal processing will be
introduced in the future.
INPUT SIGNAL ROUTING AND SUMMING
The input signal can be routed back out the amplifier via the DIN
plug or RCA jacks. The signal can be routed through the internal
crossover or be a full range output. The input signal can also be
summed mono.
GAIN STAGE BYPASS
The internal gain stage of the amplifier can be bypassed so that
one master amplifier can be used to control the gain of the slave
amplifiers. This can be used in systems with multiple low frequency
amps to perfectly level match the system. In addition, the gain stage
on the high frequency amplifier can be bypassed for improved sound
quality and a better signal to noise ratio. The signal to noise ratio is
improved by as much as lOdB.
REMOVABLE TOP PANEL
This provides easy access to the crossover ports and signal jumpers.
After the amplifier is installed it is very easy to add a crossover
module or reconfigure the input jumpers. To remove panel use a
small flat blade screwdriver. Use screwdriver on endplate in the hole
marked "cover release".
LARGE QUICK DISCONNECT POWER, GROUND
AND SPEAKER CONNECTORS
These new connectors accept larger gauge wire and simplify the
installation. With less power loss, the overall power and performance
of the system is improved.
MILITARY SPEC. DOUBLE SIDED PLATED THROUGH
CIRCUIT BOARDS
All ORION circuit boards are reinforced with nickel and plated
through for greater reliability with through hole parts.
15 VOLT PHANTOM POWER SUPPLY FOR ORION
SIGNAL PROCESSORS
On board power supplies for external processors eliminates
grounding problems that can cause engine noise in the system.
COMPLIMENTARY BI-POLAR MATCHED OUTPUTS
Matched outputs have less distortion and better sound quality.
Thermal stability is improved as heat is dissipated from the devices
more evenly.
NO (AUDIO) CURRENT LIMITING CIRCUITRY
The amplifier will produce more power at lower impedance loads,
without going into early protection.
MODULE SLOTS
JNPUT JUMPER
DIN
POWER
LEFT AUXIUA.RV
RIGHT AUXILARY
LEFT INPUT
RIGHT INPUT
INPUT GAIN

SVSTEM PLy^NNING
The most important part of your amplifier installation is system
planning. Deciding on a system plan will determine the configuration
of your signal jumpers, modules and amplifier wiring. To help you, we
have included seven of the most common systems with the
information necessary to configure the signal Jumpers and the
modules. New XTR amplifiers have the unique ability to be set up in a
master/slave configuration. In this configuration, the master amplifier
controls the gain of the slave amplifier(s).
SVSTEM #1
Full Range operation
One amplifier drives a pair of full range speakers. The amplifier is
configured for this system from the factory.
• Amplifier output is full range.
• The lowest recommended impedance is 2^2 per channel stereo.
SOURCE
SVSTEM #2
Bridged operation with a 12 dB/octave low-pass crossover for low
frequency drivers.
• Amplifier output is low-pass for woofer.
• Amplifier is configured for summed bridged mono operation.
• The lowest recommended impedance is 4Q bridged mono.
SOURCE
AMPUniR
mSe' L OW-PASS
■ C ROSSCipiR'' ''
CON FIC^RATtON

SYSTEM #3
Mixed-mono for bridged operation to the woofer and stereo
operation for the left and right speakers. Note: he sure to use the
correct passive crossoi^ers.
• Amplifier output is full range.
• The lowest recommended impedance 2^2 per channel stereo.
• The lowest recommended impedance 4^2 bridged mono.
SYSTEM #4
Bi-amplified system
• The lowest recommended impedance 2Q per channel stereo.
• The lowest recommended impedance 4Q bridged mono.
• Master amplifier is configured for summed bridged mono
operation.
• Slave amplifier is configured for high-pass stereo operation.
• Slave amplifier gain is operational.
AMTOFIER
AIVIPUFIER
Qj:, 700.7 Ig*^ III

ratio,
AMPPFIER
itlilli;
CROSSOVER
CONFIGURATION
SOHte
I'iMB LOW PAS.
AMPURER
A^PUFIER
120 Hz
12 dB HIGH-j
SYSTEM #5
Audiophile Bi-amplified system. This system bypasses the gain
stage of the high frequency amplifier for a better signal to noise
ratio.
SYSTEM #6
Multiple amp system for woofers with one amplifier as the master
and two slave amplifiers. The master amplifier controls the gain for
the slave amps.
I1II ■ B'^RANGE
liOVIPUFIER
• The lowest recommended impedance 4^2 bridged mono.
• All amplifiers are operating in a summed bridged mono
configuration.
• Slave amplifiers have both module slots and gain controls bypassed
for easy system tuning and improved signal to noise ratio.
• The lowest recommended impedance 2Q per channel stereo.
• The lowest recommended impedance 4^2 bridged mono.
• Master amplifier is configured for summed bridged mono
operation.
• Slave amplifier is configured for high-pass stereo operation.
• Slave amplifier gain is bypassed for improved signal to noise

SYSTEM #7
Tri-Amped System
• The lowest recommended impedance 2Q per channel stereo.
• The lowest recommended impedance 4Q bridged mono.
• Master amp is configured for summed bridged mono low-pass operation.
• Slave amp 1 is configured for stereo 12dB/octave bandpass operation.
• Slave amp 2 is configured for stereo 12dB/octave high-pass operation.
• All gain controls are operational.
AMRJRER
200 Hz
12 dB HJGH-PASS
MIDR/
Ampui
Aiiiiiiii:
SETTING SIGNAL JUMPERS
FACTORY SETTING
Your new amplifier has two pair of RCA jacks and an 8 pin DIN
connector. These can be configured using the Jumper pins inside the
amplifier for a variety of options. In the factory setting, RCA jacks
marked "IN" are used as the input for the amplifier. The RCA jacks
marked "AUX"are in parallel with input RCAs. Page 12 and 13 show 3
common configurations. Page 14 shows a configuration diagram for
custom applications.
OTHER INPUT/OUTPUT OPTIONS
RCA's AUX can be an unaltered full range signal or routed through
the internal module slots.
DEFAULT SETTINGS
When you take the amplifier out of the box, the amplifier
operates like a standard 2 channel, full range amplifier. The default
position for Input Jumpers is shown on the next page. (page12)
A CAUTION: Do not change Input Jumpers or module slots
when the amplifier is turned on. Serious
amplifier or speaker damage may occur

DEFAULT SIGNAL JUMPER CONFIGURATION
• RCA AUX jack is paralleled to RCA Inputs.
• DIN inputs are paralleled to RCA inputs.
• DIN AUX pins are disabled.
• Internal Gain Stage is enabled.
• Both module slots are enabled.
• Amplifier is configured for stereo or stereo/mono operation.
activating summed mon o operation
• Adding the single jumper pictured below sums the output of the
amplifier under any condition.
• Left and Right inputs are internally summed.
ACTIVATING FILTERS ON AUX RCAs _
• Left and Right AUX RCAs are filtered through both internal
module slots and gain stage.

AMPLIFIER CONFIGURATION
DIAGRAM
CROSSOVER CONFIGURATION
USING CROSSOVER MODULES _
The ORION HCCA Series amplifiers have two module slots in series
that can be used for crossovers and other future modules.
* The HCCA Series amplifiers are shipped with two bypass modules
installed. In default operation, the amplifier output is full range
(see figure 1).
Included with the amplifier is an additional module which can be
installed in either slot depending on the system configuration
desired. The SLF-1 (Selectable Low Frequency-1 slot size) module can
be configured for either high or low-pass 12 dB per Octave filter
operation. It has four selectable frequencies: 80Hz, 120Hz, 160Hz and
200Hz. The modules have unidirectional mounting capability. This
means the module can be correctly installed either right-side up or
up-side down without affecting its operation.
i .
w * *
BYPASS
K*.
Icooni^
BYPASS
ps. ^
03899
Full range (figi)
12 dB/oct High-pass
24 dB/oct Low-pass
12 dB/oct Bandpass
14
15

Listed below are the eight possible configurations when using the
SLF-1 crossover module.
• The module slots are configured in series, this amplifier has the
capability of 12 dB/octave high-pass, low-pass, or bandpass
operation. 24 dB octave high-pass or low-pass operation is also
possible. An additional module Is required for bandpass or
24 dB per octave operation.
80 Hz
LOW-PASS
120 Hz
LOW-PASS
160 Hz
LOW-PASS
200 Hz
LOW-PASS
These Jumpers
determine
crossover type,
high-pass or
low-pass
: iSSSSBi
. : '
These Jumpers
determine
frequency.
i iU, f I
1
iQBBGBi
INSTALLATION
This section details the mechanical and electrical procedures you
will need to perform the installation of your ORION amplifier. Take a
moment to look over the list of precautions, tools and additional
parts needed to successfully complete the job.
GENERAL PRECAUTIONS
Before installation, make sure you pick a location that will provide
adequate ventilation around the amplifier. The ORION amplifier has
massive heatsink fins to couple generated heat to surrounding air
space via thermal conduction. However, if the amplifier is mounted In
a tight space without any air movement, over time the amplifier can
fail, in spite of its thermal protection circuits.
Therefore, we recommend that you mount the amplifier flat on
the floor under the front seat or in the trunk. Remember, heat travels
up away from the heatsink fins. In addition, please observe these
precautions:
• Do not enclose the top of the amplifier unless you
have a cooling fan.
• Direct cool air along the length of the fins, rather than across
them, for the most efficient cooling. Remember, any moving air
will dissipate heat.
Note: When two low-pass filters of the same frequency are
used for 24 dB per octave operation, the cut off
frequency will decrease by 20 percent.
When two high-pass filters of the same frequency are
used for 24 dB per octave operation, the cut off
frequency will increase by 20 percent.