Orion CO2400.1D2 User manual

Amplifier
LIMITED TWO MONTH CONSUMERWARRANTYAND ONE YEAR CONSUMER WARRANTY
WHEN PURCHASED AND INSTALLED FROM AUTHORIZED ORION DEALER
Electronics Limited Warranty
Please keep your originalbox. Orion warrants thisproduct to be freefrom defects in materialsand workmanship
under normal use for a period of TWO (2) months from the date of original purchase receipt. When
purchased and installed from anAUTHORIZED ORION dealerit is warranted for a period of ONE(1) Yearfrom
the date of theoriginal purchase receipt.
The ORIGINAL Receiptmust be provided for all claims. Should service be necessary under thiswarranty for any
reason due to manufacturingdefect or malfunction during the warranty period.
ORION will repair or replace(at its discretion) the defective merchandise with equivalent merchandise with
equivalent merchandise at no charge. Warranty replacements may have cosmeticscratches or blemishes.
Discontinued products may bereplaced with more current equivalent products.
This warranty is valid only to the original purchaser and is non-transferable toany other person or party. Any
applicable implied warranties are limitedin duration to a period of the express warranty provided herein
beginning with the date of the originalpurchase at retail, andno warranties, whether express or implied,
shall apply to thisproduct thereafter. Some states donot allow limitations onimplied warranties; therefore
these exclusions may notapply to you. This warranty gives you specific legalrights; however you may have
other rights that varyfrom state to state.
What to Do ifyou need Warranty or Service
Defective merchandise should be returned to your localauthorized ORION dealer for warrantyservice.
Merchandise Authorization (RMA)number. Package all defective items in the original container or ina package
that will prevent shipping damage. The shipping address and instructions will be givento you by ourcustomer
care representative upon their issuing the RMAnumber.
The RMA numbermust be clearly markedon the outside ofthe package. Please returnonly defective compone-
nts. The return offunctioning items increases yourreturn freight charges. NON-DEFECTIVE items will notbe
exchanged.You willbe contacted by customercare advising you ofsuch situations, and product will be returned
to you upon yourpayment of freight charges for the return ofsuch product back toyou.
Include a copy ofthe original receipt withthe PURCHASE DATE clearly visible, anda ROOF of PURCHASE
statement listing the CUSTOMERSNAME, DEALER's NAME and INVOICE number, andproduct purchased.
Warranty expiration onitems without ROOF of PURCHASE will be determined from the type of sale
and manufacturing date code. FREIGHT on defectives products returnedmust be PREPAID by you or your
authorized dealer; items sentfreight collect, or COD will be REFUSED.
What is not covered?
The warranty is validonly if the product is used for thepurpose for which itwas designed and doesNOT COVER
the following;
Damage due to improperinstallation and sound settings, excessive or insufficient voltage spikes,
and use of inferiorlow grade wiring.
Subsequent Damage to othercomponents
Damage caused by exposureto moisture, excessive heat,chemical cleaners, and/or UV Radiation.
Damage through negligence, misuse,accident or abuse. Repeatedreturns for the same damagemay be
considered abuse.
Any cost or expenserelated to the removalor installation of product. No Installation Fee reimbursements.
Items previously repaired ormodified by any unauthorizedrepair facility
Return shipping costs fromORION to you onnon-defective items
Products with tampered ormissing barcode labels
Products returned without aReturn Merchandise Authorization(RMA) number
Freight Damage
The cost of shippingproduct to ORION, fromyou to Orion
Service performed by anyoneother than Orion
Damage related toActs of Nature, lightning, hurricanes, flood, tornadoes, and wildfires.
Products Sold outside ofUnited States have NOWARRANTY expressed or implied
MODEL
CO2400.1D2
CO1200.1D
CO2400.1D
CO3200.1D
CO5000.1D
CO2400.1D2
CO1200.1D
CO2400.1D
CO3200.1D
CO5000.1D
Amplifier

Thank you for purchasing our caraudio amplifier.These power amplifier has been
designed to provide high quality performance with minimum
maintenance. However,it's performance will only be as good as the care and
quality of components with which is installed. We therefore advise thatyou read
these instructions very carefully to familiarize yourself with the product and
it'sfeatures.
Before installing thepower amplifier pleaseread this instruction manual carefully.
The instructions for mounting and connecting the set have to be followed precisely.
If necessary, a servicecenter should be consulted.
All connection forDC power, signal input and speaker outputs can be carried
outeasily and safelyby way ofRCA andscrewed terminals.
Please choose a mounting place without any direct weather influences. Note that
the amplifier generates heat so that a well ventilated place is necessary.
According to yourcar's construction the set can be made very carefully in order to
ensure the amplifier'sfull performance andreliability.
Keep the wire connections as short as possible with sufficient length in
order to minimizepower losses andprovide a higher audio output of the system.
For safety reasons route all power and speaker wiring by using the exiting wire
channels.
Tominimize damage to the cables, take care that they do not pass sharp edged
metal.
Lay all cables as far away as possible from the ignition cables, modules in the
boot and underthe key dashboard,as these createinterference.
Add a fuse into the (+) power cable in a distance of not more than30cm from the
positive battery pole.
Keep the length of the power wires as short as possible . It is better to use power
cables which areshort and thenlonger speaker cables.
In order toreduce interference , please pay attention to the wiring instructions.
INTRODUCTION
INSTALLATION INSTRUCTIONS
Toensure your warranty, please record the following information regarding
your new amplifier.
RECORD YOUR SERIAL NUMBER AND DATE
Model:
Serial Number:
Date of Purchase:
Purchased from:

FUNCTIONS
CO1200.1D/CO2400.1D/CO2400.1D2/CO3200.1D
Phase Control
Gain control
LPF control
Mosfet power supply
Mono Channel Power Amplifier
Sub Sonic control
Bass Boost control
Thermal protection
LED Power and Protection Indicator
Low Input
OPERATION
GND(-)=GROUND CONNECTION
Connect the GND terminal to the chassis ground of your car and take care of best
electric and mechanic contact. In doing so, drill a hole in to the car chassis near
the amplifier then remove color, dirt or any other substance from the ground point.
After that fasten the cable end with added ring terminal by using a screw. Ensure
that the ground connection is as short as possible and that the cable diameter is
sufficient ( min 4 mm" ). Route the ground cables from the radio and all other
equipment parts. like equalizer. active crossover network or other amplifiers, to
the same ground point.
+12V=POWER SUPPLY
Connect the +12V terminal to the positive pole of the battery with a lead cable
and add a fuse in to the power cable in a distance of not more then 30 cm from the
battery. The lead cables's diameter should be at least 4 mm' for a length of 3m
and 6 mm" for a length of 6m.
REM(ON/OFF)REMOTE CONTROL
Connect the REM terminal to the automatic antenna connector of your car radio.
Now when turning on and off your car radio. the amplifier automatically switches
ON and OFF. Acable diameter of 0.5mm is sufficient.
FUSE
The amplifier is equipped with a plug-in auto fuse protecting the set against fault
conditions. Do not use a fuse with a higher value and never bridge the fuse over,
as this may lead to irreparability damage so that ant any claim for warranty is
denied.
No Function:
The connection cable is not connected correctly ( = terminal BATT/GND /REM).
Ensure that all connections and mechanic contact and that the jacket has been
removed. The fuse is defective-pay attention to the correct value of a new fuse!
No Sound:
Speaker cable or speaker plug are not connected correctly.
No Sound /Red LED Protection Shines:
The plus and minus wires of the speaker cable have contact, thus eliminate the
short circuit. If you use a 2 Ohm speaker in stereo mode, a 4 Ohm speaker in
bridge mode or tri-mode and the se is overloaded, then turn the gain control to
"min " until the operation is free of trouble.
Poor Sound Quality ( Distortions ):
The speakers are overloaded, therefore turn down the volume level and check
the volume control positions.
No Stereo Sound And A Weak Bass:
Speaker cables (+) and (-) are mixed up, unit wired out of phase.
t
TROUBLE SHOOTING
R
L
PRO
PWR
BRIDGED
OUT
IN
PRO
PWR
GAIN BASS BOOST
LPF REMOTE
15Hz 0dB +18dB
Min Max
LINE INPUT
LINE OUT
400Hz
PHASESUB SONIC
25HzOFF O 0O
180
PRO
R
L
PRO
PWR
CO5000.1DCO5000.1D
LL
GAIN BASS BOOST LPF REMOTE
15Hz 0dB +18dB
Min Max
LINE INPUT
LINE OUT
400Hz
PHASESUB SONIC
25HzOFF O 0O
180
CO5000.1D

PRECAUTIONS
FUSE REPLACEMENT
If the fuseblows, check thepower connection andreplace the fuse. If the fuse
blows again afterreplacement, there maybe an internalmalfunction. In thiscase,
consult your dealer.
WARNING:
Use the specifiedamperage fuse. Useof a higheramperage fuse maycause
serious damage.
PROTECTION CIRCUIT:
This amplifier isprovided with aprotection circuit whichoperates in thefollowing
cases when:
the unit is overheated.
the speaker terminals are short circuited.
This unit isdesigned for negativeground 12V DCoperation only.
Use speakers withan impedance of2 or 4Ohms ( 2 to 4 Ohm when used as
bridging amplifier )
Avoid installing the unit where:
-It would besubject to hightemperatures, such asfrom direct sunlightor hot air
from the heater.
-It would beexposed to rainor moisture.
-It would besubject to dustor dirt.
If your caris parked indirect sunlight andthere is aconsiderable rise in
temperature inside thecar, allowthe unit tocool off before operation.
When installing theunit horizontally, be surenot to cover the heatsink fins with
the floor carpet.
If this unitis placed tooclose to thecar radio, aninterference may occur. In this
case, separate theamplifier from thecar radio.
This power amplifieremploys a protectioncircuit to protectthe transistors and
speakers if theamplifier m lfunctions. Do notattempt to test the protection
circuits by coveringthe heatsink orconnecting improper loads.
Do not usethe unit with a weak autobattery as its optimum performance
depends on anormal battery supplyvoltage.
For safety reasons,keep the volumeof your caraudio system moderateso that
you can stillhear normal traffic sounds outsideyour car.
a
STEREO MODE
CAR STEREO
R
L
Low IeveI input: These are driven by the line output of your in dash radio or
intermediate signal processor, Separate Leftand Right signals can be applied for
Stereo or Monooperation but both inputs must be driven with the same signal for
proper Bridged operation.lf only monosignal is available,a " Y" adapter is required .
CO1200.1D/CO2400.1D/CO2400.1D2/CO3200.1D
R
L
PRO
PWR
BRIDGED
OUT
IN
PRO
PWR
GAIN BASS BOOST
LPF REMOTE
15Hz 0dB +18dB
Min Max
LINE INPUT
LINE OUT
400Hz
PHASESUB SONIC
25HzOFF O 0O
180
PRO
CAR STEREO
R
L
CO5000.1D
R
L
PRO
PWR
CO5000.1DCO5000.1D
LL
GAIN BASS BOOST LPF REMOTE
15Hz 0dB +18dB
Min Max
LINE INPUT
LINE OUT
400Hz
PHASESUB SONIC
25HzOFF O 0O
180

SPEAKERS CONNECTIONS
CO1200.1D
POWER INPUT
SPEAKER OUTPUT
FUSES +12V REM GND
MIN 1
25A X 3
++
MONO SPEAKER
1~4Ohm
CO2400.1D
POWER INPUT
SPEAKER OUTPUT
+12V REM GND
FUSES
25A X 4
MIN 1
++
MONO SPEAKER
1~4Ohm
SPEAKERS CONNECTIONS
CO3200.1D
POWER INPUT
SPEAKER OUTPUT
+12V REM GND
FUSES
25A X 5
MIN 1
++
MONO SPEAKER
1~4Ohm
CO2400.1D2
POWER INPUT
SPEAKER OUTPUT
+12V REM GND
FUSES
25A X 4
MIN 2
++
MONO SPEAKER
2~4Ohm
Note that the two speakers & four speakers have been connected to the four
terminal following the (+) and (-)graphic. Your speaker terminalmay be marked
(+) and (-) or there may be red dot by one terminal which means the same as (+).
Connecting the speakers in this manner assures that the two speaker cones will
move in and out together according to the original recording. If oneof the two
speakers is reversed , stereo imaging and bass response will be degraded.
CO5000.1D
POWER INPUT
SPEAKER OUTPUT
+12V REM GND
FUSES
30A X 5
MIN 1
++
MONO SPEAKER
1~4Ohm

POWER CONNECTION LEADS
Connect the +12V power input lead only after allother leads havebeen
connected.
Be sure toconnect the groundwire of theunit securely toa metal partof the car.
A loseconnection may causea malfunction ofthe amplifier.
REM: The unit is turnedon by applying+12 Voltsto this terminal. This terminal
does not draw heavy current like the Power Terminals so a thinner
connecting wire isacceptable. Standard 18GAUGE is fine and the standard
color is yellow.lf the radiois equipped witha PowerAntenna control wire, it can
drive this terminal. If thePower Antennawire is alreadyin use, you can still
splice into it.With this method,the unit willturn on automaticallywith the radio.
Use the powersupply lead with a fuse attachedwhose value isthe same as
original fuse.
Place the fusein the powersupply lead asclose as possibleto the car battery .
During a fullpower operation, maximum current will run through the system
Therefore, make surethat the leads to be connected to the +12V and GND
terminals of the unit respectively mustbe larger than 10-Gauge (AWG.10).
NOTES ON THE POWER SUPPLY :
GND
REM
+12V
POWER
++
BATTERY
DC 12V
HEAD UNIT
( +12V)
REMOTE OUT
FUSE
to a metal part of car
POWER CONNECTION
The battery terminal(+12V) must be connected directly to the positive terminal of
the vehicle batteryto provide an adequate voltage source and minimize noise.
Connecting the batteryterminal lead to any other point (such as the fuse block )
will reduce thepower output and may cause noise and distortion. Use only #10
gauge or thicker(smaller gauge # ) wire for this lead and connect it to the terminal
of the batteryafter all otherwiring is completed.
GROUND CONNECTION
The ground terminal(GND) connection is also critical to the correct operation of
the amplifier.Use a wireof the same gauge as the power connection ( #10 or thic-
ker)and connect itbetween the ground terminal (GND ) of the amplifier and a
metal part ofthe vehicle close to the mounting location. This wire should be as
short as possibleand any paint or rust at the grounding point should be scraped
away to providea clean metal surface to which the end of the ground wire can be
screwed or bolted.
REMOTE TURN-ON CONNECTION
The amplifier isturned on by applying +12V to the remote turn-on terminal (REM).
The wire leadto this terminal should be connected to the "Auto-Antenna " lead
from the carstereo which will provide the +12V only when the car stereo is turned
on. If thecar stereo doesnot provide an Auto-Antenna" lead, the remote turn-on
lead may bewired to an"Accessory " or "Radio "terminal in the car's fuse block.
This will turnthe amplifier on and off with the ignition key, regardless of whether
the car stereois on oroff. The remote turn-on lead does not carrylarge currents.
So #20 gauge wire may beused for this application.
SPEAKER CONNECTIONS
Depending on thetype and number of speakers used with the amplifier, wire them
to the speaker terminals as per the appropriate wiring diagram. For most
applications #18gauge wire should be used for the speaker leads but in no case
thinner than #20gauge. For leads in excess of 10 feet # 16 gauge is recommen-
ded. When wiringthe speakers, pay careful attention to the polarity of the termi-
nals on thespeakers and make certain they correspond to the polarity of the c-
orresponding terminals onthe amplifier. Do not ground any speaker leads to the
chassis of the vehicle.
INPUT CONNECTIONS
This amplifier featureslow-level input capability.
If the carstereo does notprovide low-level outputs, the amplifier may be connec
-ted via the speaker (high-level) outputs from the stereo with a AUTOCRAFT line
converter.
WIRING INSTRUCTIONS

After the amplifier has been installed and all connections have been made careful
-lyand securely, turn the radio on so that the amplifier is switched on automatically.
After a short power-on period, the amplifier reaches its full performance.
Now turn up the volume slowly using the volume control of the radio. If there is no
sound or only a distorted replay, switch off the radio immediately, the amplifierwill
also switch offautomatically, and check if all connections have been made correctly.
POWER=LED POWER INDICATOR
After the orderly connection of the three power terminals, the LED indicator shines
green and goes out with off.
PROTECT =LED PROTECTION INDICATOR
This set is equipped with an overload protection, immediately upon overloading
due to short circuit or much increased temperature the overload protection is
activated and the red LED indicator is shining. Through this the amplifier is
protected against damage. In case of the thermal protection a certain short cooling
time must be allowed after which the amplifier automatically resumes operation.
LEVEL CONTROL
The input level control allows the system to work well within a wide range of output
level. Choose the adjustment in the way that you achieve a sound most possibly
without any distortion. as a guideline the following procedure is recommended:
If you use several amplifier, the adjustment has to be made for each set separately,
tune up the volume of your car radio to 2/3 of the maximum volume.
Now turn the gain control of the amplifier from " Min " to " Max " direction until you
can hear distortions. Then turn the levelcontrol a little back to " Min ". The gain
control adjustment is finished now.
Attention! If you use 2 Ohm speakers in stereo mode. Tri-mode or 4 Ohm speakers
in bridge mode and the overload protection is triggered, turn the gain control to
" Min " direction, until the operation is free of trouble.
LOW PASS CONTROLS
This amplifier has controls for making good sound
combination.
high pass and low pass
OPERATION INTERFERENCE
Use only ascreened audio cablefor the wiringbetween " low level in " of the
amplifier and RCAor DIN output of the radio .
Lay the signal, speaker and power cables separately with enough distance
from one anotherand also fromeach other carcable. lf notpossible, you can
lay the circuit and ground cable together with the serial cables. Audio and
speaker cable shouldbe as faraway from theseas possible. The REM cableto
the automatic antennaoutput of the radio can belaid together with the signal
cables.
Avoid ground loops by laying the ground wiring of all components to a center
point in astar-like way. You can find the best central point in measuring the
voltage directly atthe battery. Now comparethis voltage value with the chosen
ground point andthe (+) terminal of the amplifier. lf the measured voltage in
only less different you've found thecorrect central.Otherwise youhave to look
for another point. You should measure withthe ignition being switched on and
additionally switched on other electronics ( rear window heating and light ).
If there are pickups from external electrical sources into the speaker cables,
divide the coreleads and twistthem together.
If there are noises from the car electronics. Add an interferencesuppression
choke to thepower wiring .
If there are huming noises, use thicker ground cables or add further ground
cables to thechassis.
Toreduce contact resistance and bad andloose contacts, please tin the cable
ends or use multi core cable ends, spade terminals or others. Gold Plated
spade terminal are free of corrosion and have thelowest contact resistance.
Should all these measures to without any success. theuse of aground loop
isolator may solvethe problem.
All cables aresources of interference. The power cable and RCA audio cable
are very proneto interference; theremote cables areless prone . There is often
interference caused bythe generator (piping), ignition ( cracking ) or other car
electronic parts. Mostof these problemscan be eliminatedby correct and careful
cabling. In doingso, these arethe following guidelines:

SPEAKERS CONNECTIONS AT BRIDGEDSPEAKERS CONNECTIONS AT BRIDGED
CAR STEREO
AMP 2
AMP 1
BATTERY
DC 12V
To a metal
part of car
AMP 2
AMP 1
CO2400.1D2
4~8Ohm
MASTER
SAVEL
CO2400.1D2
R
L
PRO
PWR
BRIDGED
OUT
IN
PRO
PWR
GAIN BASS BOOST
LPF REMOTE
15Hz 0dB +18dB
Min Max
LINE INPUT
LINE OUT
400Hz
PHASESUB SONIC
25HzOFF O 0O
180
PRO
R
L
PRO
PWR
BRIDGED
OUT
IN
PRO
PWR
GAIN BASS BOOST
LPF REMOTE
15Hz 0dB +18dB
Min Max
LINE INPUT
LINE OUT
400Hz
PHASESUB SONIC
25HzOFF O 0O
180
PRO
POWER INPUT
SPEAKER OUTPUT
+12V REM GND
FUSES
25A X 4
MIN 2
POWER INPUT
SPEAKER OUTPUT
+12V REM GND
FUSES
25A X 4
MIN 2

SPEAKERS CONNECTIONS AT BRIDGEDSPEAKERS CONNECTIONS AT BRIDGED
CAR STEREO
AMP 2
AMP 1
BATTERY
DC 12V
To a metal
part of car
AMP 2
AMP 1
POWER INPUT
SPEAKER OUTPUT
+12V REM GND
FUSES
MIN 1
POWER INPUT
SPEAKER OUTPUT
+12V REM GND
FUSES
MIN 1
CO1200.1D/CO2400.1D/CO3200.1D CO1200.1D/CO2400.1D/CO3200.1D
2~8Ohm
MASTER
SAVEL
R
L
PRO
PWR
BRIDGED
OUT
IN
PRO
PWR
GAIN BASS BOOST
LPF REMOTE
15Hz 0dB +18dB
Min Max
LINE INPUT
LINE OUT
400Hz
PHASESUB SONIC
25HzOFF O 0O
180
PRO
R
L
PRO
PWR
BRIDGED
OUT
IN
PRO
PWR
GAIN BASS BOOST
LPF REMOTE
15Hz 0dB +18dB
Min Max
LINE INPUT
LINE OUT
400Hz
PHASESUB SONIC
25HzOFF O 0O
180
PRO

200
300
600
CO2400.1D
10Hz~400Hz(-3dB)
CO1200.1D
CLASS D MONOCHANNEL
Frequency Response
Signal Noise Ratio
Input Impedance
Input Sensitivity
T.H.D.
Subsonic
Low Pass Freq.
Phase
Bass Boost
Supply Voltage
RMS Watts @4 Ohm
Mono 14.4V
POWER DESCRIPTION
Watts Nominal
RMS Watts @2 Ohm
Mono 14.4V
RMS Watts @1 Ohm
Mono 14.4V
Dimensions(mm)
11~15V DC
400
800
1200
90dB
22K Ohm
150mV~5V
<0.05%
25Hz
15Hz-400Hz
O O
0 / 180
0~+18dB
2400
379x190x50
11~15V DC
10Hz~400Hz(-3dB)
90dB
22K Ohm
150mV~5V
<0.05%
25Hz
15Hz-400Hz
O O
0 / 180
0~+18dB
1200
344x190x50
SPECIFICATION
CO2400.1D2
600
CLASS D MONOCHANNEL
Frequency Response
Signal Noise Ratio
Input Impedance
Input Sensitivity
T.H.D.
Subsonic
Low Pass Freq.
Phase
Bass Boost
RMS Watts @4 Ohm
Mono 14.4V
POWER DESCRIPTION
RMS Watts @2 Ohm
Mono 14.4V
RMS Watts @1 Ohm
Mono 14.4V
Watts Nominal
Supply Voltage
Dimensions(mm)
11~15V DC
1200
90dB
22K Ohm
150mV~5V
<0.05%
25Hz
15Hz-400Hz
O O
0 / 180
0~+18dB
2400
10Hz~400Hz(-3dB)
379x190x50
N/A
CO5000.1D
11~15V DC
1200
1800
2500
10Hz~400Hz(-3dB)
90dB
22K Ohm
150mV~5V
<0.05%
25Hz
15Hz-400Hz
O O
0 / 180
0~+18dB
5000
CO3200.1D
700
10Hz~400Hz(-3dB)
11~15V DC
1100
1600
90dB
22K Ohm
150mV~5V
<0.05%
25Hz
15Hz-400Hz
O O
0 / 180
0~+18dB
3200
399x190x50 444x190x50