Orion XTREME 200 User manual

XTREME 200/400.4
OWNER’SMANUAL
H IGH P ERFORMANCE C AR A UDIO

TABLE OF CONTENTS
INTRODUCTION 1
WARRANTY 4
SPECIFICATIONS 6
TECHNICAL DESIGN FEATURES 8
SYSTEM PLANNING 10
INSTALLATION 18
POWER CONNECTIONS 19
SPEAKER CONNECTIONS 20
OUTPUT CONFIGURATIONS 27
4-CHANNEL INPUT CONFIGURATIONS 28
INTERNAL CROSSOVER CONFIGURATION 28
SIGNAL INPUT AND OUTPUT LEVEL CONTROLS 29
CHOOSING MOUNTING LOCATIONS 30
STEP BY STEP INSTALLATION 32
TESTING THE SYSTEM 33
ADJUSTING THE SOUND OF THE SYSTEM 34
TROUBLESHOOTING TIPS 36
AUTOSOUND 2000 TROUBLESHOOTING TIPS 38

Thank you for your purchase of ORION’s XTREME amplifier. Each ORION amplifier is designed to be the leader in its class offering the
most power, advanced features and ease of use. The ORION XTREME amplifiers are designed as the best “affordable high end” car
audio amplifier money can buy. Listed below are the features of the new ORION COBALT amplifiers.
•XTREME 200 – 50 watts per channel, 2-channel amplifier with built-in continuously variable high-pass or low-pass 12dB/octave
crossover from 45 to 5kHz. The XTREME 200 is capable of 3, 2, or 1 channel operation.
•XTREME 400.4 – 50 watts per channel, 4-channel amplifier with dual built-in continuously variable high-pass or low-pass 12dB/octave
crossover from 45 to 5kHz. The XTREME 400.4 is capable of 6, 5, 4, 3, or 2 channel operation.
NOTE: The installation of all ORION XTREME 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 this digital processor. 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, read the entire installation section of this manual before beginning the installation.
INTRODUCTION
page 1

ABOUT THIS MANUAL
This manual is divided into different sections for different needs. Whether you are the owner, salesperson or installer, we have devoted
sections of this manual to answer your questions. If you just purchased this amplifier and have yet to decide on a system configuration,
refer to the System Planning section of this manual for awesome system ideas.
We, at ORION, strive to give you the latest up to date information about our products. What we cannot give you is personal installation
or technical experience. If you have questions regarding the installation or the set-up or tuning of this product, please refer to your
nearest Authorized ORION Dealer for assistance. Additionally, you can call ORION’s Technical Support Hotline at 1-800-315-2052 or 602-
705-5600 for assistance.
PRACTICE SAFE SOUND™
Continuous exposure to sound pressure levels over 100dB may cause permanent hearing loss. High powered 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.
RECORD YOUR SERIAL NUMBER AND DATE:
Model: __________________________________________________________
Serial Number: __________________________________________________________
Date of Purchase: __________________________________________________________
Company Purchased From: __________________________________________________________
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(1) XTREME amplifier
(1) 8 gauge power and ground connector
(1) 14 gauge speaker and remote connector
(4) #8 self-tapping black Phillips pan head screws
(1) XTREME installation and operation manual
WHAT’S IN THE BOX
page 3

WARRANTY
ORION Industries Inc. warrants this product to be free from defects in material and workmanship under the following terms:
Parts and Labor are warranted for a period of 3 years IF:
a. The product is purchased from an Authorized ORION Dealer
b. The product is installed by an Authorized ORION Dealer
Parts and Labor are warranted for a period of 1 year IF:
a. The product is purchased from an Authorized ORION Dealer
b. The product is NOT installed by an Authorized ORION Dealer
Parts and Labor are warranted for a period of 90 days IF:
a. The product is NOT purchased from an Authorized ORION Dealer
If you are uncertain as to whether your dealer is authorized, please contact ORION at 1-800-775-7150 or 602-705-5600. In countries
other than the USA, each distributor warrants the ORION product it sells.
The following conditions and situations are NOT covered by this warranty:
Any product on which the serial number has been defaced, modified or removed. Damage or malfunction resulting from:
a. Accident, misuse, abuse, unauthorized modification or failure to follow the instructions provided with this product
b. Repair by anyone NOT authorized by ORION
c. Damage due to shipping (these claims must be presented to the freight carrier)
d. Removal or installation of this product
e. Any failure that has NOT been caused by a defect in material or workmanship
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This warranty is in effect for the original purchaser only. ORION will pay for labor and material expense for covered items. ORION does
not cover removal or installation charges, payment of shipping charges to ORION, payment of OUT-OF-WARRANTY shipping charges, or
damage to other property caused by any defects in this product.
For IN-WARRANTY service, you must include a copy of the original, dated sales receipt, including serial number, from an Authorized
ORION Dealer. Please also provide your name, return street address (No P.O. Boxes) and a detailed description of the problem.
For out-of-warranty products, please include ORION E-Z Repair Form. These are available by contacting ORION Repair at 1-888-362-5283
or 602-705-5600 and ask for the Repair Department.
• If you do not have the original packaging, the product must be packaged to prevent damage during shipment.
ORION Industries Inc.
ATTN: Repair Department
9235 South McKemy Street
Tempe, Arizona 85284 USA
Exclusion
1. This warranty is in lieu of all other warranties expressed or implied.
2. In no event will ORION be liable for any consequential damages resulting from the use of this product or any defect of this product.
This warranty gives you specific legal rights. You may also have other rights that vary from state to state.
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Amplifier Section XTREME 200 XTREME 400.4
Power output 4Ωstereo (watts)150 x 2 50 x 4
50 x 2, 200 x 1
Power output 2Ωstereo (watts)2100 x 2 100 x 4
Power output 4Ωmono (watts)1200 x 1 200 x 2
Distortion all channels driven <0.1% THD <0.1% THD
(from 20Hz to 20kHz)
Frequency Response 20Hz to 20kHz ±0.25dB 20Hz to 20kHz ±0.25dB
Linear Bandwidth 6Hz to 50kHz ±3dB 6Hz to 50kHz ±3dB
Signal-to-noise ratio full bandwidth >100dB >100dB
@ rated output power
Damping factor @ output connector >400 at output connector >400 at output connector
@ full bandwidth
Slew Rate >30Vµs >30Vµs
Input Sensitivity3200 mV to 5 Vrms 200 mV to 5 Vrms
Input Impedance 20kΩ20kΩ
Fuse Type 30 Amp ATC (2) 20 Amp ATC
SPECIFICATIONS
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1All channels driven, continuous rated 4Ωload, 20Hz to 20,000Hz, >0.1% THD, per input voltage at 12.0VDC.
2All channels driven, continuous rated 2Ωload, 20Hz to 20,000Hz, >0.1% THD, per input voltage at 12.0VDC.
3XTREME amplifers are designed to accept full 9 Volts RMS input when set to the minimum gain position.
4All crossovers are with a slope rate of 12dB/octave and a “Q” of .0707.
Crossover Section3XTREME 200 XTREME 400.4
Low-Pass Crossover Continuously variable Continuously variable
Low-Pass Frequency Range 45Hz to 5kHz 45Hz to 5kHz
High-Pass Crossover Continuously variable Continuously variable
High-Pass Freqency Range 45Hz to 5kHz 45Hz to 5kHz
General
Dimensions 8”L x 10.25”W x 2.25”H 13”L x 10.25”W x 2.25”H
(305mm x 260mm x 57mm) (457mm x 260mm x 57mm)
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TECHNICAL DESIGN FEATURES
page 8
PRS Power Supply
Complementary Matched
Bipolar Outputs
16 Gauge Speaker
and Remote
ATC Fuse
Crossover Frequency Control
Stereo/SUM/MONO Switch
Gain Control
RCA Input
Crosssover Selector
8 Gauge Power &
Ground
Power Supply Controller
PRS Power supply
MOSFET switches
Power LED
Rectifier
Diodes
XTREME 200

1. Power LED - when lit indicates that the amplifier is on
2. Front Output Configuration Switch - determines the output
configuration of the amplifier
3. Front Gain Control - continuously adjusts from 200mV to 5Vrms
for full power output
4. 2-Channel / 4-Channel Switch - configures the amplifier for two or
four RCA inputs
5. Front RCA inputs - accepts RCA input from a source unit,
preamplifier or equalizer
6. Rear RCA outputs - accepts RCA input from a source unit, preampli-
fier or equalizer
7. Rear Crossover Control - adjusts the frequency for the rear channels
8. Rear Crossover Switch - configures the rear channel for high-pass,
low-pass or full range operation
9. Rear Output Configuration Switch - determines the output
configuration fo the amplifier
10. Front Crossover Switch - configures the front channel for high-
pass, low-pass or full range operation
11. Front Crossover Control - adjusts the frequency for the front
channels
12. Rear Gain Control - continuously adjusts from 200mV to 5Vrms
for full power output
TECHNICAL DESIGN FEATURES
13. REM Remote Turn-on Input - turns on the amplifier when
fed 12 V+
14. Speaker Connections - allow up to 12 gauge speaker wire
15. Fuse - protects the amplifier from over current situations
16. Power Connections - allow up to 4 gauge power and
ground cables
123456789
10 11 12
13 15 1614
page 9

SYSTEM PLANNING SYSTEM 1
The easiest way to maximize the performance for your
ORION XTREME amplifier is to properly plan your sys-
tem. By planning your system, you can avoid situation
where the performance of the reliability of your system
is compromised. Your Authorized ORION dealer has been
trained by ORION Industries on how to maximize your
system’s sonic potential. Authorized ORION dealers are
a valuable resource in helping you with your system de-
sign and installation. If you wish to venture on with your
own system design, here are some systems designed by
ORION Industries.
System 1 is a simple 2-channel amplifier driving a pair
of satellites. This is a great start to an awesome sound-
ing system.
• Lowest recommended impedance is 2Ωper channel
• Amplifier can be configured for high-pass or full range
stereo operation
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SYSTEM PLANNING SYSTEM 2
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System 2 adds a subwoofer to system 1.
Amplifier 1 is configured high-pas for
the satellite speakers and Amplifier 2 is
configured low-pass for a single 4Ωsub-
woofer.
Amplifier 1
• Lowest recommended impedance is 2Ω
per channel
• Amplifier is configured high-pass for
satellite operation
• Amplifier is configured for stereo op-
eration
Amplifier 2
• Lowest recommended impedance is 4Ω
per channel
• Amplifier is configured for low-pass for
subwoofer operation
• Amplifier is configured for summed
bridged operation

SYSTEM PLANNING SYSTEM 3
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System 3 uses a 4-channel amplifier to drive an entire system. The front channels are configured high-pass operation for satellites. The rear channels
are configured low-pass for two dual voice coil subwoofers.
• Lowest recommended impedance for front channels is 2Ωper channel
• Front channels configured for high-pass operation
• Front channels configured for stereo operation
• Lowest recommended for rear channels is 2Ωper channel
• Rear channels configured for low-pass operation
• Rear channels configured for summed stereo operation
• Amplifier can be configured either for 2-channel or four-channel inputs
Note: when the amplifier is configured for 4-channel input the fader on the source unit can control the output level between the subwoofer and
satellites.
SYSTEM PLANNING SYSTEM 3
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SYSTEM PLANNING SYSTEM 4

SYSTEM PLANNING SYSTEM 4
System 4 uses a 4-channel amplifier to power the front satellites and a single 4Ωsubwoofer and a 2-channel amplifier for the rear satellites.
Amplifier 1
• Lowest recommended impedance for the front channels is 2Ωper channel
• Front channels configured for high-pass operation
• Front channels configured for stereo operation
• Lowest recommended impedance for the rear channels is 2Ω
• Rear channels configured for low-pass operation
• Rear channels configured for summed stereo operation
• Amplifier is configured for 2-channel input
Amplifier 2
• Lowest recommended impedance is 2Ωper channel
• Amplifier is configured for high-pass or full range operation
• Amplifier configured for stereo operation
• Amplifier input received from the rear RCAs of Amplifier 1
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SYSTEM PLANNING SYSTEM 5

SYSTEM PLANNING SYSTEM 5
System 5 uses two 4-channel amplifiers for the front and rear satellites and two 2-channel amplifiers for two subwoofers. This system is designed
to really rock.
Amplifier 1
• Amplifier 1 is configured for 2-channel stereo operation
• Lowest recommended impedance is 4Ωper channel stereo
• Amplifier channels configured for high-pass operation
• Amplifier is configured for 2-channel input
Amplifier 2
• Amplifier 2 is configured for 2-channel stereo operation
• Lowest recommended impedance is 4Ωper channel stereo
• Amplifier channels configured for high-pass operation
• Amplifier is configured for 2-channel input
page 17
Amplifier 3
• Lowest recommended impedance is 4Ωmono
• Amplifier channels configured for low-pass operation
• Amplifier is configured for summed bridged operation
Amplifier 4
• Lowest recommended impedance is 4Ωmono
• Amplifier channels configured for low-pass operation
• Amplifier is configured for summed bridged operation
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INSTALLATION
The installation of all ORION components 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 this 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, read the entire
installation section of this manual before beginning installation.
TOOLS OF THE TRADE
Listed are the majority of the tools required to perform the installation. Having the proper tools will make the installation much easier. Some of
these tools are necessities. Some make the job much easier.
• marking pen • heat shrink tubing
• electric drill with assorted drill bits • nylon tie straps
• utility knife • volt-ohm meter (optional)
• Phillips and flat blade screw drivers • wire cutters
• pliers (standard and needle nose) • wire crimpers
• wire brush or sandpaper for chassis grounding • wire strippers
• solder iron and solder
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