Orion Car Audio HCCA D2400 User Manual

HCCA-D1200  
HCCA-D2400  
HCCA-D5000  
INTRODUCTION  
Thank you for your purchase of Orion's HCCA-D1200, HCCA-D2400, or HCCA-D5000 power  
amplifier. Each Orion amplifier is designed to be the leader in its class offering the most  
power, advanced features, and extreme ease of use. In high-end sound systems or high SPL  
systems, Orion amplifiers will give you years of trouble-free performance.  
HCCA-D1200 - 1200 Watt single-channel Class D amplifier with built-in infrason-  
ic filter, with INTELLi-Q, ESP2, and remote bass. The HCCA-D1200 is capable of  
one-channel operation with a maximum power of 1200 Watts into 1W.  
HCCA-D2400 - 2400 Watt single-channel Class D amplifier with built-in infrason-  
ic filter, with INTELLi-Q, ESP2, and remote bass. The HCCA-D1200 is capable of  
one-channel operation with a maximum power of 2400 Watts into 1W.  
HCCA-D5000 - 5000 Watt single-channel Class D amplifier with built-in infrason-  
ic filter, with INTELLi-Q, ESP2, and remote bass. The HCCA-D5000 is capable of  
one-channel operation with a maximum power of 5000 Watts into 1W.  
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Each of these amplifiers has security and programmable features controlled via a ESP -2  
serial databus and Directed's proprietary Bitwriter tool (998T). The Bitwriter unit must  
have version 2.3 or above to access the amplifier features menu.  
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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 assis-  
tance 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) Spare fuse(s)  
(1) Allen wrench 2.5mm  
(1) Allen wrench 3mm  
(8) #8 self-tapping black Phillips head pan head screws  
(4) flat washers with adhesive  
(1) 3’ phono cable  
(1) 15’ ESP cable (amplifier to security system cable)  
(1) Amplifier installation and operation manual  
(1) Window decal  
IMPORTANT NOTE  
Prior to servicing your vehicle ensure that the alarm system is disarmed. Due to the ampli-  
fier’s anti-theft feature (if enabled), if the main power to the amplifier is removed while the  
security system is armed the amplifier operation is disabled. To reset the amplifier, refer to  
Appendix—Programmable Features.  
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© 2005 Directed Electronics, all rights reserved  
PRACTICE SAFE SOUND™  
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.  
RECORD YOUR SERIAL NUMBER AND DATE  
To ensure your warranty (see back cover), please record the following information regard-  
ing your new amplifier.  
Model:  
__________________________________________________  
__________________________________________________  
Serial Number:  
Date of Purchase: __________________________________________________  
Purchased from: __________________________________________________  
END PANEL LAYOUTS  
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5
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7
8
9
10 11 12  
POWER  
(GREEN)  
INPUT  
L CH  
LINE OUT  
L CH  
ESP PORT  
REMOTE  
PHASE  
GAIN  
INFRASONIC  
HPF  
INTELLI-Q  
LPF  
PROTECT  
(RED)  
MASTER  
SLAVE  
ON  
OFF  
º
º
O
180  
MIN  
MAX  
20Hz  
150Hz  
MIN  
MAX  
30Hz  
250Hz  
ESP  
INDICATOR  
(YELLOW)  
R CH  
R CH  
1. RCA Input - accepts RCA input from a head unit, preamplifier, or equalizer.  
2. RCA Line Output - provides easy connection to additional amplifiers.  
3. Master/Slave Switch - controls whether the amplifier is a slave or master when  
connected in combined amplifier configurations. (Refer to the Combined  
Amplifiers section of this guide.)  
4. Gain Control - continuous adjustment for full power output.  
5. Infrasonic Switch - when On cuts off extremely low bass frequencies (below the  
range of human hearing, that speakers cannot effectively reproduce). The high  
pass filter is engaged when the infrasonic switch is On. This improves efficiency of  
the amplifier’s power supply, improves sound reproductive performance, and  
reduces chances of damaging the subwoofers.  
6. High-Pass Frequency Control - adjusts the frequency of the high-pass crossover.  
7. INTELLi Q Control - continuously adjusts the "Q" boost of the high-pass  
crossover from 0 to 10dB of boost.  
8. Low-Pass Frequency Control - adjusts the upper crossover frequency of the  
amplifier.  
9. Remote Bass Jack - connects optional HP-RB1 remote bass control to control the  
bass level from the driver’s seat.  
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© 2005 Directed Electronics, all rights reserved  
10. Phase Control Switch - provides either 0 or 180 degree phase shift of the ampli-  
fied output (speaker) with respect to the input signal to facilitate bridging of  
amplifiers.  
11. Power LED - when illuminated (green) indicates that the amplifier is on.  
Protect LED - when illuminated (red) indicates that the amplifier protective cir-  
cuitry has been activated due to thermal, output short, supply undervoltage or  
supply overvoltage.  
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ESP Indicator LED - when illuminated (yellow) indicates ESP functionality and  
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is used to diagnose ESP features. The LED flash characteristics will assists in diag-  
nosing the type of fault (see Appendix).  
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NOTE: The LED on top of the amplifier may also illuminate and flash with the ESP LED  
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indicator, if this option has been enabled by your installer (requires Bitwriter ).  
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12. ESP Port - connection port for Bitwriter or ESP2 security system.  
HCCA-D1200  
1
2
3
4
5
SPEAKER  
FUSE  
+BAT  
REM  
GND  
+
+
-
-
HCCA-D2400  
1
2
3
4
5
SPEAKER  
FUSE  
+BAT  
REM  
GND  
+
+
-
-
HCCA-D5000  
2
3
4
2
3
4
5
SPEAKER  
+BAT  
REM  
GND  
+BAT  
REM  
GND  
+
+
-
-
1. ATC Fuse - this fuse(s) protects the amplifier against internal electrical damage  
and is meant to protect the amplifier only. All other power connections should be  
fused at the source. The HCCA-D1200 has two 30-amp fuses. The HCCA-D2400 has  
three 40-amp fuses. The HCCA-D5000 has one inline 250-amp fuse.  
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© 2005 Directed Electronics, all rights reserved  
2. +BAT - connect this terminal through a FUSE or CIRCUIT BREAKER to the positive  
terminal of the vehicle battery or the positive terminal of an isolated audio sys-  
tem battery.  
WARNING: Always protect this power wire by installing a fuse or circuit breaker of the  
appropriate size within 12 inches of the battery terminal connection.  
3. REM - this terminal turns on the amplifier when (+) 12 volt is applied. Connect it  
to the remote turn on lead of the head unit or signal source. If a (+) 12 volt remote  
turn lead is not available, a Remote Power Adapter (P/N #55000) can be used to  
supply a remote turn on signal. DO NOT connect this terminal to constant (+) 12  
volt.  
4. GND - power return connection. Connect this terminal directly to the sheet metal  
chassis of the vehicle, using the shortest wire necessary to make this connection.  
Always use wire of the same gauge or larger than the (+) 12 volt power wire. The  
chassis connection point should be scraped free of paint and dirt. Use only quali-  
ty crimped and/or soldered connectors at both ends of this wire. DO NOT connect  
this terminal directly to the vehicle battery ground terminal or any other factory  
ground points.  
5. Speaker - connect the speakers to these terminals. (refer to the Speaker  
Connection section of this guide.)  
NOTE: Make all connections to power, ground, speakers, and remote terminals before  
final positioning and installation of the amplifier in the vehicle.  
NOTE: the HCCA-D5000 has two terminal strips for power connections. The +BAT and  
GND connections can be made to either of these terminals.  
CEA SPECIFICATIONS  
HCCA-D1200  
Power Output: 250 Watts RMS x 1 at 4 ohms and < 1% THD+N  
Signal to Noise Ratio: -60 dBA (reference 1 Watt into 4 ohms)  
Additional Power Output: 600 Watts RMS x 1 at 1 ohm at 14.4 Supply<1% THD+N  
HCCA-D2400  
Power Output: 450 Watts RMS x 1 at 4 ohms and < 1% THD+N  
Signal to Noise Ratio: -60 dBA (reference 1 Watt into 4 ohms)  
Additional Power Output: 1200 Watts RMS x 1 at 1 ohm at 14.4 Supply<1% THD+N  
HCCA-D5000  
Power Output: 1000 Watts RMS x 1 at 4 ohms and < 1% THD+N  
Signal to Noise Ratio: -60 dBA (reference 1 Watt into 4 ohms)  
Additional Power Output: 2500 Watts RMS x 1 at 1 ohm at 14.4 Supply<1% THD+N  
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© 2005 Directed Electronics, all rights reserved  
SPECIFICATIONS  
Amplifier Section  
HCCA-D1200  
250 x 1  
400 x 1  
600 x 1  
HCCA-D2400  
450 x 1  
HCCA-D5000  
1000 x 1  
Power Output 4W  
(Watts)  
1
Power Output 2W  
(Watts)  
2
800 x 1  
1600 x 1  
2500 x 1  
Power Output 1W  
(Watts)  
1200 x 1  
Amplifier  
Efficiency  
> 70% into 1W load > 70% into 1W load > 70% into 1W load  
at max. power  
at max. power  
at max. power  
Externally  
Bridgeable  
Remote Bass  
Function  
yes  
yes  
yes  
yes (HP-RB1  
supplied)  
yes (HP-RB1  
supplied)  
yes (HP-RB1  
supplied)  
Distortion at  
Rated Power  
< 1.0% THD+N  
< 1.0% THD+N  
< 1.0% THD+N  
Frequency  
Response  
20Hz to 250Hz  
2.5dB  
20Hz to 250Hz  
2.5dB  
20Hz to 250Hz  
2.5dB  
10Hz to 500Hz  
3dB  
10Hz to 500Hz  
3dB  
10Hz to 500Hz  
3dB  
Linear Bandwidth  
Damping Factor  
Input Sensitivity  
> 200  
> 200  
> 200  
150mV to 5V rms  
150mV to 5V rms  
150mV to 5V rms  
Supply Voltage  
Range  
9 to 16V  
9 to 16V  
9 to 16V  
thermal, DC offset,  
reverse polarity,  
short protection,  
under-voltage,  
over-voltage  
thermal, DC offset,  
reverse polarity,  
short protection,  
under-voltage,  
over-voltage  
thermal, DC offset,  
reverse polarity,  
short protection,  
under-voltage,  
over-voltage  
Protection  
Power 0/1 AWG,  
Remote 12 AWG,  
Ground 0/1AWG,  
Speaker 12 AWG  
Power 0/1 AWG,  
Remote 12 AWG,  
Ground 0/1AWG,  
Speaker 12 AWG  
Power 0/1 AWG,  
Remote 12 AWG,  
Ground 0/1AWG,  
Speaker 12 AWG  
Terminal Wire  
Gauge  
20kW  
20kW  
20kW  
Input Impedance  
Fuse Type  
(2) 30 Amp  
13"x10.5"x2.3"  
8 lbs.  
(3) 40 Amp  
13"x10.5"x2.3"  
8 lbs.  
In-line 250 Amp  
13"x10.5"x2.3"  
8 lbs.  
Dimensions  
Weight  
Crossover Section  
High Pass  
Crossover  
Continuously  
variable (20-150Hz)  
Continuously  
variable (20-150Hz)  
Continuously  
variable (20-150Hz)  
Low Pass  
Crossover  
Continuously  
variable (30-250Hz)  
Continuously  
variable (30-250Hz)  
Continuously  
variable (30-250Hz)  
Selectable On/Off  
24dB/Octave  
Selectable On/Off  
24dB/Octave  
Selectable On/Off  
24dB/Octave  
Infrasonic Filter  
-6dB at 20Hz  
-6dB at 20Hz  
-6dB at 20Hz  
Intelli-Q  
0–10dB boost  
0–10dB boost  
0–10dB boost  
1. Continuous 4W load 20Hz to 200Hz, < 1% THD, with input voltage at 14.4VDC.  
2. Continuous 2W load 20Hz to 200Hz, < 1% THD, with input voltage at 14.4VDC.  
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© 2005 Directed Electronics, all rights reserved  
AMPLIFIER SETTINGS  
Signal Input and Output Configurations  
The input section of the amplifier consists of a phase switch that sets the output configura-  
tion, infrasonic switch, gain controls, high pass and low pass crossovers controls, Intelli-Q  
control, and RCA inputs. The input section makes it easy to adapt this amplifier to most sys-  
tem configurations.  
Input Gain  
These Orion amplifiers have level adjustments to allow for easy integration with any source  
unit. The input sensitivity can be adjusted from 150mV to 5V. Refer to Testing the System  
and Adjusting the Sound of the System sections of this guide for detailed instructions on  
setting the gain.  
Phase Switches  
0° - leaves output unaffected. The output signal is in phase with the input signal.  
180° - inverts the output. The channel is 180° output of phase. This configuration  
is useful for inverting the phase of subwoofers to improve staging in a vehicle.  
This is also used when bridging two amplifiers into one speaker.  
Line Output Configurations (System Expansion)  
NOTE: When expanding your system by adding additional Orion amplifiers in the signal  
chain use only the same model(s) as the first amplier in the chain.  
The line outputs on Orion amplifiers offer easy, unlimited system expansion. Routing signal  
from a source unit, pre-amplifier, or equalizer is a matter of connecting RCAs to the RCA  
Inputs of the first Orion amplifier and then the RCA line outputs to the next Orion amplifi-  
er’s RCA line inputs in the signal chain. Then the Master/Slave switch on each of the amplif-  
ers is set as follows:  
The first amplifier in the signal chain will have its Master/Slave switch set to the MASTER  
position. In effect this first amplifier will set the gain for the remainder of the amplifiers in  
the signal chain.  
The remaining amplifiers following in the signal chain will have their Master/Slave switch  
set to the SLAVE position. This allows the signal to be input directly, bypassing the subse-  
quent amplifiers gain control. The audio level is set and supplied by the output of the mas-  
ter amplifier at its gain setting.  
Internal Crossover Configurations  
The crossover section of the Orion HCCA-D1200, HCCA-D2400, and HCCA-D5000 amplifiers  
is continuously variable and extremely flexible. In addition to the variable built-in low-pass  
filters, the high-pass crossover incorporates the INTELLi Q feature. This circuit is designed to  
optimize the performance of Orion subwoofers in all types of enclosures.  
When using Orion 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.  
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© 2005 Directed Electronics, all rights reserved  
WARNING! DO NOT set crossover frequencies lower than the speakers recommended  
operating range. This can cause driver failure that is not covered by the man-  
ufacturer's warranty.  
Low-Pass Crossover  
When the switch is to the left (OFF position), the low-pass crossover is bypassed. When the  
switch is in the middle (12 position), the low-pass crossover is active with a 2nd order (12dB  
per octave) slope. When the switch is to the right (24 position), the low-pass crossover is  
active with a 4th order (24dB per octave) slope. The low-pass crossover is continuously vari-  
able from 30Hz to 250Hz.  
High-Pass Crossover  
When the switch is to the left (OFF position), the high-pass crossover is bypassed. When the  
switch is to the right (ON position), the high-pass crossover is active with a 2nd order (12dB  
per octave) slope. The high-pass crossover is continuously variable from 20Hz to 150Hz and  
is optimized for use as a subsonic filter. Additionally, boost can be added at the high-pass  
crossover frequency for improved bass output while still protecting the woofer from exces-  
sive excursion. The INTELLi Q adjustment allows up to 10 dB of boost at the selected  
crossover frequency.  
WARNING! Exercise caution when setting INTELLi Q. Maximum boost can potentially  
cause woofer damage due to over-excursion.  
Fine Tuning the Crossovers  
The low-pass and high-pass crossover sections are each marked at four frequency points for  
ease of system adjustment. The low-pass crossover section is marked at 30Hz, 50Hz, 150Hz,  
and 250Hz. The high-pass crossover section is marked at 20Hz, 33Hz, 90Hz and 150Hz.  
Specific crossover points can be chosen based on the recommended operational bandwidth  
of your speakers.  
Adjusting INTELLi Q  
Incorporated in the high-pass crossover, INTELLi Q maximizes the performance of a sub-  
woofer. The high-pass subsonic filter removes unwanted bass output from the woofer,  
increasing the output of a subwoofer by as much as 3 dB due to the increased mechanical  
power handling. Depending on the enclosure, using INTELLi Q can increase the low fre-  
quency response by an additional 10dB! The type of enclosure used and the woofer's excur-  
sion capability determine acceptable boost levels. Listed below are recommended boost lev-  
els for different enclosure designs.  
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© 2005 Directed Electronics, all rights reserved  
Enclosure Type  
Boost Levels  
0dB  
+3dB  
+6dB  
+10dB  
Not  
Infinite Baffle  
Tune above  
High X-Max  
Not  
Fs of woofer Drivers--Tune Recommended Recommended  
above Fs of  
woofer  
Sealed  
Tune above  
Tune above  
High X-Max  
Not  
Fs of woofer Fs of woofer  
Drivers--Tune Recommended  
above Fs of  
woofer  
Vented  
Tune to port Tune to port  
Tune to port High X-Max  
frequency  
frequency  
frequency  
Drivers--Tune to  
port frequency  
Sealed Band-pass  
Tune above  
Tune above  
High X-Max  
Not  
Fs of woofer Fs of woofer  
Drivers--Tune Recommended  
above Fs of  
woofer  
Vented Band-pass  
Aperiodic  
Tune to port Tune to port  
Tune to port High X-Max  
frequency  
frequency  
frequency  
Drivers--Tune to  
port frequency  
Set crossover Set crossover Set crossover Not  
to Fs of  
woofer  
to Fs of  
woofer  
to Fs of  
woofer  
Recommended  
Infinite Baffle Example High-Pass Set at 30Hz  
By removing low frequency signal that the woofer cannot produce, the woofer can play its  
capable range louder. The first example is an infinite baffle situation. The left graph displays  
the frequency response of a 12-inch woofer in an infinite baffle application without the  
high-pass filter, with the filter and with the filter and the INTELLi Q set to +3dB. As you can  
see, with +3dB of boost and the high pass filter set to 30Hz, the woofer has more output  
down to 25Hz and less overall excursion when compared to the non-high-pass response.  
Maximum physical excursion capability of the woofer is 15mm.  
NOTE: The left graph is the response; the right graph is the driver excursion. These des-  
ignations apply to the following graphs as well.  
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© 2005 Directed Electronics, all rights reserved  
Sealed Example High-Pass Set at 20Hz  
This sealed example is the same 12-inch woofer in the recommended sealed enclosure. Up  
to 6 dB of boost is capable if 20 Hz was used. With +6dB of boost, the woofer has more out-  
put down to 15 Hz.  
Sealed Example High-Pass Set at 30Hz  
In this example, the frequency has been increased to 30 Hz. Up to 6 dB of boost is capable  
at this frequency. With +6dB of boost, the woofer has more output down to 23 Hz. The  
overall usable output is increased.  
Vented Example High-Pass Set at 30Hz  
Vented enclosures benefit most from the INTELLi Q. Up to 10 dB of boost is capable at the  
box tuning frequency of 30 Hz. With +10dB of boost, the woofer has more output down to  
22 Hz. The excursion below the tuning frequency has been greatly reduced.  
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© 2005 Directed Electronics, all rights reserved  
Remote Gain Operation  
NOTE: Do not use the Remote Gain control when you have an expanded system installed  
(see Line Ouput Configurations). The Slave amplifier(s) gain will not be controlled.  
The remote gain port provides easy remote access to the internal gain structure of the HCCA  
power amplifier. The HP-RB1 plugs into the amplifier via the 1/8" mini jack plug. The HP-RB1  
can be installed in the front of the vehicle to control the amplifier gain level. The HP-RB1 can  
be used as a bass level control when used on an amplifier dedicated to subwoofers.  
AMPLIFIER WIRING  
Power Connections for the HCCA-D1200, and HCCA-D2400  
Orion HCCA-D1200 Fuse Size: 2 x 30 AMP ATC.  
Orion HCCA-D2400 Fuse Size: 3 x 40 AMP ATC.  
Power connections accept up to 4 AWG wire.  
4 AWG power and ground wire recommended for optimal performance.  
Connect 12V+ to the battery through fuse holder. This connection provides +12V  
main power to the amplifier.  
Power wire must be fused no more than 18" from battery.  
Ground amplifier to a good chassis ground as close as possible to the amplifier.  
Connect REM terminal to remote turn-on lead from source unit. This connection  
provides +12V power to turn-on the amplifier.  
Add extra ground wire between the negative terminal of the battery and the  
chassis.  
Power Connections for the HCCA-D5000  
Orion HCCA-D5000 Fuse Size: inline 250 AMP.  
Power connections accept up to 4 AWG wire.  
Dual 4 AWG power and ground wire required for proper performance.  
Connect 12V+ to the battery through power distribution and fuse holder. This  
connection provides +12V main power to the amplifier.  
Power wires must be fused no more than 18" from battery.  
Terminate both grounds of the amplifier to a good chassis ground as close as pos-  
sible to the amplifier.  
Connect REM terminal to remote turn-on lead from source unit. This connection  
provides +12V power to turn-on the amplifier.  
Add an extra ground wire between the negative terminal of the battery and the  
chassis. Either dual 4 AWG or single 1/0 AWG is recommended.  
NOTE: The addition of a ground wire from the battery to the chassis of the vehicle  
improves the ability of the battery to supply power to the amplifier. This is recom-  
mended because the current delivery of the factory electrical system was designed  
only to accommodate electronics supplied by the auto manufacturer.  
WARNING! The Orion HCCA-D5000 has two separate four-gauge power and ground  
inputs. Both pairs of connections must use 4 AWG power wire for proper  
operation. Failure to do this may damage the amplifier and is not covered  
under warranty. The HCCA-D5000 cannot be operated in a bridge or strapped  
configuration, attempting to do so will damage the amplifier.  
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© 2005 Directed Electronics, all rights reserved  
Speaker Connections  
The Orion HCCA-D1200, HCCA-D2400, and HCCA-D5000 amplifiers offer two positive and  
two negative output terminals for ease of connecting the speakers to the amplifier. Since  
these are mono amplifiers, the speaker connectors are paralleled internally. Each amplifier  
is stable to 1W. See diagrams below.  
MASTER  
SLAVE  
Bridging  
For bridging into a single speaker load, the Orion HCCA-D1200 and HCCA-D2400 have the  
ability to be bridged with another amplifier of the same model. To do this you must utilize  
the MASTER/SLAVE switch settings. For the MASTER amplifier, set the switch setting to MAS-  
TER. This will route the signal through RCA to the other (slave) amplifier. On the Slave  
amplifier set this switch to the SLAVE position. Refer to Auxiliary Output Configuration sec-  
tion of this guide. Set the PHASE switch on the slave amp, move the phase switch from 0 to  
180, exactly opposite of the master amp. Refer to the Phase Switches section of this guide.  
On the slave amplifier be sure to turn off all crossovers. For the speaker connections, con-  
nect the positive (+) speaker lead from the speaker to the positive (+) speaker terminal of  
the master amplifier. On the negative (-) speaker connection, take the negative (-) speaker  
terminal of the master amplifier and connect it directly to the negative (-) speaker terminal  
of the slave amplifier. The remaining positive (+) speaker terminal of the slave amplifier  
must be connected to the negative (-) speaker lead from the speaker. The impedance of the  
speaker must not exceed 2W. See diagram below.  
NOTE: For best results, connect both negative speaker terminals on the master amp to  
both negative terminals on the slave amp using at least 12 AWG cable.  
WARNING! The Orion 2500D is not designed to work in a bridged or strapped configu-  
ration. Attempting to apply these configurations will damage the amplifier  
and will not be covered under warranty.  
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© 2005 Directed Electronics, all rights reserved  
MASTER AMPLIFIER  
SLAVE AMPLIFIER  
PHASE  
PHASE  
MASTER  
SLAVE  
0 °  
180°  
MASTER  
SLAVE  
0 °  
180°  
AMPLIFIER INSTALLATION  
Choosing Mounting Locations  
The location of your amplifier will depend on several important issues. Due to the low pro-  
file size of the Orion amplifiers, there are many possible installation locations that will yield  
satisfactory amplifier performance. Always mount the amplifier in a place that protects the  
amplifier from the elements. In addition, mount the amplifier on a stable, flat surface.  
NOTE:  
Mounting amplifiers upside down is not recommended and may cause premature  
thermal shutdown.  
WARNING! Do not mount any amplifier in the engine compartment. Amplifiers are not  
designed to endure the harsh environment of the exterior elements.  
Passenger Compartment  
If you are going to mount the amplifier in the passenger compartment, make sure you have  
adequate room for ventilation. The amplifiers have been designed to make under-seat  
mounting possible. When mounting your amplifier under a seat or similar area, keep a min-  
imum of 1" of clearance around the amplifier for adequate cooling.  
Trunk Compartment  
Mounting your amplifier in the trunk provides excellent performance as long as you do not  
restrict the airflow around the heatsink of the amplifier. For optimal results, mount the  
amplifier with as much clearance as possible. This type of mounting will yield the best cool-  
ing due to the convection effect of the amplifier chassis.  
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© 2005 Directed Electronics, all rights reserved  
General Precautions and Installation Tips  
WARNING! Be careful not to cut or drill into gas tanks, fuel lines, brake lines, hydraulic  
lines, vacuum lines, or electrical wiring when working on your vehicle.  
Disconnect the vehicle's ground wire at the battery before making or breaking connections  
to the audio system's power supply terminals.  
Do not use this amplifier unmounted. Failing to securely mount the amplifier can result in  
damage or injury, particularly in the event of an accident. An unmounted amplifier becomes  
a dangerous projectile in the event of a crash. Never mount the amplifier where it might  
get wet. Mount the amplifier so the wire connections will not be pulled. Route the wires  
where they will not be scraped, pinched or damaged in any fashion.  
The +12V power supply wire must be fused as close as possible to the battery terminal, ide-  
ally within 18". Use the recommended fuse size or circuit breaker listed in the Power  
Connections section of this manual.  
If you need to replace the fuse plugged into the side of the amplifier, replace the fuse with  
the same size and type fuse that came with the amplifier. If you are not sure as to the correct  
value, refer to the Power Connections section of this manual for details. Using a higher cur-  
rent fuse may result in damage to the amplifier that is not covered under warranty.  
NOTE: Make sure all the equipment in the system is turned off when making or break-  
ing connections to the input RCAs or speaker terminals. Turn on the system and  
slowly turn up the volume control only after double checking all wire connections.  
Power for systems with a single amplifier can be supplied by most automotive electrical sys-  
tems. Systems with multiple amplifiers may require a higher capacity battery, alternator or  
the use of a storage capacitor. We strongly recommend the use of a Directed Audio  
Essentials power capacitor with an extra battery in larger stereo systems.  
Orion amplifiers generate a certain amount of heat as part of normal operation. Be sure the  
area around the amplifier is unobstructed to allow adequate air circulation. Remember,  
beach blankets, last week's laundry, school books and homework papers located on top of  
the amplifier do not improve air flow and may become damaged.  
Tools of the Trade  
Listed below are the majority of the tools required to perform an installation. Having the  
proper tools will make the installation that much easier. Some of these tools are necessities;  
some will just make the job easier.  
Allen Wrenches (2.5mm and 3mm)  
DMM or VOM  
Electric drill with assorted drill bits  
Grommets  
Heat shrink tubing  
Marking pen  
Nylon tie straps  
Phillips and flat blade screw drivers  
Pliers (standard and needle nose)  
Reference CD with 1 kHz Sine Wave at 0dB level (all bits high)  
14  
© 2005 Directed Electronics, all rights reserved  
RTA (real time analyzer)  
Soldering iron and solder  
Utility knife  
Wire brush or sandpaper for chassis grounding  
Wire crimper  
Wire cutters  
Wire strippers  
Step By Step Installation  
Step 1  
Step 2  
Step 3  
Determine the location for the amplifier. Refer to the Choosing Mounting  
Locations section of this guide for detailed information.  
Decide on the system configuration for your amplifier. For system sugges-  
tions, refer to the Speaker Connections section of this guide.  
Run all the wires from the amplifier location to the speakers, source unit, and  
battery. Do not connect the battery at this time. Be sure to run RCAs and  
power and speaker wires away from factory electrical wires and system as  
they pose a great potential for induced system noise.  
Step 4  
Step 5  
Pre-drill amplifier mounting holes. Be sure to "think before you drill". Gas  
tanks, fuel lines, and other obstructions have a nasty way of hiding them-  
selves. For best results use a marking pen to mark the mounting holes and  
pre-drill these holes with a standard 1/8" drill bit.  
Mount the amplifier. Make sure the amplifier is mounted on a flat surface. If  
this is not possible, do not over tighten the screws so that the chassis of the  
amplifier is twisted or bent.  
Step 6  
Step 7  
Step 8  
Step 9  
Turn the vehicle's key switch to the off position.  
Disconnect the vehicle's battery ground terminal.  
Connect power wires to the amplifier (ground first, then 12 V(+) and REM).  
Connect the RCA and speaker wires to the amplifier. Check the quality of  
your speakers and signal connections. This will determine the ultimate per-  
formance of your Orion amplifier. Refer to the Signal Input and Output Level  
Controls and Speaker Connections sections of this guide for correct wiring  
instructions.  
Connect the ESP®-2 cable that came with the amplifier from the amplifier’s  
ESP port to the security system’s ESP port.  
Step 10 Reconnect the ground terminal to the battery after power, speaker, and RCA  
connections are completed.  
Step 11 Set crossovers. Refer to the Internal Crossover Configuration section of this  
manual for detailed instructions.  
Step 12 Once satisfied that all connections and settings are correct, install the fuse  
located near the vehicle's battery and proceed to the Testing the System sec-  
tion of this manual.  
WARNING! Never exceed the recommended fuse size of this amplifier. Failure to do so will  
result in the voiding of your warranty and possible damage to the amplifier.  
15  
© 2005 Directed Electronics, all rights reserved  
SET UP AND TROUBLESHOOTING  
Testing the System  
After you have completed the installation, you need to test the system. This will help ensure  
years of trouble-free operation. Please refer to the listed steps below when testing the  
sound of your Orion system.  
Step 1  
Step 2  
Check all the wiring connections to be sure they are correct and secure.  
Turn the signal source volume control all the way down. Set any tone con-  
trols to their flat or defeated positions. This includes the loudness control.  
Step 3  
Step 4  
Turn the level controls of the amplifier to their minimum positions.  
Turn the source unit on. Check to see if the power LED located on the con-  
nection side of the amplifier is on. If not, please refer to the Power  
Connections and the Troubleshooting Tips sections of this manual for instruc-  
tions.  
Step 5  
Step 6  
Step 7  
If using an aftermarket source unit, turn the level controls of the amplifier  
about one quarter of a turn. Slowly increase the volume level of the source  
unit to so that you can hear the output of the system. If no sound is heard or  
if the output is distorted, turn the system off immediately. Refer to the Power  
Connections and the Troubleshooting Tips sections of this manual to solve  
your installation problems.  
Check to make sure the output for each channel is correct. If the active  
crossovers are used, check to make sure that each output is correct from the  
amplifier. When using active crossovers on midrange and tweeters, do not  
use crossover frequencies lower than recommended. If the system is not con-  
figured properly, refer to the Internal Crossover Configuration section of this  
manual and take corrective action.  
If the output is clear and undistorted, continue to the Adjusting the Sound  
of the System section of this manual.  
Adjusting the Sound of the System  
Once you have checked the system's operation, adjust the sound of the system. Adjusting  
the sound of the system is accomplished by setting the level controls and adjusting the  
internal crossovers.  
Step 1  
Turn the signal source volume control all the way down. Set any tone con-  
trols to their flat or defeated positions. This includes the loudness control.  
Step 2  
Step 3  
Turn the level controls of the amplifier to their minimum positions.  
Choose music with high dynamic content that you like, with which you are  
familiar, and will be used most often in the system.  
Step 4  
Step 5  
Turn the source unit's volume control up to its highest undistorted output  
level. If you lack test equipment, this point occurs between 3/4 to full volume  
depending on the quality of your source unit. Listen for any audible distor-  
tion. If any distortion is audible, reduce the volume of the source unit until  
you have an undistorted output. Leave the volume control at this position  
during your system tuning.  
While listening to your chosen dynamic music, turn up the level control corre-  
sponding to the midrange output until you hear slight distortion and turn the  
level control back slightly for an undistorted output. Depending on your sys-  
tem, the midrange and tweeter output may be on the same output channels.  
16  
© 2005 Directed Electronics, all rights reserved  
Step 6  
Step 7  
Turn up the level control corresponding to the tweeter output until you hear  
slight distortion and turn back the level control slightly for an undistorted  
output. Depending on your system the midrange and tweeter output may be  
on the same output channels.  
Fine-tune the output level between midrange and tweeters. Refer to the  
Internal Crossover Configuration section of this manual for detailed instruc-  
tions.  
Step 8  
Step 9  
Repeat Steps 5-7 for the rear speakers. If you do not have rear speakers con-  
tinue to Step 10.  
Set levels between the front and rear midrange and tweeters for optimum  
front/rear balance.  
Step 10 Turn up the level control corresponding to the woofer output until you hear  
slight distortion and turn back the level control slightly for an undistorted  
output.  
Step 11 Fine-tune the output level between satellite speakers and the woofers. Refer  
to the Internal Crossover Configuration section of this manual for detailed  
instructions. If using an HP-RB1, adjust the level to the output of the woofer  
to match the sonic requirements of the system.  
Step 12 Enjoy your awesome Orion sound system.  
17  
© 2005 Directed Electronics, all rights reserved  
Troubleshooting Tips  
Symptom  
Probable Cause  
Action To Take  
No output  
Low or no remote turn-on Check remote turn-on voltage  
at voltage amplifier and repair  
as needed.  
Fuse blown  
Check power wire's integrity  
and check for speaker shorts. Fix  
as needed and replace fuse.  
Power wires not connected Check power wire and ground  
connections and repair or  
replace as needed.  
Audio input not connected Check RCA connections and  
repair or replace as needed.  
Speaker wires not  
connected  
Check speaker wires and repair  
or replace as needed.  
Speakers are blown  
Check system with known work  
ing speaker and repair or  
replace speakers as needed.  
Audio cycles  
on and off  
Thermal protection engages Make sure there is proper venti  
when amplifier heat sink lation for amplifier and improve  
temperature exceeds 90°C ventilation as needed.  
(190°F)  
Loose or poor audio input Check RCA connections and  
repair or replace as needed.  
Loose power connections  
Check power wire and ground  
connections and repair or  
replace as needed.  
Distorted output  
Amplifier level sensitivity  
set too high exceeding  
maximum capability of  
amplifier  
Readjust gain. Refer to the  
Adjusting the Sound of the  
System section of this manual  
for detailed instructions.  
Impedance load to amplifier Check speaker impedance load,  
too low  
if below 1W, rewire the speakers  
to achieve higher impedance.  
Shorted speaker wires  
Check speaker wire connections  
and fix or replace as needed.  
Speaker not connected  
to amplifier properly  
Check speaker wiring and repair  
or replace as needed. Refer to  
the Speaker Connections section  
of this guide for detailed  
instructions.  
18  
© 2005 Directed Electronics, all rights reserved  
Symptom  
Probable Cause  
Action To Take  
Distorted output  
Internal crossover not set  
properly for speakers  
Readjust crossovers. Refer to the  
Internal Crossover Configuration  
section of this guide for detailed  
instructions.  
Speakers are blown  
Check system with known work  
ing speakers and fix or replace  
as needed.  
Poor bass response  
Speakers wired with wrong Check speaker polarity and fix  
polarity causing cancellation as needed.  
at low frequencies  
Crossover set incorrectly  
Reset crossovers. Refer to the  
Internal Crossover Configuration  
section of this guide for detailed  
instructions.  
Impedance load at amplifier Check speaker impedance load,  
is too low  
if below 1W, rewire speakers to  
achieve higher impedance.  
Battery fuse  
blowing  
Short in power wire or  
incorrect wiring  
Check power and ground con-  
nections and replace or repair as  
needed.  
Fuse used is smaller than  
recommended  
Replace with proper fuse size.  
Actual current exceeds fuse Check speaker impedance load.  
rating  
If below 1W, rewire speakers to  
achieve higher impedance.  
Amplifier fuse  
blowing  
Fuse used is smaller than  
recommended  
Replace with proper fuse size.  
Impedance load at  
amplifier too low  
Check speaker impedance load.  
If below 1W, rewire speakers to  
achieve higher impedance.  
Speaker is blown with  
shorted outputs  
Check system with known work  
ing speakers and fix or replace  
as needed.  
Actual current exceeds  
fuse rating  
Check speaker impedance load.  
If below 1W, rewire speakers to  
achieve higher impedance.  
19  
© 2005 Directed Electronics, all rights reserved  
APPENDIX—PROGRAMMABLE FEATURES  
®
The following listing are ESP -2 features that can be programmed or accessed by your  
installer to customize or troubleshoot your system. Factory default settings are shown in  
bold.  
®
NOTE: The Bitwriter must have software version 2.3 or above to access the amplifier fea-  
tures menu.  
NOTE: A setting marked “Reserved” is for future development.  
Turn On Delay - 0.75, 1.25, 1.75, 2.25, 2.75, 3.25 seconds. Delays the amplifier turn-on when  
the head or source unit is turned on. This eliminates any annoying pops or noise during  
power up from the head or source unit from feeding through to the amplifier.  
Service Code Display - OFF, Flash Code on LED, Reserved, Clear Last Fault.  
When set to “Off” the service code display will not be displayed on top of the  
amplifier (see Top Light Options feature below) and the amplifier operates nor-  
mally.  
When set to “Flash Code on LED”, the LED on top of the amplifier will be enabled  
to flash the diagnostic code (see table below).  
The “Clear Last Fault” setting is used by your installer to clear the last fault event  
detected by the amplifier.  
NOTE: When the Clear Last Fault setting is used, execute a “read” cycle from the  
®
Bitwriter® prior to attempting further writes. This resynchronizes the Bitwriter .  
®
ESP -2 Status Indicator  
Solid Illumination  
Flashing  
Mode  
Normal Operation  
Turn On delay or TX learn  
Thermal shutdown  
Overcurrent  
Flashing Slowly  
Flashing Rapidly  
Slow Flash (50% duty cycle) Overvoltage  
Slow Flash (mostly off)  
Off  
Under-voltage  
Amplifier Off  
Flashing  
Flashing Rapidly  
Flashing  
Arm/Valet received  
Amplifier in Anti-theft/Valet  
Amplifier armed  
Input Gain Range (Volts) - Default, 0.15–0.50 V, 0.50–1.00 V, 1.00–3.00 V, 3.00–5.00 V. This  
feature allows the input gain range to be limited. This feature is useful to prevent the  
amplifier from being overdriven. The “Default” setting turns the Input Gain Range feature  
off, the input gain adjustment is settable over the full range of the control.  
NOTE: If the Input Gain Adjustment is set to Lock (see below), the Input Gain Range  
adjustment will not be altered until the Input Gain Adjustment is set to Unlock.  
Input Gain Adjustment - Unlock, Lock. When set to “Lock”, the input gain adjustment is  
disabled. This can be set to lock after the amplifier has been installed and set up to prevent  
accidental or unwarranted adjustment.  
20  
© 2005 Directed Electronics, all rights reserved  
NOTE: Use caution when adjusting or unlocking gain as restricting the range or unlock-  
ing the range can result in sudden increases in gain.  
The Valet Monitoring and Anti Theft options (below) require the ESP2 alarm to be  
“learned” into the amplifier. Prior to setting the valet or anti theft to Enable or On, execute  
the TXID routine. The ESP2 alarm must be the one installed in the vehicle.  
®
Valet Monitoring - Disable, Enable. Used in conjunction with an ESP -2 security system to  
prevent operation of the amplifier when the security system is in Valet mode. When Valet  
mode is Enabled, and the valet code is received from the alarm system, the amplifier will  
not power up the next time it goes through a remote line On cycle (using the head unit or  
other device that turns the amplifier on).  
®
Anti Theft - Off, Reserved, On. When set to “On”, and when the ESP -2 security system is  
armed, the amplifier will not operate until the security system is disarmed (the remotes used  
by the security system must be learned by the amplifier—see “Learn TX IDs” below). If the  
security system is armed and then the amplifier is disconnected from 12V DC, the amplifier  
will be locked out from operation. You can reset the amplifier by disarming the security sys-  
tem (it must be one of the transmitter learned by the system), then cycling the remote  
power on/off.  
Top Light Options - Light Off W/Service Code, Light On W/Service Code, Light Off W/O  
Service Code, Light On W/O Service Code. This feature allows the toplight to duplicate the  
function of the ESP status indicator. This is set by the W/Service Code. The toplight may also  
be turned off if desired (Light On/Light Off) independent of the Service Code (see table  
below).  
1. Light Off W/Service Code  
2. Light On W/Service Code  
Top light is off, but service codes will be shown.  
Top light is on, and service codes will be shown.  
3. Light Off W/O Service Code Top light is off, but service codes will not be shown.  
4. Light On W/O Service Code Top light is on, but service codes will not be shown.  
Learn TX IDs - Off, On. When On learns the amplifier learns the remotes (press arm and then  
disarm on just one of the remotes) used by a Directed Electronics ESP®-2 security system. If  
any remotes are added or replaced in the system your vehicle must be returned to the deal-  
er to have the amplifier learn the new/replaced remotes. The installer uses the following  
procedure to learn the security system’s remotes:  
®
1. Unplug the amplifier ESP -2 port from the security system.  
®
®
2. Connect the Bitwriter to the amplifier ESP -2 port using the cable that came with  
®
the Bitwriter .  
®
3. Turn on the Bitwriter and read the file from the amplifier.  
4. Scroll down to Learn TX IDs and select the On setting.  
®
®
5. Unplug the Bitwriter and reconnect the ESP -2 cable from the security system.  
®
6. Arm the security system (the amplifier ESP LED will flash), then disarm the secu-  
rity system. The remotes used with the security system are now learned into the  
amplifier. After a short time frame (approximately 20-seconds) the Learn TX IDs  
feature will automatically revert back to the default Off setting.  
NOTE: The next three features are read only. The amplifier will not permit them to be  
changed. If a change is attempted, an “Unable to Verify” error message will appear on the  
®
Bitwriter .  
21  
© 2005 Directed Electronics, all rights reserved  
Event 1 through 7 - Stores up to seven recent events that have occurred to aid in diagnos-  
tic troubleshooting. The events that are retained are: Undervoltage, Overvoltage, Reserved,  
No Fault, Thermal, Overcurrent. These events are read-only, they cannot be written to the  
amplifier by the installer. Event 1 is the most recent event, then Event 2, and so on. If event  
memory is full (Event 7 has a stored diagnostic message), then if another event occurs the  
7th event will be pushed out of memory.  
®
NOTE: That while the Bitwriter can be used to read the amplifier during an event, the  
priority of the amplifier is given to continually checking its health. Attempts to Write to the  
amplifier during and immediately following an event may result in communication errors.  
The Major and Minor Rev levels of the ESP2 software should be referenced should it be nec-  
essary to contact Directed Electronics or Orion.  
Major Rev - Major revision level of the ESP2 software.  
Minor Rev - Minor revision level of the ESP2 software.  
22  
© 2005 Directed Electronics, all rights reserved  
NOTES  
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23  
© 2005 Directed Electronics, all rights reserved  
Warranty  
LIMITED TWO YEAR CONSUMER WARRANTY:  
Directed Electronics 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 is 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. Note: This warranty does not cover labor costs  
for the removal and reinstallation of the unit.  
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.  
© 2005 Directed Electronics, All rights reserved. G47505.10.15 11-05  

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