Orion 425HCCA User's Manual
Contents
1. Not Used The high frequency output of the 200 CRX Active Crossover is applied to two high midrange amplifiers which reproduce the full spectrum of selected high and mid frequencies say 200 to 4200 Hz The high frequency output is also applied to an ORION 30 dBHP High Pass Filter that selects a cutoff frequency that will emphasize only the highest frequencies say 4000 Hz and above An ORION 600 EOM Equalizer or 500 PMO Parametric Equalizer is used to balance the overall system SUBWOOFERS TWEETER AMPLIFIER Black Yellow au ORION Sp CRON mm TWEETERS Orange Black Orange RCA DIN Cable ORION 600 EQM TWEETER AMPLIFIER TWEETERS EQUALIZER lt or Yellow ORION 500 PMQ PARAMETRIC Black Yellow EQUALIZER 0 TONE LO BO Watts RMS ORION 300 CRX Orange CROSSOVER 2 8 MODULE 8 Black Orange z T a HT MIDRANGE AMPLIFIER HI Yellow HL Black Yellow DIN Cable ORION E ooa MIDRANGE DIN Cable 100 Watts RMS SPEAKERS Orange DIN Cable Black Orange o 9 MIDRANGE AMPLIFIER ORION 400 BDG Yiia ORION BRIDGING z 400 BDG MODULE a Black Yellow 3 c ORION _ 2oneca MIDRANGE Noo Wea RAs SPEAKERS Orange Black Orange DIN Cable Figure 15 Killer System Utilizing a 300 CRX 3 Way Active Crossover and Individual Amplifiers for Each Speaker Type U2. The left mid high speaker is connected normally but the connections to the right mid high speaker must be turned over to retain the stereo effect This means that the yellow lead now becomes the negative lead and the black yellow lead becomes the positive lead RIGHT MID HIGH SPEAKER Black Yellow Yellow AMPLIFIER SUBWOOFER Yellow ORION _ 2eucca 100 Watts RMS Orange MID HIGH SPEAKER Orange Black Orange A REMINDER The speakers must never be grounded to the car chassis or body To do so will cause severe noise problems and in the case of bridging cancel out the two phase operation fey e 5V DIN CONNECTOR All ORION Accessories and Lert WO a 8 RIGHT Amplifiers have this DIN NS configuration AUDIO GROUND Phantom Power 15V amp 15V is supplied to all ORION accessory modules by the amplifier through the DIN cable When ORION amplifiers are not used the ORION PPS 100 Phantom Power Supply is required Figure 10 Mixed Mono Connections in a Single Stereo Amplifier System Using a 400 BDG Bridging Module RIGHT FRONT AMPLIFIER RIGHT LEFT FRONT AMPLIFIER LEFT FRONT FRONT SPEAKER SPEAKER Orange Orange ORION zas nuca DA ORION P 50 Watts RMS Yellow A Yellow 50 Watts RMS Not Black Orange Not Black Orange Used Black Yellow Used _ Black Yellow ORION 600 EMO EQUALIZER or ORION 500 PMQ PARAMETRIC RIGHT REAR A
3. SUBWOOFERS Yellow Black Yellow Black Orange ORION 500 PMQ PARAMETRIC EQUALIZER ORION 200 CRX tka CROSSOVER O fre ORION 200 CRX Nr Low Freq High i Output Freq Output This is a simple two amplifier system using a 200 CRX Active Crossover for better control of the frequencies applied to the speakers The LOW FREQ output is con nected to the lows amplifier to drive the subwoofers and the HIGH FREQ output is connected to the highs amplifier for driving the midrange and highs speakers This allows you to carefully balance the higher and midrange frequencies with the lows In practice over lapping the crossover point slightly results in smooth transitions of sounds delivered to the speakers For example the cutoff frequency for lows could be ad justed to 400 Hz This would mean that all frequencies HIGHS AMPLIFIER ORION _zoncca 100 Watts RMS 250 HCCA MID HIGH FREQUENCY SPEAKERS Yellow Black Yellow Orange Black Orange DIN Cable below 400 Hz would be passed to the lows amplifier at 100 power The attenuation reduction in power is 12 dB which is a reduction in power of about 90 An octave is a doubling of frequency so that at 800 Hz only about 10 of the power would go to the sub woofers In this example the high output would be ad justed to pass only frequencies above 300 Hz This would give you about 100 Hz overlap Then you could
4. a OBLIGATION OF THE ORIGINAL 1 The dealer s Original Dated Bill of Sale must be retained as Proof of Purchase and must be presented with the defective product KER S ba f Wy s E Warranty shipments to ORION are the responsi bility of the consumer NS N esp es Q A j Orion Industries 9235 S McKemy Tempe AZ 85284 602 705 5600 Manual No 0289 EXCLUSIONS This warranty does not cover products that have been subjected to misuse modification improper installation incorrect voltage marred or damaged housings or improper or unauthorized repair This is in lieu of all other warranties expressed or im plied In no event will ORION be liable for any damages resulting from equipment or any defect This warranty gives you specific legal rights and you may have other rights which vary from state to state AASR 55 RASES Rar pa Bar Map D A pert Fe oes oy uy CK HONORS A Le n
5. ply is required DIN CONNECTOR All ORION Accessories and Amplifiers have this DIN configuration Figure 13 Typical Use of an ORION 30 dBHP High Pass Filter to Set Lower Limits of High Frequencies 19 MID HIGH HIGH MID AMPLIFIER SPEAKERS es HEN X Yellow 4 LE o2 Black Yellow Z 2 eA ORION _ 2s0ncca 100 Watts RMS Orange RCA Cables Black Orange E ORION 600 EOM i 9 8 EQUALIZER 5 3 8 or o d ORION 500 PMQ z PARAMETRIC a EQUALIZER Pi 2 o 5 tI MID HIGH 8 SPEAKERS HIGH MID AMPLIFIER a Yellow o gt Black Yellow gt 9 2 6 oOo uv MAE ORION 200 CRX p Ont CROSSOVER Sx ORION sew MODULE 100 Watts RMS T Orange 4 Low E Black Orange S High Freq z 2 3 Freq Output DIN Cable a Output b ao TWEETER T AMPLIFIER ORION 30 DBHP HIGH PASS FILTER P O A S m indui mi a Yellow ORION 400 BDG d18 Black Yellow ORION e 400 BDG BRIDGING i DIN MODULE Cable J N ape ORION 20 08H Seid ORION 2zsneca TWEETERS fj BO Watts RMB Ie Orange 4 Summed 9 Mono Black Orange Output M Rm DIN Cable Phantom Power 15V amp 15V is supplied to all ORION accessory modules by the amplifier through the DIN cable When ORION amplifiers are not used the ORION PPS 100 Phantom Power Supply is require
6. The metallic red color of the amplifiers would provide visual impact and the audio performance and sonic quality would be very impressive Yellow Black Yellow FRONT NGF SPEAKERS Left Orange Black Orange DIN Cable DIN Cable lt OR ION 425 HCCA 100 WATTS RMS 4X25 wee Hand Crafted in USA Rig Green Black Green ORION 200 DAB DUAL AMP BALANCER ORION 200 DAB OO w Front Control Rear Control REAR SPEAKER i White Left Black White Figure 16 Typical Use of a 425 HCCA 4 Channel Amplifier in a System Using Existing Front and Rear Speakers 24 Yellow Black Yellow 425 HCCA 4 CHANNEL AMPLIFIER Orange to RCA Cables DIN Cable z z ORION 425 HCCA 100 WATTS RMS 4X25 Hand Crafted in USA DIN Cable Green ORION 600 EQM EQUALIZER Black Green or ORION 500 PMQ White 4 PARAMETRIC EQUALIZER Black White I H 3 H 1 High Freq ORION 400 BDG BRIDGING MODULE Black Yellow Black Orange ORION 300 CRX CROSSOVER Not 425 HCCA 4 CHANNEL AMPLIFIER Used M81 ouow pariy ouow peuung iybiy DIN Cable Hand Cra ted in USA Green Summed DIN Cable Mono Lo R Le a ee E P re ee L0 O ORION Not Black White 200 DAB Used Black Green DUAL AMP BALANCER Figure 17 Typical Use
7. see figure 16 ORION 300 PRQ PRE AMP EQUALIZER Yellow Black Yellow FRONT SPEAKERS Left Orange Black Orange AMPLIFIER RCA DIN Cable _ OR ION 225 HCCA 50 Watts RMS Figure 3 Basic Two Amplifier System Using Equalizer and Existing Front and Rear Speakers 3 Adding Subwoofers For added punch you could add a couple of subwoofers to the system as shown in figure 4 This will give you the most coherent and natural sound In this system a pair of mid range tweeter speakers are located in the front usually in the top of the dash and a midrange tweeter speaker is located in each rear door or side panel The subwoofers are installed in the rear This does not mean that the passengers seated in the rear will be overcome by the bass Low fre quency sound waves tend to wrap around the in terior such that they are perceived as coming from all directions MID HIGHS AMPLIFIER E aa Yellow 4 Black Yellow FRONT OJA OINEI 50 Watts RMS Orange Black Orange ORION 600 EQM EQUALIZER or 500 PMQ PARAMETRIC IMPORTANT NOTE At this point you must deter MID HIGHS mine if your car has enough power to supply the needs of the engine lighting system and air conditioning system as well as the audio system An existing car electrical system can generally handle up to four 225 HCCA or up to three 250 HCCA amplifiers If you plan to u
8. the DIN cable When ORION amplifiers are not The ORANGE lead from each amplifier is used as the positive lead and the used the ORION PPS 100 Phantom Power Sup YELLOW lead is used as the negative lead The BLACK YELLOW and is BLACK ORANGE leads are not used Figure 11 Method of Doubling Output of Amplifiers Using Bridged Stereo Right and Left 17 15V OON cas NE RIGHT AUDIO LEFT used the ORION PPS 1 GROUND ply is required ORION 30DBLP Phantom Power 15V amp 15V is supplied to all ORION accessory modules by the amplifier through the DIN cable When ORION amplifiers are not 00 Phantom Power Sup FILTERED SUBWOOFERS LOWS AMPLIFIER LOW PASS FILTER o 5 E t ORION 600 EOM EQUALIZER or ORION 500 PMQ PARAMETRIC EQUALIZER RCA Cables RCA DIN Cable 1408 ORION 200 CRX dio Mild CROSSOVER MODULE Low Freq Output DIN Cable DIN Cable Output This diagram shows a typical application for an ORION 30 dBLP Low Pass Filter used to control the low frequencies applied to a pair of subwoofers A 200 CRX Active Crossover is used to select the full range of the mid and high range fre quencies and to select the full range of lows applied to the unfiltered lows ampli fier Overall frequency control is provided by an ORION 600 EOM Equalizer or a 500 PMO Parametric Equalizer The RCA and DIN connectors at the INPUT to the 200 CRX Active Crossover are connected in paralle
9. 150 Hz and below The HIGH OUT should be adjusted to permit the tweeters to reproduce only frequencies of about 4 kHz and above The MID OUT should be adjusted to pass a band of frequencies of about 100 Hz to 4500 Hz The response of the various speakers greatly affects these adjustments however so it is generally al ways better to trust your ears and simply adjust the various frequency outputs to where they sound best to you a Unplug the cables from the MID OUT and HIGH OUT connectors and adjust the LOW PASS control until the lows from the sub woofers sound good to you Unplug the cable from the LOW OUT con nector and plug in the HIGH OUT cable Ad just the HIGH PASS control to where the highs from the tweeters sound best Unplug the cable from the HIGH OUT con nector and plug in the MID OUT cable Adjust MID PASS controls until the instruments and voice sounds delivered by the mid range speakers sound the fullest Use the left hand MID PASS control to adjust the low end and the right hand MID PASS control to adjust the high end Now plug in the HIGH OUT and LOW OUT cables and make minor adjustments to suit your taste l RM NU A EO WARRANTY ERNES ORION products are guaranteed against defects in workmanship and materials for a period of 2 years from date of purchase All warranty repairs are performed by ORION This warranty period begins on the date of purchase by the original consumer HEIMEN LR
10. An ORION 200 CRX Active Crossover is used to select the full range of mid and high frequencies and to select the lows applied to the subwoofers An ORION 600 EOM Equalizer or 500 PMQ Parametric Equalizer is used to pro vide overall frequency control The RCA and DIN connectors at the INPUT to the 200 CRX Active Cross over are connected in parallel so that the RCA connectors can be used to connect the input stereo signals to the 30 dBHP High Pass Filter Since the high pass filter input is received directly from the equalizer the crossover module has not affect on the high pass filter Low Freq 7 Output DIN Cable DIN Cable TWEETER AMPLIFIER TWEETERS ORION 30 DBHP Front HIGH PASS FILTER o Yellow Black Yellow t 5 ORION 30 DBHP DIN Cable l i 30 d8 Per Octave High Pass Crossover i j E ORION gns Orange Black Orange MIDRANGE SPEAKERS MIDRANGE AMPLIFIER Front Yellow Black Yellow ORION zsoncca 100 Watts RMS Orange Black Orange SUBWOOFERS ORION zoncca 100 Watts RMS A REMINDER The speakers must never be connected to the car chassis or body To do so will cause severe noise problems 15V 15V Nu gt veer Ng SL RIGHT AUDIO GROUND Phantom Power 15V amp 15V is supplied to all ORION accessory modules by the amplifier through the DIN cable When ORION amplifiers are not used the ORION PPS 100 Phantom Power Sup
11. ESCRIPTION The ORION 225 HCCA is a stereo power amplifier that includes all the features of the larger ORION amplifiers and provides 25 watts RMS output per channel or 100 watts at 4 ohms or 200 watts at 2 ohms when bridged using ORION Bridging Module 400 BDG refer to page 6 The 225 HCCA can be used to greatly improve existing factory sound systems utilizing 6 x 9 speak ers In customized systems the 225 HCCA can be used to drive twecters and mid range speakers in multiple amplifier applications TURN ON CONNECTION WIRE BLUE Output Power Per Channel with both channels driven into 4 ohms 12 Vdc Distortion Typical Maximum Frequency Response Signal to Noise Ratio Input Sensitivity Output Impedance EQUIPMENT SUPPLIED CHASSIS GROUND TERMINAL MOUNTING LUG HARDWARE TWO 30 AMP FUSES FUSEHOLDER BATTERY POWER LEAD CONNECTION LUG SPEAKER CONNECTIONS POWER CABLE ASSY CABLE ASSY FUSEHOLDER SPECIFICATIONS Input Impedance 25 WRMS Remote Turn on Current Current Consumption No Signal Maximum Output 0 00596 Voltage Requirements Damping Factor Output Section Slew Rate 30V per microsecond Stereo Separation Overall Dimensions ORION 250HCCA rm High Current Stereo Power Amplifier 100 Watts RMS _ MEC AMPLIFIER POWER ON LED CHASSIS MOUNTING b GROUND HARDWARE TERMINAL 40 AMP FUSE BUTT SPLICE LEFT INPUT RCA CONNECTOR FUSEHOLDER DI
12. SUBWOOFER AMPLIFIER ORION 200 DAB DUAL AMP Yellow BALANCER Black Yell ow DIN Cable ORION zoncca This is a 3 amplifier system using a 200 CRX Active Crossover The LOW J 100 Watts RMS FREQ output is connected to the lows amplifier to drive the subwoofers The HIGH FREO output is connected through a 200 DAB Dual Amp Balancer Black Orange that provides individual level adjust for the front and rear high mid speakers You would balance the higher and midrange frequencies and the lows similar to that described in figure 5 on page 13 For this system you would probably want to use three 250 HCCA 2 2 channel amplifiers BO watts per channel You could also build a satis For installation connections and adjustments refer to pages 26 through 35 factory system using two 225 HCCA 2 channel amplifiers to drive the mid range speakers and tweeters and a 250 HCCA to drive the subwoofers You Figure 6 Three Amplifier System Using 200 CRX Active might also use a 425 HCCA 4 channel amplifiers to drive the midrange and Crossover and 200 DAB Dual Amp Balancer tweeters and a 250 HCCA to drive the subwoofers Orange Phantom Power 15V amp 15V is supplied to all ORION accessory modules by the amplifier through the DIN cable When ORION amplifiers are not used the ORION PPS 100 Phantom Power Sup ply is required TWEETERS TWEETER AMPLIFIER Yellow Black Yellow DIN Cable OINONEN This is a 3 a
13. adding accessories and additional amplifiers A USING EXISTING SPEAKERS If you want a good performance system without having to install special speakers a single 225 HCCA amplifier will do an excellent job for you A basic single ampli fier system is shown in figure 1 Speakers Right Yellow J Yellow ORION ET TA 50 Watts RMS Orange 4 Black Orange RCA Cables Figure 1 Basic Single Amplifier System Using Existing Speakers 1 Adding Equalization To improve the system even more you could add an equalizer such as an ORION 300 PRQ Pre Amp Equalizer 600 EQM Equalizer or 500 PMQ Parametric Equalizer see page 6 The equalizer would be inserted in the system between the deck and the amplifier as shown in figure 2 ORION 300 PRQ PRE AMP EQUALIZER Speakers Right Yellow Black Yellow ORION E17 50 Watts RMS Orange Black Orange Phantom Power 15V amp 15V is supplied to all ORION accessory modules by the amplifier through the DIN cable OwW 15V 15V yy Leer o So RIGHT AUDIO DIN CONNECTOR GROUND Figure 2 Basic Single Amplifier System Using an Equalizer and Existing Speakers 8 2 Front and Rear Speakers If your car is equipped with front and rear speakers you will want to use a separate amplifier for each pair of speakers as shown in figure 3 A single 4 channel 425 HCCA could also be used for this system
14. of 425 HCCA 4 Channel Amplifiers in a Multi Amplifier System 25 MOUNTING THE AMPLIFIER When planning where to install your amplifier you must first think in terms of keeping the amplifier cool enough to function properly Amplifiers are heat sensitive This means that the operating parameters may change with fluctuations in temperature and an amplifier can literally be destroyed by excessive heat during operation The finned outer surface of the amplifier is a heat sink which helps to carry heat away by means of thermal conduction Therefore you must allow the amplifier to breathe so that the heat sink can best do its job It is always best to mount the amplifier flat on the floor under the front seat on in the front of the car trunk Remember heat travels up Avoid heat traps Don t put a glass or metal cover over the top of the amplifier unless you have a cooling fan at one end Keep in mind that any moving air dissipates heat If possible duct the car air conditioning system so that cooling air is directed along the fins of the amplifier heat sink Cooling air should be directed along the fins rather than across them for the most efficient cooling Don t mount the amplifier on plastic or use a plastic cover The plastic will melt Once you have selected the mounting location mount the amplifier using the four self tapping screws provided Tighten the screws securely CAUTION Be very ca
15. or body To do so will cause severe noise problems and in the case of bridging cancel out the two phase operation 3 Bridged Stereo Right and Left This application is used when you want to maintain the stereo effect while increasing the output power of vour amp by 4 times A typical system is shown figure 1 D USE OF 30 DBLP LOW PASS FILTER NOTE Low pass and high pass filters can only be used effectively in multi amp systems such as shown in fig ures 12 13 and 14 If you are using mismatched subwoofers or having speaker box resonance problems or experiencing bass distortion consider using a 30 DBLP Low Pass Filter as 10 shown in figure 12 This filter will keep the midrange and high frequencies out of your subwoofers The cut off frequency is selected by plugging in two resistive chips This means that if you install 80 Hz chips in the filter only frequencies of 80 Hz and below will pass through to your subwoofers and frequencies above 80 Hz will be blocked E USE OF 30 DBHP HIGH PASS FILTER The 30 DBHP High Pass Filter is used primarily to make your tweeters sound more lively Keep in mind that it is the low frequencies that hurt the tweeter per formance A typical application of a high pass filter is shown fire 1 Jn high pass filter produces large amounts of attenuation reduction in power to fre quencies be ow the cutoff frequency and no attenua tion to frequencies above the cutoff frequency This mean
16. used in the summed mono mode ed mono mode or bridged stereo right and left see figure 8 1 Summed Mono Mode In the summed mono mode true mono the bridging module is generally used to drive the subwoofers in mono bridged power This application is very practical since in stereo recordings the kick drums and bass are centered between stereo right and stereo left along with the other rhythm instruments Always keep in mind that it takes much more power to drive low fre quencies than high frequencies A typical 3 amplifier system using a bridging module is shown inffigure 9 Mixed Mono Mode If you are installing a single amplifier system the mixed mono mode can be used as shown in ORE mode is used to provide more power to the subwoofers while maintaining stereo left and right In this system the 400 BDG Bridging Module accepts the stereo inputs and turns one channel over 180 inverts the channel Both channel outputs of the ampli fier are now connected to the subwoofer with the inverted channel being used as the negative input This works because the two channels are 1809 out of phase The left mid high speaker is connected norm ally but the connections to the right mid high speaker must be turned over to retain the stereo effect This means that the yellow lead now be comes the negative lead and the black yellow lead becomes the positive lead CAUTION The speakers must never be grounded to the car chassis
17. 00 Hz but the settings are dependent on the settings of the high and low frequency outputs There should be a certain amount of overlapping The low frequency output is an adjustable low pass filter A common adjustment would be to pass all frequencies below 180 Hz The actual settings of the frequencies depend on what sounds best in your system If you intend to use this system we highly recommend that you 4 times the output of your subwoofer amplifier by adding a 400 BDG Bridging Module as shown in figure 9 Figure 7 Three Amplifier System Using a 300 CRX 3 Way Active Crossover 13 DIN Cable ORION zsoncca 100 Watts RMS Orange Black Orange For installation connections and adjustments refer to pages 26 through 35 15V 15V NL Phantom Power 15V amp 15V is supplied to all Y ORION accessory modules by the amplifier through the Leer SH RIGHT AUDIO DIN CONNECTOR GROUND ORION 300 PRO PRE AMP EQUALIZER or ORION 600 EQM EQUALIZER or ORION 500 PMQ PARAMETRIC EQUALIZER RCA Cables ORION 200 CRX CROSSOVER DIN Cable bors ybi LINT ORION 400 BDG BRIDGING MODULE abr 105 THA um 18080 wy ORION 200 CRX mw Low DIN Cable Freq Output High Freq Output Ne Summed Mono Output This diagram shows a method for summing only the lows and permitting the midrange and highs to remain in stereo In this system an ORION 200 CRX Active Crossover is used to
18. 5V __ 40 Qo D PHANTOM PHANTOM POWER POWER INPUT DIN CONNECTOR 28 Phantom Power Phantom Power 15V and 15V is present at all DIN connectors at the INPUT to all ORION amplifiers This voltage is for use in providing operating power to any ORION accessory that contains active electronic circuits This includes all crossover modules bridging modules equalizers and low pass and high pass filters NOTE Active electronic circuits require a source of dc power for operation offer no resistance to the sig nals and often add gain Passive electronic circuits such as used for speaker crossovers do not require dc power and add resistance to signals The ORION accessories use insignificant amounts of power and need not be figured into the overall power requirements for you audio system RCA INPUT CONNECTORS CONNECTED IN PARALLEL WITH DIN CONNECTOR SIGNAL CONNECTIONS gt Q gt Power Connections for 225 HCCA BATTERY CONNECTIONS Always connect the power cable assembly directly to the positive terminal on the battery Do NOT connect to the car fuse panel The 225 HCCA is provided with two fuses The fuse at the battery is designed to prevent fire or damage to your car should there be a ground short The second fuse protects the amplifier itself Do NOT substitute fuses Always replace with fuses of the same fast blow current rating as those supplied with your amplifier AMPLIFIER REMOTE CONTROL LEAD Connect the rem
19. D GROUND CONNECTIONS A Low Power Systems Before installing your audio system you must make sure that your car has enough 12 volt power to service all of the car electrical components engine headlights windshield wipers air conditioning etc and still handle the power required to supply your audio system at full power Use a little common sense If you are installing a sys tem containing two or three 225 HCCA or a single 250 HCCA amplifier your existing factory electrical system will probably handle your power requirements An existing system will handle a 250 HCCA or 425 HCCA amplifier just fine but if you install two of these amplifiers you probably won t be able to run the system at full power at night with the headlights on If you want to install two of these amplifiers and run at full power at night you will probably have to install a heavy duty alternator and a premium or even a second battery as described in B below If you attempt to overload your existing system you will burn out the brushes or field diodes in your alter nator and greatly reduce the life of your battery B Multiple Amplifier Systems Multiple amplifier systems except as described in A above require additional battery and or charging power Competition systems such as those shown in figures 14 15 and 17 should contain multiple batteries or be powered by an external battery charger or dc power supply with a current rating in excess of
20. E ORION zoncca 100 Watts RMS SUBWOOFERS Orange Black Orange Figure 4 Typical Way of Adding Subwoofers to a System 9 woofers a bandpass filter section for the midranges and a high pass filter section for the tweeters 1 Use of 200 CRX Active Crossover This crossover module can be used in a variety of ways It could be added to the simple two amplifier system as shown in figure 5 ould also be used in a 3 amp system as shown i ote in figure 6 that an ORION 200 DAB Dual Amp Balancer has been added to control the level of sound that comes from each section of the car audio system 2 Use of 300 CRX 3 Way Active Crossover For even better control use the 300 CRX as shown in fig ure 7 Jrhis will give you separate control of the low eguena midrange frequencies and high frequencies C USE OF A BRIDGING MODULE The ORION 400 BDG Bridging Module can turn your amplifiers into real power houses Bridging an ampli fier converts a two channel amplifier into a single channe amplifier mono output Each internal chan nel sees half of the total impedance of the load For example when using 4 ohm speakers each chan nel in the amplifier sees half of this 4 ohms or 2 ohms If you were using a 225 HCCA amplifier which de livers 25 watts per channel the output delivered to each speaker will be 100 watts when bridged thus a 4 times increase in output The 400 BDG ation Module can be
21. Installation Manual ORION car Audio Power Amplifiers High Current Output Models 225 HCCA 250 HCCA and 425 HCCA Built in the U S A from the ground up specifically for high performance car stereo systems S2 ORION When Only The Best Will Do INTRODUCTION You have purchased the finest car audio power Optically isolated remote turn on circuit isolates Table of Contents amplifier available on the market ORION amplifiers the radio or deck from the amplifier really do set new standards for performance and re 225 HCCA Description and Equipment Supplied liability They are superbly crafted and precision itche udi enua reduces m calibrated If you install each amplifier properly T M RUD VERE t 250 HCCA Description and Equipment Supplied with careful attention to all the details covered in this manual you will be astonished with the quality Parallel RCA and DIN inputs provide considerable of sound and you will have an audio system that versatility for interconnections you can be proud of and enjoy for many years 425 HCCA Description and Equipment Supplied Orion Accessories Description 6 Hz high pass filter eliminates dc offset Orion Cable Assemblies The HCCA series amplifiers incorporate high out A wide variety of accessories are available for flex Using Existing 6x9 Speakers ibility in designing overall audio systems refer to put current enhancing audio performance and pag
22. MPLIFIER RIGHT LEFT REAR AMPLIFIER LEFT REAR EQUALIZER REAR SPEAKER SPEAKER RCA DIN Cable RCA DIN Cable DIN Cable Orange Orange ORION 225 HCCA ORION 225 HCCA i i PS TRAIN zacna Yellow 50 Watts RMS Yellow ORION g 400 BDG OR ee BRIDGING MODULE on Black Orange Not N ot Right Black Yellow Used Black Yellow Output DIN Cable Loft DIN Cable Output This application is used when you want to maintain the stereo effect A REMINDER The speakers must never be grounded to the car chassis while doubling the output power of your amplifiers The right amplifiers or body To do so will cause severe noise problems and in the case of bridging are connected to the RIGHT output of the 400 BDG Bridging Module and cancel out the two phase operation the left amplifiers are connected to the LEFT output DIN CONNECTOR In this system the 400 BDG Bridging Module accepts the stereo inputs and des yey TM All ORION Accessories and turns one channel over 180 degrees inverts the channel Both channel CERT 0 MS nicur Amplifiers have this DIN outputs of each amplifier are now connected to the speaker with the inverted AUDIO configuration channel being used as the negative input This works because the two chan GROUND nels are 180 degrees out of phase Phantom Power 15V amp 15V is supplied to all ORION accessory modules by the amplifier through
23. N wn CONNECTOR i 3 j BATTERY In parallel with a CONNECTION RCA connections LUG includes Phantom Power output RIGHT INPUT UT P RCA oP 1 SPEAKER CONNECTOR fm CONNECTIONS GAIN CONTROL TURN ON C NNECTION CABLE ASSY DESCRIPTION ucc SPECIFICATIONS The ORION 250 HCCA is an excellent choice for Output Power Per Channel Input Impedance easy listening systems where you want full range with both channels driven with smooth highs and rich tight bass The amplifier into 4 ohms 12 Vdc 50WRMs Remote Turn on Current is also ideal for handling tweeters and mid range Current Consumption speakers in competition systems Because of the high No Signal current output and low impedance characteristics it Distortion is the answer to adding additional speakers in parallel Typical 0 005 The 250 HCCA provides 50 watts RMS of distor Maximum Voltage Requirements tion free power per channel or 400 watts at 2 ohms when bridged using the ORION Bridging Module Frequency Response Damping Factor 400 BDG see page 6 Maximum Output Signal to Noise Ratio Output Section Slew Rate 30V per microsecond Input Sensitivity Stereo Separation Output Impedance Overall Dimensions ORION 425 HCCA Four Channel High Current Power Amplifier 100 Watts RMS 4 CHANNEL AMPLIFIER POWER ON LEDS A SIDE GAIN CONTROL A SIDE DIN CONNECTOR B SIDE DIN CONNECTOR B SIDE GAIN CONTROL DESC
24. PHANTOM POWER SUPPLY ORION CABLE ASSEMBLIES A large variety of top quality ORION cable assem blies are available through your dealer as follows 5 PIN DIN TO DIN Lengths 6 inches 1 2 3 4 5 6 10 and 20 feet 5 PIN DIN TO RCA Lengths 1 2 4 10 and 20 feet Order by description Prices are reasonable and cable assemblies are shipped the same day the order is received Speaker connections cable assemblies and power wire are also available Provides 15 and 15V dc phantom power for use with all ORION acces sories DIN and RCA output connec tors Remote turn on wire Pulls mini mal current so is not a factor in overall power usage for audio system 100 LED DISPLAY Ideal for input monitoring to avoid overdriving 12V dual 10 segment display Continuously adjustable for fine tuning Does not add audio distortion in the sig nal path Can be mounted under the dash or in the dash 7 PLANNING YOUR CAR AUDIO SYSTEM It is important that you decide what you are trying to achieve Car audio systems can vary from merely upgrading your existing factory installation to multi amplifier systems that include equalizers bridging modules crossover modules low pass filters high pass filters and a variety of speakers This section contains the simple approaches to audio system design to the very complex By studying the diagrams you will see that you can start with a relatively simple system that can gradually grow by
25. RIPTION The 425 HCCA contains two pairs of stereo ampli fiers with a separate power supply for each pair of amplifiers It has been designed for installations where space limitations preclude the use of separate stereo amplifiers Each of the four channels supplies 25 watts RMS or 400 watts at 1 ohm when bridged using ORION Bridging Module 400 BDG refer to page 6 As shown above two power cable assemblies and two power leads are provided one for each of the internal power supplies Each pair of amplifiers must be grounded separately as shown on pages 30 and 31 A single blue turn on wire is used to turn on all four channels TURN ON CONNECTION EQUIPMENT SUPPLIED FUSEHOLDER FUSEHOLDER POWER CABLE ASSEMBLIES SPEAKER CONNECTIONS CABLE ASSY MOUNTING HARDWARE WIRE BLUE TWO 30 AMP SPECIFICATIONS FUSES Output Power Per Channel Input Impedance 10K ohms with all channels driven into4ohms 12Vdc 25 WRMS Remote Turn on Current 50 mA Distortion Current Consumption Typical 0 essen 0 005 No Signal 500 mA Maximum 0 0000 ce eee 0 03 9 Maximum Output 70 Amps Frequency Response 6 Hz to 50 KHz 0 5 dB Voltage Requirements 10V to 16V Signal to Noise Ratio 112 dB Damping Factor Greater than 500 Input Sensitivity 150 mV to 2 Vrms Ou
26. S Orange Black Orange raont A ORION _ 2soncca 100 Watts RMS Orange Black Orange SUBWOFFER AMPLIFIER Orange 4 ORION 100 Watts RMS y EEE ar Black Yellow Not Used Black Orange 250 HCCA Yellow A single amplifier is used to drive all tweeters another amplifier is used to drive all mid range speakers in addition to the amplifier that drives the subwoofers This makes for a very clean and efficient system since each speaker only has to handle those frequencies for which it was specifically designed Figure 9 Three Amplifier System Using a 300 CRX 3 Way Active Crossover to Select High Mid and Low Frequencies and a 400 BDG Bridging Module 15 ORION 300 PRO PRE AMP EQUALIZER or ORION 600 EQM EQUALIZER ORION 400 BDG ORION BRIDGING 100 BOG MODULE Mixed DIN Cable Mono Output Mixed mono operation using a 400 BDG Bridging Module is the approach to use when you want to add a subwoofer to the a single amplifier system This mode can be used to provide more power to the subwoofer while maintaining stereo left and right In this system the 400 BDG Bridging Module accepts the stereo inputs and turns one channel over 180 degrees inverts the channel Both channel outputs of the amplifier are now connected to the subwoofer with the inverted channel being used as the negative input This works be cause the two channels are 180 degrees out of phase
27. as shown and described in the connection diagrams in figures 1 through 15 the yellow wire is positive and the black yellow wire is negative Also the orange wire is positive and the black orange wire is negative SPEAKER WIRE Use substantial wire for speaker connections We rec ommend that speaker wires be at least 16 AWG Some installers prefer the use of specially made heavy duty speaker wiring SYSTEM ADJUSTMENTS IMPORTANT You will get less system noise if you keep the amplifier gain as low as possible If you are adjusting a system containing ORION acces sories refer to the adjustment procedures contained in each applicable ORION accessory manual In general make adjustments as follows 1 2 Turn all power off Set the gain controls on all amplifiers to their mini mum positions If an ORION 200 DAB Dual Amp Balancer is in stalled in the system set both fader controls to maximum fully clockwise Set all frequency controls on the 300 PRQ or 600 EQM Equalizers to flat response dots in top center position If a 500 PMQ Parametric Equalizer is being used set the frequency controls to the center position and set the boost cut controls to the center position If a 600 EQM is being used set the input gain con trol to minimum fully counterclockwise If a 300 PRQ or 500 PMQ is being used set both input controls to minimum fully counterclockwise and the VOLUME control for maximu
28. d DIN CONNECTOR Alt ORION Accessories and Amplifiers have this DIN configuration Figure 14 Killer System Using ORION Low Pass and High Pass Filters to Fine Tune the System 20 UNFILTERED LOWS AMPLIFIER A ORION zsoncca 100 Watts RMS e Black Yellow ot Black Orange RCA DIN Cable ORION 30 DBLP LOW PASS FILTER EE Per Octave Low Pass Crossover ORION soose ij This diagram shows a full competition Killer System that has been fine tuned using ORION Low Pass and High Pass Filters An ORION 200 CRX Active Crossover is used to separate the high mids from the lows The lows are then applied to a 400 BDG Bridging Module The SUMMED MONO output is supplied to two lows amplifiers that amplify the full spec trum of lows selected at the 200 CRX say 260 Hz and below Each low amplifier then drives two subwoofers Up to 20 amplifiers could be connected in parallel as shown here The lows output of the 200 CRX Active Crossover is also applied to an ORION 30 dBLP Low Pass Filter that selects a cutoff frequency that will emphasize only the lower range say 72 Hz and below 21 SUBWOOFERS RCA DIN Cable DIN Cable UNFILTERED LOWS AMPLIFIER Orange Yellow E ORION zoncca 100 Watts RMS Black Yellow Not Black Orange Used FILTERED LOWS AMPLIFIER Orange Yellow E ORION zsoncca 100 Watts RMS Black Yellow Black Orange
29. designed for operation with 1 to 16 ohm speakers For best operation we recommend high quality 8 ohm speakers The efficiency of 8 ohm speakers tends to be a little better than 4 ohm speakers You only get 3 dB gain from the increase in power by going from 8 ohms to 4 ohms Many high quality 8 ohm subwoofers are actually 5 to6 dB more efficient than 4 ohm subwoofers Also if you use 8 ohm speakers your amplifier will run half as hot and your battery will last longer NOTE OR ON amplifiers have an excellent damping factor Damping factor is the reflected output imped ance in the amplifier The higher the damping factor in the amplifier the less tendency for the speaker to move on its own say when it is bumped The ampli fier controls the damping in the speaker CONNECTIONS NEVER connect any speaker to chassis ground This will introduce ground loops that cause noise in the system and in the case of bridging cancels out the two phase effect NEVER use twisted wire connections Always make connections using spade connectors insulated butt connectors quick disconnect connectors or solder connections If quick disconnects or solder connec tions are used insulate the connections using shrink tubing Do not use electrician s tape since the ad hesive on such tapes tends to deteriorate with time and cause short circuits Do NOT route the speaker wires next to any power wires Be sure to observe speaker wire polarity Except
30. e 6 Use of a Crossover Module improving sonic quality Use of a Bridging Module All ORION amplifiers are built in the U S A from This manual covers the following ORION HCCA the ground up specifically for high performance amplifiers car stereo systems Car stereo systems are our only business 225 HCCA refer to page 3 Use of a 30 dBLP Low Pass Filter Use of a 30 dBHP High Pass Filter Killer Systems All ORION amplifiers and accessories are manu 250 HCCA refer to page 4 factured to exacting military standards Extensive Use of a 4 Channel Power Amplifier 425 HCCA 10 testing and burn in makes for super reliability in 425 HCCA refer to page 5 even the toughest situations Mounting the Amplifier Each amplifier contains a 15 volt power supply Power and Ground Connections which also services ORION accessories phantom power This ensures maximum dynamic per Speaker Connections formance from all accessories while maintaining optimum ground isolation to minimize potential engine noise A POWER ON indicator light is included System Adjustments Variable input sensitivity gain adjust allows use with most radios and decks ORION 225HCCA High Current Stereo Power Amplifier 50 Watts RMS POWER ON LED LEFT GAIN CONTROL LEFT INPUT RCA CONNECTOR DIN CONNECTOR In parallel with RCA connections includes Phantom Power output D AMPLIFIER RIGHT INPUT RCA CONNECTOR RIGHT GAIN CONTROL
31. er and fast blow 40 ampere fuse is provided with the amplifier Install the fuseholder at the battery positive terminal Always connect the power cable assem bly directly to the battery Do NOT connect to the car fuse panel f the batteries are not installed side by side as shown here install a heavy duty fuse in the hot lead between the two batteries Also install a ground strap for the second battery Always replace the fuse with the same fast blow current rating as the one supplied with the amplifier POWER CABLE FUSEHOLDER BUTT SPLICE AUDIO GROUND Connect the small black wire to the deck floating ground if the deck uses a floating ground Refer to the discussion on floating grounds on page 28 BATTERIES GROUND STRAP Install a ground strap at least 1 inch wide from the battery negative terminal to a metal member to ensure adequate ground If the batteries are installed in opposite sides of the engine compartment or in the rear of the car install a separate ground strap for the second battery Burnish to bare metal to ensure good ground AMPLIFIER AMPLIFIER REMOTE CONTROL LEAD Connect the remote blue lead to the power antenna or the deck turn on connection Do NOT connect the remote blue lead directly to 12 volts as this will not allow the amplifier to turn off BLUE REMOTE TURN ON OFF WIRE SPEAKER CONNECTIONS d CABLE ASSY b bar SS GROUND CONNECTION The large blac
32. er ground leads will usually cause ground loops Do NOT ground the amplifiers at the same point Use a separate grounding point for each amplifier The ground point should be a metal chassis member that is welded to the main body of the car Scrape any paint from the grounding point and clean with sand paper just before attaching the ground lug After the ground lug has been securely tightened cover the bare metal area with paint or grease to prevent rust The ground lead is every bit as important as the power lead Many audio systems troubles are the re sult of improper ground connections Ground is a term generally used to describe the com mon connection in an electrical or electronic circuit The common connection is usually the same potential for all circuits in the system It is the source of electron flow Remember that the basic princple is that electrons flow from negative to positive In cars the ground is almost always the metal chassis or body and originates at the negative terminal of the battery A ground connection should have the least possible re sistance which is why we emphasize that the ground wire for an amplifier should be as short as possible 18 inches long maximum Longer wires add resistance and make the circuit susceptible to ground loops which can result in hum pickup and other electromagnetic interference Electromagnetic interference is a combination of elec tric and magnetic fields ca
33. fier System Using 200 CRX Active Crossover and the Summed Mono Output of a 400 BDG Bridging Module to Increase the Power Delivered to the Subwoofers by Four Times 14 Phantom Power 15V amp 15V is supplied to all ORION accessory modules by the amplifier through the DIN cable When ORION amplifiers are not TWEETER AMPLIFIER TWEETERS used the ORION PPS 100 Phantom Power Sup ply is required 15V 15V TADI ic AMI RIGHT AUDIO GROUND ORION 600 EOM EQUALIZER or ORION 500 PMQ PARAMETRIC EQUALIZER RCA Cables DU UJ ULL ORION 300 CRX CROSSOVER MODULE o DIN Cable E nm Freq Eon Midrange Output DIN Cable DIN Cable H 9 Hi H Li H i e DIN Cable ORION 400 BDG BRIDGING MODULE For this application the 300 CRX 3 Way Active Crossover is used to select the high mid and low frequencies as described in figure 7 The low frequency stereo output is applied to a 400 BDG Bridging Module where one channel is turned over 180 degrees inverted with respect to the other channel The inverted channel output of the amplifier is now used as speaker ground and the non inverted channel is used as speaker positive The BLACK YELLOW and BLACK ORANGE leads are NOT used Two 8 ohm subwoofers are connected in parallel This reduces the impedance to 4 ohms thus increasing the effective power even more Yellow 4 Black Yellow E Er nt d ORION zasucca 50 Watts RM
34. hantom Power 15V amp 15V is supplied to all ORION accessory modules by the amplifier through the DIN cable When ORION amplifiers are not used the ORION PPS 100 Phantom Power Sup ply is required All ORION Accessories and Amplifiers have this DIN configuration This figure shows the use of a 425 HCCA 4 Channel Amplifier in a car equipped with front and rear full range speakers The 425 HCCA does not have input RCA connectors connected in parallel with the input DIN connector as used in the other HCCA amplifiers An ORION 200 DAB Dual Amp Balancer is installed in the system to provide the connec tions for separating front and rear and to provide a means for front and rear level adjust ORION 300PRQ PRE AMP EQUALIZER 425 HCCA 4 CHANNEL AMPLIFIER Figure 17 on the next page shows a typical method of using two 425 HCCA 4 Channel Amplifiers as an efficient multi amplifier system In this system each pair of tweeters and midrange speakers are driven by a separate stereo amplifier within the 425 HCCA An ORION 300 CRX Crossover Module is used to select the frequency ranges applied at the input to the amplifiers Each pair of subwoofer amplifiers is bridged to provide 200 watts of power to a pair of 4 ohm subwoofers connected in parallel An ORION 200 DAB Dual Amp Balancer is used to fine tune the level delivered to each pair of subwoofers in the right vehicle this system would be an impressive competition system
35. k wire must be connected to a welded chassis member Do NOT lengthen the ground wire If more than one amplifier is used do NOT use the same ground screw but always connect both amplifiers to the same metal member as close together as possible Failure to do this will introduce ground loops P and result in a noisy system o oN i W l D Burnish to bare metal to ensure good ground Power Connections for 425 HCCA n BATTERY CONNECTIONS For most cars the existing battery and charging system will handle a single 425 HCCA 4 channel amplifier If two or more amplifiers are to be used or if the headlights dim when the amplifier is cranked up to full power use two batteries connected in parallel as shown in this diagram Refer to the discussion on page 27 The 425 HCCA is provided with four fuses The fuse for each power cable assembly is designed to prevent fire or damage to your car should there be a ground short in the power cable The second set of fuses protect each pair of amp lifiers Do NOT substitute fuses Always replace fuses with the same fast blow current rating as those supplied with your amplifier Always connect the power cable assemblies directly to the positive terminal on the battery Do not connect to the fuse panel f the batteries are not installed side by side as shown here install a heavy duty fuse in the hot lead be tween the two batteries Also install a ground strap for the second ba
36. l so that the RCA connectors can be used to connect the output of the equalizer directly to the Low Pass Filter so that the crossover module has no effect on the Low Pass Filter This is an ideal application when you are using mismatched subwoofers or are experiencing speaker box resonance problems A REMINDER 7he speakers must never be grounded to car chassis or body To do go will cause severe noise problems ORION 30 pate 30 dB Per Octave Low Pass Crossover Yellow Black Yel low DIN Cable ES ORION E 100 Watts E f Orange Black Orange NONFILTERED LOWS AMPLIFIER Yellow Black Yellow e 0 250 HCCA 100 Watts RMS Orange Black Orange HIGH MID SPEAKERS 9 f D d 9 HIGH MID AMPLIFIER Yellow Black Yellow Passive Crossover ORION 250 HCCA 100 Watts RMS Orange Black Orange Passi ve Crossover Figure 12 Typical Use of an ORION 30 dBLP Low Pass Filter to Set Upper Limits of Low Frequencies 18 ORION 600 EQM EQUALIZER or ORION 500 PMQ PARAMETRIC EQUALIZER RCA Cables Il V o Es o Z O RCA DIN Cable LINE LI Y 7405 ORION 200 CRX LE Marl FU ORION 200 CRX M CROSSOVER MODULE High Freq Output This diagram shows a typical application for an ORION 30 dBHP High Pass Filter used to control high frequencies applied to a set of tweeters
37. m fully clockwise 6 Turn on power to the amplifiers Turn on the radio and set the VOLUME control for approximately 3 4 volume If a 600 EOM is being used adjust the input gain control clockwise until the speakers just start to distort clipping If the gain control on the 600 EOM does not provide full volume increase the gain setting of each amplifier just enough to produce clipping If a 300 PRQ or 500 PMQ is being used adjust each input gain control until the speakers just start to distort clipping If the input gain controls on the 300 PRQ or 500 PMQ do not produce full volume increase the gain setting of each amplifier as re quired to produce clipping Decrease the setting of the VOLUME control on the 300 PRQ or 500 PMQ for desired listening level CAUTION Be sure to turn off the power when dis connecting and reconnecting cables 8 If a 200 CRX Active Crossover is installed in the system unplug the cable from the ow output and adjust the HIGH FREQ control to where the mid range and highs sound best Then plug in the ow output cable and unplug the high output cable Using the LOW FREQ control adjust the lows until sound good to you Now plug in the high output and make minor adjustments to suit your taste If a 300 CRX 3 Way Active Crossover is installed in the system proceed as follows NOTE deally the LOW OUT should be adjusted to permit the subwoofers to reproduce all fre quencies of 100 to
38. make slight adjustments to provide the sound that pleases you the most This system could be designed using two 225 HCCA 2 channel amplifiers 25 watts per channel or a 425 HCCA 4 channel amplifier For added power you could choose two 250 HCCA amplifiers 50 watts per channel For installation connections and adjustments refer to pages 26 through 35 Figure 5 Two Amplifier System Using an ORION 200 CRX Active Crossover 11 E EA VAVE LETI RIGHT AUDIO GROUND Phantom Power 15V amp 15V is supplied to all Yellow ORION accessory modules by the amplifier through the DIN cable When ORION amplifiers are not Black Yellow used the ORION PPS 100 Phantom Power Sup ply is required ORION 250 HCCA 100 Watts RMS Tweeter FRONT AMPLIFIER Midrange Tweeter Orange ORION 600 EQM Black Orange EQUALIZER or 500 PMO PARAMETRIC EQUALIZER RCA Cables Crossover Midrange REAR AMPLIFIER Tweeter DIN Cable Yellow oe n Black Yell ow 1 Midrange E DEI Passive Crossover p HOS osi 9 D EL 200 CRX 100 Watts RMS pom MaRa ORION 200 CRX i A ORION zoncca RION CROSSOVER E ORION om T 5 i Orange Tweeter ane Low Freq Output DIN Cable Black Orange Freq amp DIN Cable Output ee a Input selector awn teh a be Select passive crossovers ORION Ikee position per speaker manufacturer s specifications Crossover Midrange uj ui
39. mp system using a 50 Watts RMS Orange 300 CRX 3 Way Active Cross over The 300 CRX makes it possible to use separate ampli fiers for the tweeters midrange speakers and subwoofers Black Orange 600 EQM ORION MIDRANGE SPEAKERS Less power is required to drive the high frequencies to the tweet ers than that required for mid range and low frequencies so this diagram shows a 225 HCCA 25 watts per channel being used for the tweeters MIDRANGE AMPLIFIER ORION 600 EQM ERAN AMPE EQUALIZER Be Yellow ORION 500 PMQ Black Yellow PARAMETRIC EQUALIZER DIN Cable f 1 ORION _ 2oucca 100 Watts RMS Orange Black Orange The midrange and subwoofer amplifiers could be selected according to your output power requirements and space avail ability If you decide to use three 250 HCCA s you may High Freq Output a Midrange Output Omo NOP INOW orm ri RL Low Freq have to add an additional bat tery Refer to page 27 Output ORION 300 CRX SUBWOOFER AMPLIFIER SUBWOOFERS N CROSSOVER V Yellow Black Yellow The high frequency output of the 300 CRX is an adjustable high pass filter A common adjustment would be to pass all frequencies 4000 Hz and above to the tweeters The mid range output is a bandpass filter with separate controls for adjusting the low end and the high end A common adjustment might be to pass all frequencies between 100 Hz and 41
40. only the mid range frequencies and some amplifiers dedicated to 1 only the low frequencies Crossover frequencies are con tinously adjustable between 50 Hz and 5 kHz on all bands Total frequency response is 10 Hz to 50 kHz Phantom power is supplied by any ORION amplifier or by an ORION PPS 100 Phantom Power Supply 30 DBLP LOW PASS FILTER and 30 DBHP HIGH PASS FILTER When you want pure sound add a 30 DBLP Low Pass Filter or a 30 DBHP High Pass Filter or both to your system 30 dB per octave low pass or high pass Cutoff frequency from 48 Hz to 6 kHz through the use of two plug in chips The 30 DBLP Low Pass Filter is used to keep the midrange and high frequen cies out of your subwoofers correct for mismatched speakers eliminate speaker box resonance problems and remove distortion The 30 DBHP High Pass Filter is used to make your tweeters sound more lively Isolated audio ground to prevent audio ground loops and eliminate engine noise Powered by any ORION amplifier or an ORION PPS 100 Phantom Power supply 200 DAB DUAL AMP BALANCER The ORION 200 DAB Dual Amp Balancer allows individual level adjust for multi amplifier use You can crank up the front speakers and tone down the rear speakers or the other way around For use with decks and radios with or without fader controls A switch is provided on the rear of the unit for selecting dual or single input termina tions No operating power required PPS 100
41. ote blue lead to the power antenna or the deck turn on connection Do NOT connect the remote blue lead p directly to 12 volts as this will not allow the amplifier to turn off AMPLIFIER AUDIO GROUND Connect the small black wire to the deck floating ground when the deck uses a floating ground Refer to the discussion on floating grounds on page 28 FUSE SPEAKER CONNECTIONS CABLE ASSY GROUND CONNECTION The large black wire with the terminal lug must be connected to a welded chassis mem FUSEHOLDER ber Do NOT lengthen the ground wire If more than one amplifier is used do VA uf GROUND STRAP install a ground NY Te NOT use the same grounding screw strip at least 1 inch wide from the Burnish to QS but always connect both amplifiers P battery negative terminal to a metal cone M ie gt to the same metal member as close BATTERY MU tee member to ensure adeqate ground adod ground p together as possible Failure to do this will introduce ground loops and result to ensure in a noisy system good ground 29 bare metal Power Connections for 250 HCCA BATTERY CONNECTIONS For most cars the existing battery and charging system will handle a single 250 HCCA amplifier If two or more amplifiers are to be used or if the headlights dim when the amplifier is cranked up to full power use two batteries connected in parallel as shown in this diagram Refer to the discussion on page 27 A heavy duty fusehold
42. p to 20 Subwoofer Amplifiers Can be Used 22 SUBWOOFER AMPLIFIER Orange Yellow E ORION zoncca 100 Watts RMS Black Yellow N ot Used Black Orange SUBWOOFER AMPLIFIER RCA DIN Cable Orange 4 ORION ESTESA 100 Watts RMS M X Black Yellow tel Black Orange RCA DIN Cable This diagram shows a full competition Killer System using an ORION 300 CRX 3 Way Active Crossover to separate the highs midranges and lows This allows each type of speaker to handle only those frequencies it was designed to reproduce The lows are then applied to an ORION 400 BDG Bridging Module The Summed Mono output can now be used to drive up to 20 amplifiers connected in parallel as shown in the diagram The selected high frequencies are kept in stereo and applied to a pair of tweeter amplifiers Since the high frequencies require much less power the diagrams shows smaller amplifiers for driving the tweeters than those used for the mid and low frequencies SUBWOOFER AMPLIFIER Orange 4 ZA ORION ELS 100 Watts RMS Black Yellow Black Orange RCA DIN Cable SUBWOOFER AMPLIFIER Orange ZA ORION monoa 100 Watts RMS Yellow Black Yellow Black Orange The selected midrange frequencies are also kept in stereo and applied to a pair of amplifiers that drive the midrange speakers DIN CONNECTOR 15V a Y Lert g V RIGHT AUDIO GROUND P
43. points 30 Hz 90 Hz 180 Hz 2 kHz 5 kHz and 15 kHz Input sensitivity is adjustable Powered by phantom power provided by any ORION amp lifier or an ORION PPS 100 Phantom Power Supply 300 CRX 3 WAY ACTIVE CROSSOVER The ORION 300 CRX is a versatile 12 dB per octave 3 way crossover Designed for use in multi amplifier sys tems with some amplifiers dedicated to only the high BRIDGING MODULE The ORION 400 BDG Bridging Module is used to convert two stereo channels to mano to increase out put power 4 times Generally used to convert lows bass to mono while leaving the midranges and highs In stereo Four modes of operation 1 Mixed mono output 2 Summed mono output 3 Bridged stereo right 4 Bridged stereo left Powered by phantom power provided by any ORION amplifier or an ORION PPS 100 Phantom Power Supply 500 PMQ PARAMETRIC EQUALIZER Outstanding flexibility Allows you to change the frequency of boost and cut The ORION 500 PMQ Parametric Equalizer features five dual controls outer knob for selecting the frequency band and an inner knob for controlling boost or cut for each band Frequency bands are 30 ta 75 Hz 50 to 150 Hz 500 to 1 5 kHz 1 5 to 5 kHz and 5 to 15 kHz Boost and cut for each frequency band is 10 dB up or 10 dB down The EQ curve is fixed Includes a high quality volume control Gain adjustment is 30 mV to 3V RMS Powered by phantom power frequencies some amplifiers dedicated to
44. reful not to drill into the fuel tank fuel lines or through electrical wiring SELF TAPPING SCREW TWO EACH SIDE AMPLIFIER IMPORTANT CAUTIONS Improper wiring connections can seriously damage amplifiers accessories or speakers Follow the con necting instructions in this manual carefully When in doubt contact your dealer Disconnect the battery positive lead before mak ing any power connections Always connect the power cable assembly directly to the positive terminal on the battery Do NOT connect to the car fuse panel Do NOT use a smaller gage wire for the hot lead than that coming out of your amplifier Make sure that the power ON OFF switch that con trols the amplifiers is turned OFF when making any connections Make sure that all connections are clean and properly secured Failure to do so may result in damage to your equipment Always replace fuses with the same FAST BLOW current rating as those supplied with your amplifier Incorrect fuses can result in serious damage to the components in the system The speakers must never be grounded to the car chassis or body To do so will cause severe noise problems and in case of bridging cancel out the two phase operation 8 Make sure that your car has enough power to handle all car systems as well as your audio system Read about power requirements below carefully POWER AN
45. s that if you install 4 kHz chips in the filter only frequencies of 4 kHz and above will pass through to your tweeters and frequencies below 4 kHz will be blocked F KILLER SYSTEMS Figure 14 shows a Killer System that uses an ORION 200 CRX Active Crossover to separate the highs from the lows A 30 DBHP High Pass Filter is used to enhance the performance of separate pair of tweeters All sub woofers are driven from the SUMMED MONO output of a 400 BDG Bridging Module A 30 DBLP Low Pass Filter is used to control the lows to a selected set of subwoofers Figure 15 shows a Killer System that uses an ORION 300 CRX Active Crossover to separate the highs mid ranges and lows This approach offers the best overall control of the speakers and makes it possible to use several amplifiers connected in parallel G USE OF 4 CHANNEL POWER AMPLIFIER 425 HCCA Figu reste dnd 17 show typical systemsusing 425 HCCA Amplifiers slg Mag RIGHT DIN CONNE R E C CTO All ORION Accessories and Amplifiers have this DIN configuration ply is required Gn GROUND LOWS AMPLIFIER DIN Cable ORION 100 Watts RMS ORION 300 PRQ PRE AMP EQUALIZER or ORION 300 PRO or ORION 600 EQM EQUALIZER 250 HCCA Phantom Power 15V amp 15V is supplied to all ORION accessory modules by the amplifier through the DIN cable When ORION amplifiers are not used the ORION PPS 100 Phantom Power Sup
46. se more or larger amplifiers refer to the dis cussion on power requirements on page 29 4 Adding Crossover or Bridging Modules An existing speaker system can also include a crossover module and or bridging module similar to the custom sys tems described in paragraphs B through F below B USE OF A CROSSOVER MODULE An ORION 200 CRX Active Crossover or 300 CRX 3 Way Active Crossover can be one of the most im portant additions to your car audio system It lets you adjust the highs and midranges to where they sound best then independently adjust the lows to where they sound great The 200 CRX Active Cross over contains a low pass filter section for your sub woofers and a high pass filter section for midranges and tweeters The 300 CRX 3 Way Active Cross over contains a low pass filter section for the sub EQUALIZER DIN Cable NOTE The DIN and RCA input connect ors for all amplifiers are wired in parallel This means that when an input is connected to the DIN connector it is also present at the RCA connectors and the other way around This makes it pos sible to connect several amplifiers in parallei as shown in this figure Phantom power is supplied to the equalizer by the amplifier through the DIN cable RCA DIN Cable AMPLIFIER Yellow 4 RCA DIN Cable res e ORION ET REAR 50 Watts RMS SPEAKERS Orange 4 Black Orange SUBWOOFER AMPLIFIER Yellow Black Yellow
47. separate the lows from the highs as described in figure 5 and the 400 BDG Bridging Module is connected only to the lows side In this way the midrange and high frequencies are applied to the highs amplifier as stereo Both channels of the low frequencies are applied to the Bridging Module In the 400 BDG Bridging Module the signals for one channel are turned over 180 degrees inverted with respect to the other channel The inverted channel output of the amplifier is now used as speaker ground and the non inverted channel output is used as speaker positivo The BLACK YELLOW and BLACK ORANGE leads are NOT used DIN Cable DIN cable When ORION amplifiers are not used the ORION PPS 100 Phantom Power Supply is required SUBWOOFERS LOWS AMPLIFIER Orange 250 HCCA ORION _ 100 Watts RMS eo Black Orange Used Black Yell ow MID HIGH FREQUENCY SPEAKERS Select Passive Crossovers per Speaker Manufacturer s Specifications L 9 Tweeter HIGHS AMPLIFIER Yellow Passive Crossover Black Yellow SER Ye Midrange ORION 100 Watts RMS 250 HCCA Orange Tweeter Black Orange Passive Crossover Midrange This diagram shows two 8 ohm subwoofers connected in parallel This reduces the impedance to a total of 4 ohms thus increasing the effective power output even more For installation connections and adjustments refer to pages 26 through 35 Figure 8 Two Ampli
48. that required by all combinations of the components in your system For standard multi amplifier systems you must install a heavy duty alternator and at least one extra battery Preferrably all batteries should be deep cycle marine batteries 27 When batteries are connected in parallel the voltage across each battery is the same and the batteries share the load current The alternator will generally maintain the charge on both batteries equally The power lead for each amplifier should be con nected directly to the positive terminal as shown on page 32 In large multi amplifier systems the power leads can be connected to a heavy buss bar but the lead from the buss bar to the battery positive terminal must be at least No 4 wire gage for 100 ampere service Keep in mind that an amplifier can only supply its full power if it has enough battery power being supplied to it All ORION amplifiers are designed to mute 40 dB if battery power drops below 10 volts C Grounding Amplifiers For any audio system you should first go to the battery and get rid of that little 12 or 14 gage wire that goes from the ground terminal to the chassis and install a braided ground strap at least 1 inch wide from the battery negative terminal to the chassis Leave the original ground strap connected to the engine The ground wire for each amplifier must be connected directly to the car chassis not more than 18 inches from the amplifier Long
49. tput Section Slew Rate 30V per microsecond Output Impedance 0 5 ohm to 16 ohms Stereo Separation 80 dB Overall Dimensions 300 PRO PRE AMPLIFIER EQUALIZER The ORION 300 PRQ provides pre amplification plus three bands of equalization 40 Hz cut and boost 180 Hz cut and boost and 15 kHz cut and boost Designed primarily to help compensate for speaker deficiencies eliminate distortion and boost range Input is independently adjustable from 30 mV to 3V RMS Includes a high quality volume control Powered by phantom power provided by any ORION amplifier or an ORION PPS 100 Phantom Power Supply 200 CRX ACTIVE CROSSOVER The ORION 200 CRX is a highly efficient continuously adjustable 12 dB per octave 2 way crossover Designed for use in multi amplifier systems with some amplifiers dedicated to the low frequencies and some amplifiers dedicated to the high and midrange frequencies Inde pendent adjustment of low pass and high pass frequen cies from 50 Hz to 5 kHz Total frequency response is 10 Hz to 50 kHz Extremely versatile capable of driving up to 20 amplifiers Phantom power is sup plied by any ORION amplifier or by an ORION PPS 100 Phantom Power Supply ORION ACCESSORIES 600 EOM EQUALIZER MODULE Audiophile grade equalization for well set up car audio systems Features high quality troublefree rotary controls The 600 EOM provides six equal ization
50. ttery BATTERIES AUDIO GROUND Connect the small black wire to the deck floating ground if the deck uses a floating ground Refer to the discussion on floating grounds on page 28 FUSEHOLDER POWER CABLE FOR AMPLIFIER A POWER CABLE FOR AMPLIFIER B GROUND STRAP Install a ground strap at least 1 inch wide from the battery neg ative terminal to a metal member to ensure adequate ground If the batteries are installed on opposite sides of the engine compartment or in the rear of the car install a separate ground strap for the second battery Burnish to bare metal to ensure good ground Z AMPLIFIER AMPLIFIER REMOTE CONTROL LEAD Connect the remote blue lead to the power antenna or the deck turn on connection Do NOT connect the remote biue lead directly to 12 volts as this will not allow the amplifier to turn off BLUE REMOTE TURN ON OFF WIRE SPEAKER CONNECTIONS CABLE ASSY ean P f FUSEHOLDER FUSEHOLDER Burnish to bare metal to ensure good ground GROUND CONNECTION The large black wires must be connected to a welded chassis member Do NOT lengthen the ground wires Connect the ground leads to the same metal member as close together as possible Do NOT use the same ground screw for both ground leads 33 SPEAKER CONNECTIONS IMPEDANCE 225 and 425 HCCA amplifiers are designed for operation with 0 5 to 16 ohm speakers 250 HCCA amplifiers are
51. used by alternating current or frequencies radiating from the wires and being picked up on the signal leads to and from your ampli fier This type interference may show up as popping bursts of static or random noise Floating Ground Floating ground means that the ground is not connected to the car chassis or body but uses only the internal power supply ground Some radios and cassette decks use a floating ground for the output signals This is a dedicated ground connection that remains isolated from the common circuit ground car chassis or body Some ORION amplifiers contain a small diameter black lead in addition to the larger common ground wire This lead is for connections to the floating ground for those decks that use a floating ground To determine if the floating ground connection should be made first connect the system WITHOUT connect ing the floating ground Start the car and turn on the audio system Temporarily connect the floating ground If the floating ground adds noise do NOT connect If the floating ground takes away noise connect the floating ground permamently If the deck utilizes a floating ground and the small black wire is not connected to the deck floating ground point any of the following conditions may result Clipped output Blown fuses Weak output from the amplifier Amplifier will run hot Squealing POWER ON INDICATOR AUDIO RIGHT GROUND LEFT INPUT INPUT SIGNAL SIGNAL AJ RS 1
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