Orion Car Audio XTREME 600.4 User Manual

XTREME 600.4
OWNER’S MANUAL

H

IGH PERFORMANCE

CAR A

UDIO

TABLE OF CONTENTS

INTRODUCTION 3
WARRANTY 6

SPECIFICATIONS 8
TECHNICAL DESIGN FEATURES 10
SYSTEM PLANNING 12
INSTALLATION 18
POWER CONNECTIONS 19
SPEAKER CONNECTIONS 20
OUTPUT CONFIGURATIONS 24
4-CHANNEL INPUT CONFIGURATIONS 24
RCA INPUT / CH 1 & 2 XVR 25
INTERNAL CROSSOVER CONFIGURATION 25
INTELLI Q 28
REMOTE GAIN 31
SIGNAL INPUT AND OUTPUT LEVEL CONTROLS 31
CHOOSING MOUNTING LOCATIONS 32
STEP BY STEP INSTALLATION 33
TESTING THE SYSTEM 35
ADJUSTING THE SOUND OF THE SYSTEM 36
TROUBLESHOOTING TIPS 38
AUTOSOUND 2000 TROUBLESHOOTING TIPS 40

INTRODUCTION

Thank you for your purchase of ORION’s XTREME amplifier. Each ORION amplifier is designed to be the leader in its class offerin g the
most power , advanced features and ease of use. The ORION XTREME amplifiers are designed as the best car audio amplifier money can
buy. Listed below ar e the features of the new ORION XTREME amplifiers.

• XTREME 600.4 – 75 watts per channel, 4-channel amplifier with fully variable low-pass crossovers from 45Hz to 5khz. The high-pass
crossover is continuously variable from 10Hz to 10kHz. The XTREME 600.4 has the INTELLiQ subwoofer optimizing circuitry and dual
remote gain capability . The XTREME 600.4 is capable of 6, 5, 4, 3, or 2 channel operation.

NOTE: The installation of all ORION XTREME amplifiers will determine the overall performance result. Improper installation will not
only limit the performance of your ORION system but also potentially compromise the reliability of this digital processor. To ensure
proper sonic results and component reliability, please refer to your Authorized ORION dealer for installation assistance or advice. If you
decide to perform the installation yourself, read the entire installation section of this manual before beginning the installation.

page 3

ABOUT THIS MANUAL

This manual is divided into different sections for different needs. Whether you are the owner, salesperson or installer, we have devoted
sections of this manual to answer your questions. If you just purchased this amplifier and have yet to decide on a system configuration,
refer to the System Planning section of this manual for awesome system ideas.

We, at ORION, strive to give you the latest up to date information about our products. What we cannot give you is personal installation
or technical experience. If you have questions regarding the installation or the setup or tuning of this product, please refer to your
nearest Authorized ORION Dealer for assistance. Additionally, you can call ORION’s Technical Support Hotline at 1-800-315-2052 or 602­705-5600 for assistance.

PRACTICE SAFE SOUND

Continuous exposure to sound pressure levels over 100dB may cause permanent hearing loss. High powered automotive sound systems
can generate sound pressure levels in excess of 130dB. When playing your system at high levels, please use hearing protection and avoid
long term exposure.

™

RECORD YOUR SERIAL NUMBER AND DATE:

Model: __________________________________________________________

Serial Number: __________________________________________________________

Date of Purchase: __________________________________________________________

Company Purchased From: __________________________________________________________

page 4

WHAT’S IN THE BOX

(1) XTREME amplifier
(1) 4 gauge power and ground connector
(1) 12 gauge speaker and remote connector
(4) #8 self-tapping black Phillips pan head screws
(1) XTREME installation and operation manual

page 5

WARRANTY

ORION Industries Inc. warrants this product to be free from defects in material and workmanship under the following terms:
Parts and Labor are warranted for a period of 3 years IF:

a. The product is purchased from an Authorized ORION Dealer
b. The product is installed by an Authorized ORION Dealer

Parts and Labor are warranted for a period of 1 year IF:

a. The product is purchased from an Authorized ORION Dealer
b. The product is NOT installed by an Authorized ORION Dealer

Parts and Labor are warranted for a period of 90 days IF:

a. The product is NOT purchased from an Authorized ORION Dealer

If you are uncertain as to whether your dealer is authorized, please contact ORION at 1-800-775-7150 or 480-705-5600. In countries other
than the USA, each distributor warrants the ORION product it sells.

The following conditions and situations are NOT covered by this warranty:
Any product on which the serial number has been defaced, modified or removed. Damage or malfunction resulting from:

a. Accident, misuse, abuse, unauthorized modification or failure to follow the instructions provided with this product
b. Repair by anyone NOT authorized by ORION
c. Damage due to shipping (these claims must be presented to the freight carrier)
d. Removal or installation of this product
e. Any failure that has NOT been caused by a defect in material or workmanship

page 6

This warranty is in effect for the original purchaser only . ORION will pay for labor and material expense for covered items. ORION does
not cover removal or installation charges, payment of shipping charges to ORION, payment of OUT-OF-WARRANTY shipping charges, or
damage to other property caused by any defects in this product.

For IN-WARRANTY service, you must include a copy of the original, dated sales receipt, including serial number, from an Authorized
ORION Dealer. Please also provide your name, return street address (No P.O. Boxes) and a detailed description of the problem.

For out-of-warranty products, please include ORION E-Z Repair Form. These are available by contacting ORION Repair at 1-888-362-5283
or 480-705-5600 and ask for the Repair Department.

• If you do not have the original packaging, the product must be packaged to prevent damage during shipment.

ORION Industries Inc.
A TTN.: Repair Department
9235 South McKemy Street
Tempe, Arizona 85284 USA

Exclusion

1. This warranty is in lieu of all other warranties expressed or implied.

2. In no event will ORION be liable for any consequential damages resulting from the use of this product or any defect of this product.

This warranty gives you specific legal rights. You may also have other rights that vary from state to state.

page 7

SPECIFICATIONS

Amplifier Section XTREME 600.4 Front Channels XTREME 600.4 Rear Channels

Power output 4 Ω stereo (watts)

Power output 2 Ω stereo (watts)
Power output 4 Ω mono (watts)

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2

1

Distortion all channels driven <0.1% THD <0.1% THD
(from 20Hz to 20kHz)
Frequency Response 20Hz to 20kHz ±0.25dB 20Hz to 20kHz ±0.25dB
Linear Bandwidth 6Hz to 50kHz ±3dB 6Hz to 50kHz ±3dB
Signal-to-noise ratio full bandwidth >100dB >100dB
@ rated output power
Damping factor @ output connector >400 at output connector >400 at output connector
@ full bandwidth
Slew Rate >30Vµs >30Vµs
Input Sensitivity

3

Input Impedance 20 k ohm 20 k ohm
Fuse Type (3) 20 Amp ATC (3) 20 Amp ATC

75 x 2 75 x 2

75 x 2, 300 x 1 75 x 2, 300 x 1

150 x 2 150 x 4
300 x 1 300 x 2

200 mV to 5 Vrms 200 mV to 5 Vrms

page 8

Crossover Section

3

XTREME 600.4 Front Channels XTREME 600.4 Rear Channels

Low-Pass Crossover Continuously variable Continuously variable
Low-Pass Frequency Range 45Hz to 5kHz 45Hz to 5kHz
High-Pass Crossover Continuously variable Continuously variable
High-Pass Frequency Range 10Hz to 10kHz 45Hz to 5kHz
High-Pass INTELLiQ Range 0dB to 10dB of Boost n/a
General
Dimensions 18”L x 10.25”W x 2.25”H 18”L x 10.25”W x 2.25”H

(457mm x 260mm x 57mm) (457mm x 260mm x 57mm)

1

All channels driven, continuous rated 4Ω load, 20Hz to 20,000Hz, >0.1% THD, per input voltage at 12.0VDC.

2

All channels driven, continuous rated 2Ω load, 20Hz to 20,000Hz, >0.1% THD, per input voltage at 12.0VDC.

3

XTREME amplifiers are designed to accept full 9 Volts RMS input when set to the minimum gain position.

4

All crossovers are with a slope rate of 12dB/octave and a “Q” of .0707.

page 9

TECHNICAL DESIGN FEATURES

XTREME 600.4

Rear Crossover
Rear Gain
2 CH / 4CH

Switch

RCA Input

Front Gain

Front HP

Crossover

INTELLiQ

Front LP

Crossover

Complementary Matched
Bipolar Outputs

PRS Power supply

MOSFET switches

12 Gauge
Speaker and
Remote

PRS Power
Supply

Remote Gain
ATC Fuse

Power Supply
Controller

4 Gauge Power
& Ground

Rectifier

Diodes

page 10

TECHNICAL DESIGN FEA TURES

1. Power LED - lights up when the amplifier is on

2. Low-pass crossover frequency control-adjusts the front channel
low-pass crossover frequency

3. Low-pass crossover switch-activates the front channel low-pass
crossover

4. INTELLiQ gain-adjusts the level of INTELLiQ from 0dB to 10dB of
boost.

5. High-pass crossover “x10” switch-changes the high-pass crossover
frequency range

6. High-pass crossover frequency control-adjusts the front channel
high-pass crossover frequency

7. High-pass crossover switch-activates the front channel high-pass
crossover

8. Front Gain Control - continuously adjusts from 200mV to 5Vrms
for full power output

9. Front Output Configuration Switch - determines the output
configuration for the front channels

10. Front RCA Inputs- accepts RCA input from a source unit, preampli­fier or equalizer for the front channels

11. Rear RCA Inputs- accepts RCA input from a source unit, preampli­fier or equalizer for the rear channels

12. 2-Channel / 4-Channel Switch - configures the amplifier for two or
four RCA inputs

13. Rear Output Configuration Switch - determines the output
configuration for the rear channels

14. Rear Crossover Control - adjusts the frequency for the rear
channels

15. Rear channel input configures rear channels for direct input or
output of front channel crossover and gain

16. Rear Gain Control - continuously adjusts from 200mV to 5Vrms for
full power output

1

2

18

6789

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10

11 12

20 21 2322

14

13543

17

16

15

17. Rear Crossover Switch - configures the rear channel for high­pass, low-pass or full range operation

18. REM Remote Turn-on Input - turns on the amplifier when fed 12
V+

19. Front speaker output- allows up to 12 gauge speaker wire

20. Rear speaker output- allows up to 12 gauge speaker wire

21. Remote Gain-allows dashboard control of the amplifier output
level

22. Fuse - protects the amplifier from over current situations

23. Power Connections - allow up to 4 gauge power and ground cables

page 11

SYSTEM PLANNING SYSTEM 1

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The easiest way to maximize the performance for your
ORION XTREME amplifier is to properly plan your sys­tem. By planning your system, you can avoid situation
where the performance of the reliability of your system
is compromised. Your Authorized ORION dealer has been
trained by ORION Industries on how to maximize your
system’s sonic potential. Authorized ORION dealers are
a valuable resource in helping you with your system de­sign and installation. If you wish to venture on with your
own system design, here are some systems designed by
ORION Industries.

System 1 is a simple two-way system. The front chan­nels are bridged mono for a single 4-ohm subwoofer.
The rear channels are configured for stereo operation
and high-passed for a set of satellite speakers.

• Lowest recommended impedance is 2Ω per channel

• Front channels are configured for summed bridged

mono operation

• Front crossover is configured for low-pass operation

• Lowest recommended impedance is 4 ohms bridged

mono for the front channels.

• Rear channels are configured for stereo operation

• Rear crossover is configured for high-pass operation

page 12

SYSTEM PLANNING SYSTEM 2

System 2 is a two-way front / rear
boomer system. Amplifier 1 powers
front and rear separates. Amplifier 2
powers four 4 ohm subwoofers. This sys­tem also has a RGC-1 for dashboard con­trol of the bass level.

Amplifier 1

• Lowest recommended impedance is 2
ohms stereo

• Front and rear channels configured for
stereo operation

• Front and rear channels set for high­pass operation

• 2ch / 4ch input selector configured for
2 channel input

Amplifier 2

• Lowest recommended impedance in 2
ohms stereo

• Front and rear channels configured for
summed stereo operation

• Front channels configured for low-pass
operation with INTELLiQ.

• Rear channel input configured from
crossover and gain output of chan­nels 1 & 2

• RGC –1 connected to front gain point
controls bass level for entire system.

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Note: INTELLiQ is a trademark feature of ORION amplifiers that maximize the performance of

any subwoofer system for information regarding the setup of INTELLiQ please refer to the
crossover section of this manual that explains INTELLiQ.

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RGC-1

page 13

SYSTEM PLANNING SYSTEM 3

RGC-1

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page 14

SYSTEM PLANNING SYSTEM 3

System 3 is a three-way tri-amplified system. Amplifier 1 is bi-amplified for the front separates. Amplifier 2 is configured for two-way operation.
The front channels are configured for two 4-ohm subwoofers. The rear channels are configured for rear satellites. The RGC-1 controls the subwoofer
level from the dashboard of the vehicle.

Amplifier 1

• Lowest recommended impedance is 2 ohms stereo operation

• Front channels are configured for stereo operation

• Front channels are configured for bandpass operation

• Rear channels are configured for stereo operation

• Rear channels are configured for high-pass operation

Amplifier 2

• Lowest recommended impedance in 2 ohms stereo

• Front channels configured for summed stereo operation

• Front channels configured for low-pass operation with INTELLiQ.

• Rear channels are configured for stereo operation

• Rear channel input configured for high-pass operation

• RGC –1 connected to front gain point controls bass level for the system.

Note: INTELLiQ is a trademark feature of ORION amplifiers that maximize the performance of any subwoofer system for information regarding the

setup of INTELLiQ please refer to the crossover section of this manual that explains INTELLiQ.

page 15

SYSTEM PLANNING SYSTEM 4

RGC-1

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page 16

SYSTEM PLANNING SYSTEM 4

System 4 is a four-way quad-amplified system. Amplifier 1 is bi-amplified for the front separates. Amplifier 2 is configured for two-way
operation. The front channels are configured for two 4-ohm midbass drivers. The rear channels are configured two 4 ohm subwoofers. The RGC-1
controls the subwoofer level from the dashboard of the vehicle.

Amplifier 1

Lowest recommended impedance is 2 ohms stereo operation
Front channels are configured for stereo operation
Front channels are configured for bandpass operation
Rear channels are configured for stereo operation
Rear channels are configured for high-pass operation

Amplifier 2

• Lowest recommended impedance in 2 ohms stereo

• Front channels are configured for stereo operation

• Front channel input configured for bandpass operation

• Rear channels configured for summed stereo operation

• RGC –1 connected to rear gain point controls bass level for the system

page 17

INSTALLATION

The installation of all ORION components will determine the overall performance result. Improper installation will not only limit the performance of
your ORION system but also potentially compromise the reliability of this amplifier . T o ensure proper sonic results and component reliability , please
refer to your Authorized ORION dealer for installation assistance or advice. If you decide to perform the installation yourself, read the entire
installation section of this manual before beginning installation.

TOOLS OF THE TRADE

Listed are the majority of the tools required to perform the installation. Having the proper tools will make the installation much easier. Some of
these tools are necessities. Some make the job much easier.

• marking pen • heat shrink tubing

• electric drill with assorted drill bits • nylon tie straps

• utility knife • volt-ohm meter (optional)

• Phillips and flat blade screw drivers • wire cutters

• pliers (standard and needle nose) • wire crimpers

• wire brush or sandpaper for chassis grounding • wire strippers

• solder iron and solder

page 18

POWER CONNECTIONS

100.1

6

FI

Vehicle Battery

–+

Connect to remote turn-on
lead of source unit

Fuse less than 18"

from battery

• Minimum 8 gauge power and ground cable is recommended for acceptable performance

• 4 gauge power and ground cable is recommended for optimal performance

• Fuse power wire less than 18” from battery

• Ground amplifier to a good chassis ground as close as possible to the amplifier

• Add extra ground wire between the negative terminal of the battery and the chassis

TUNING 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 helps especially in newer vehicles, where the current delivery of the factory electrical system was
designed only to accommodate electronics supplied by the auto manufacturer.

Amplifier Fuse Size
XTREME 600.4 (3) 20 AMP

page 19

SPEAKER CONNECTIONS 4-CHANNEL STEREO CONFIGURA TION

• Front and rear channel lowest recommended
impedance is 2 ohm stereo

• Crossover, output and gain configurations
are independently adjustable between the
front and rear channels

• 2-channel or 4-channel input can be used for
this configuration. For source unit fading,
use the 4-channel input mode

• Front outputs can be configured for high­pass, low-pass or bandpass operation.

• Front channels equipped with INTELLiQ
subwoofer optimization circuitry.

• Rear outputs can be configured for high­pass, low-pass or full range operation

• Front and rear outputs can be configured for
either stereo operation or summed for
subwoofer applications

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page 20

SPEAKER CONNECTIONS 3-CHANNEL STEREO/BRIDGED CONFIGURA TION

• Front channels are configured for 2-channel stereo
operation

• Front channel lowest recommended impedance is 2Ω
stereo

• Rear channels are configured for a single channel
bridged output

• Rear channel lowest recommended impedance is 4Ω

• Crossover, output and gain configurations are indepen­dently adjustable between the front and rear channels

• 2-channel or 4-channel input can be used for this
configuration. For source unit fading, use the 4-channel
input mode

• Front and rear outputs can be configured for high-pass,
low-pass or full range operation

• Front outputs can be configured for either stereo or
summed stereo operation

• Rear outputs can be configured for summed bridged or
single channel bridged operation for subwoofer
applications

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page 21

SPEAKER CONNECTIONS TWO-CHANNEL BRIDGED CONFIGURA TION

• Front and rear channels are configured for bridged 2­channel operation

• Lowest recommended impedance for both front and rear
channels is 4Ω

• Crossover and gain configurations are independently
adjustable between the front and rear channels

• 2-channel operation is recommended for this operational
mode

• Front and rear outputs can be configured for high-pass,
low-pass or full range operation

• Front and rear outputs can be configured for stereo (front
channels will have right output, rear channels will have
left output or summed 2-channel operation

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page 22

SPEAKER CONNECTIONS TRI-MODE 6-CHANNEL CONFIGURA TION

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4 Ohm Minimum

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4 Ohm Minimum

• Lowest recommended impedance is 2Ω stereo and 4Ω
bridged mono

• Front and rear outputs must be set for full range
operation

• Front and rear outputs must be configured for stereo
operation

• Passive crossover frequencies must not overlap.

WARNING! Failure to do so may result in damage to
the amplifier

page 23

OUTPUT CONFIGURATIONS

Three position switches determine output configuration for the XTREME amplifiers. Each stereo pair of channels can be configured in either stereo,
summed-bridged and bridged-mono. The switch or switches are located on he outermost edge of the amplifier.

When the switch is in the left position, the output channels are configured for stereo operation.

When the switch is in the center position, the output channels are configured for summed mono operation by
mixing the left and right input signals together.

When the switch is in the right position, the output channels are configured for a single bridged output using a
single RCA input. T o determine which RCA to use, refer to the marking in parenthesis. For the front outputs, the Left
RCA input is used. For the rear outputs, the Right RCA input is used.

4-CHANNEL AMPLIFIER INPUT CONFIGURATIONS

The 2-channel input / 4-channel input switch routes RCA input from the front RCA inputs to the rear section of the amplifier . This
allows the XTREME 4-channel amplifier to utilize a single set of RCAs to feed signal to both the front and rear channels of the
amplifier.

When the switch is in engaged, signal from the front RCA input is routed to the rear RCA inputs.
NOTE: In this configuration, the rear RCA inputs can be routed to another amplifier . The signal leaving the amplifier is a copy of

the incoming signal.
When the switch is disengaged, front and rear RCA inputs are independent. This allows a source unit with an internal fader to

fade between the front and rear outputs.

page 24

RCA INPUT / CH 1 & 2 XVR

The RCA Input / 1 & 2 XVR push button switch configures the input for Channels 3 & 4. The feature allows the more
advanced crossover features of the front channels to be routed to both the front and rear channels. Configured in this
manner , INTELLiQ is now available on all channels of the amplifier as well as bandpass crossovers for midbass and
midrange speakers.

When the switch is disengaged, the rear RCA input feeds channels 1 & 2.
When the switch is engaged, channels 3 & 4 receive input signal from the output of channels 1 & 2 after the crossover

output. When the switch is in engaged, signal from the front RCA input is routed to the rear RCA inputs. The front gain
control controls the level of the entire amplifier . The rear gain controls are deactiviated.

REAR INTERNAL CROSSOVER CONFIGURATION

The XTREME 600.4 use multi-position switches to determine the rear crossover configuration. The multi-position switch is located on the adjust­ment side of the amplifier . Listed below are the switch positions and their respective crossover configurations.

When the switch is in the “OFF” position, the crossover section of the amplifier is bypassed. Amplifier output is full
range.

When the switch is in the center position, the crossover is configured for high-pass operation. The rear channels of
the XTREME 600.4 are continuously variable from 45Hz to 5kHz.

page 25

REAR INTERNAL CROSSOVER CONFIGURATION

When the switch is in the right position, the crossover is configured for low-pass operation. The rear channels of the
XTREME 600.4 are continuously variable from 45Hz to 5kHz.

FRONT INTERNAL CROSSOVER CONFIGURATION

The front channels of the XTREME 600.4 can be configured for either high-pass, low-pass or bandpass operation. INTELLiQ is a feature of the
amplifier that maximizes the performance of any subwoofer system. INTELLiQ is the one feature that seperates ORION amplifiers from the
compitition.

600Hz

5kHz

6dB

10dB

120Hz

1kHz

175Hz 45Hz

LP ON

LP OFF

600Hz

5kHz

175Hz 45Hz

LP ON

LP OFF

3dB 0dB

HP x 10

HP x 1

6dB

10dB

3dB 0dB

HP x 10

HP x 1

35Hz 10Hz

HP ON

HP OFF

120Hz

1kHz

35Hz 10Hz

HP ON

HP OFF

When the puch button switch is in the “off” position, the low-pass crossover is bypassed.

When the push button switch is in the “on” position, the low-pass crossover is activated. The
crosso ver frequency range is from 45Hz to 5kHz. There are additional reference points at 85Hz,

2.5kHz and 3.5kHz respectively.

page 26

FRONT INTERNAL CROSSOVER CONFIGURATION

When the puch button switch is in the “off” position, the high-pass crossover is bypassed.

When the push button switch is in the “on” position and the “x10” button is on the on position,
the high-pass crossover is activated in the “high” range. The crosso ver frequency range is from
100Hz to10kHz. There are four corner frequencies at 100Hz, 350Hz, 1,200Hz and 10kHz. This
range is usefull when used with smaller diameter midrange and tweeter speakers.

When the push button switch is in the “on” position and the “x10” button is on the off position,
the high-pass crossover is activated. The crosso ver frequency range is from 10Hz to1kHz. There
are four corner frequencies at 10Hz, 35Hz, 120Hz and 1kHz. This range is usefull when used with
larger diameter midrange and midbass speakers. Additionally, this can also be used as a “subsonic
filter” to prevent potentially damaging low-frequency from getting to your subwoofer .

page 27

350 Hz

FINE TUNING INTERNAL CROSSOVER

85Hz

When the puch button switch is in the “off” position, the high-pass crossover is bypassed.

2,500Hz

3,500Hz

When the push button switch is in the “on” position and the “x10” button is on the on position,
the high-pass crossover is activated in the “high” range. The crosso ver frequency range is from
100Hz to10kHz. There are four corner frequencies at 100Hz, 350Hz, 1,200Hz and 10kHz. This
range is usefull when used with smaller diameter midrange and tweeter speakers.

1,200 Hz

10 kHz

When the push button switch is in the “on” position and the “x10” button is on the off position,
the high-pass crossover is activated. The crosso ver frequency range is from 10Hz to1kHz. There
are four corner frequencies at 10Hz, 35Hz, 120Hz and 1kHz. This range is usefull when used with
larger diameter midrange and midbass speakers. Additionally, this can also be used as a “subsonic
filter” to prevent potentially damaging low-frequency from getting to your subwoofer.

100 Hz

page 28

INTELLI Q

Graph 17 > Active Filter Transfer Function: dB,Phase dB

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10

5

0

-5

-10

-15

-20

-25

10 Frequency 50 100 Hz 500 1K

In the world of “me too features,” Orion has developed the INTELLi Q circuit that makes a real difference
in your automotive listening experience.

INTELLi Q (INTELLigently integrated Q adjustment) is actually an infinitely variable “Q” adjustment found
on the high-pass crossover of new XTREME and HCCA “Type R” power amplifiers. By changing the “Q” of
the high-pass from the industry standard 0.707 to any “Q” value between 0.707 and 3.5 (Figure 1), the
high-pass filters essentially becomes two filters: a single band parametric equalizer and a subsonic filter .

By increasing the “Q” value from 0.707 to 3.5, the output is boosted up to 10dB at the high-pass crossover
frequency . The end-panel display is clearly marked in 3dB boost steps. Unlike other manufacturers
“subsonic filters,” adjusting the INTELLi Q’s high-pass crossover frequency easily performed turning the
crossover pot located directly to the right of the “Q” adjustment (Figure 2). The high-pass crossover is
continuously variable from 10Hz to 1kHz or 100Hz to 10kHz via a x10 frequency selector . By correctly using
the INTELLi Q, you can increase low frequency output by as much as 10dB!

Boosting the lower bass frequency does not come without trade-offs. As anyone knows, one of the
greatest potentials for woofer damage is caused by over excursion. Excursion is the forward and backward
movement of a woofer . When the signal to the woofer is incorrectly boosted, the woofer is required to
move more than is capable. For reference, a 6dB of boost requires a woofer to quadruple its excursion to
match the input signal. Ordinary bass boost equalizers boost without protection. Without any protection,
potential for damage is high.

The difference of INTELLi Q
What makes the INTELLi Q different from all other equalizers or sub-sonic filters is that it can boost lower

frequencies the woofer can produce by 10dB while preventing over excursion that can damage the woofer .
The result is your woofer with the loudest low bass it can produce reliably. Here’ s how to use it.

C

page 29

INTELLI Q

Setting up and using INTELLi Q

1. The first step to using the INTELLi Q is to install the amplifier. Seriously , basic installation techniques for new XTREME and HCCA “T ype R”
amplifiers remain unchanged. Set the low-pass crossover as you would in “normal” installations. (Normal Orion of course.)

2. Determine which type of enclosure you are using. Refer to the table below for tuning assistance. For example: for vented enclosures, set the
high-pass crossover to the tuning frequency (port frequency) of the enclosure. If you have a woofer such as the new HCCA woofers up to
10dB of boost can be used. For woofers of lesser excursion capability, it is recommended to use up to 6dB of boost only.

3. For RTA tuning, start the INTELLi Q boost setting at 0dB. Using pink noise, slowly increase the Q adjustment until the desired frequency
response is achieved. In situations where you are require more boost than is recommended, you can lower the crossover frequency to get a
similar desired effect.

4. For tuning by ear , start the INTELLi Q boost setting at 0dB. Using music the high-energy low frequency content, slowly increase the Q
adjustment until the desired sonic performance in achieved. In situations where you are require more boost than is recommended, you can
lower the crossover frequency to get a similar desired effect

Boost Levels

0dB

+3dB

+6dB

+10dB

Enclosure Type :
Infinite Baffle

Sealed

Vented

Sealed Bandpass

Vented Bandpass

Aperiodic

Acceptable No Problems

Tune above Fs of woofer

Acceptable No Problems

Tune above Fs of woofer

Acceptable No Problems

Tune to port frequency

Acceptable No Problems

Tune above Fs of woofer

Acceptable No Problems

Tune to port frequency
Set crossover to Fs of woofer

High X-Max Drivers Tune

above Fs of woofer

Acceptable No Problems

Tune above Fs of woofer

Acceptable No Problems

Tune to por t frequency

Acceptable No Problems

Tune above Fs of woofer

Acceptable No Problems

Tune to por t frequency
Set crossover to Fs of woofer

Not Recommended

High X-Max Drivers Tune
above Fs of woofer

Acceptable No Problems
Tune to port frequency

High X-Max Drivers Tune
above Fs of woofer

Acceptable No Problems
Tune to port frequency

Set crossover to Fs of woofer

Not Recommended

Not Recommended

High X-Max Drivers Tune to
port frequency

Not Recommended

High X-Max Drivers Tune to
port frequency

Not Recommended

page 30

REMOTE GAIN

The remote gain port allows remote, user control over the output of the amplifier . When used on a
subwoofer amplifier , the remote gain allows you to change the bass level for different music styles, driving
conditions, or sonic preferences. Unlike other designs, Orion allows remote access to the level of the
amplifier via a digital micro-controller and electronic volume that does not interfere with the sonic signal
chain. The result is a clean clear control of the level of the amplifier that is unaffected by noise.

The XTREME 600.4 has two remote gain ports. This allows for individual control of either the front or rear
channels. One RGC-1 can be used to control the level of the front channels and another RGC-1 can be used
to control the output level of the rear channels. An example benefit of this is having the front channels in
bandpass mode for midbass and the rear channels in low-pass mode for subwoofers. Using two RGC-1 would
give the driver the ability to control the level of both the midbass and subwoofers for easy optimal tuning.
To utilize this function simply plug-in a RGC-1into either the front or rear gain ports. The RGC-1 is available
from your authorized ORION dealer . T

SIGNAL INPUT AND OUTPUT LEVEL CONTROLS

XTREME amplifiers have separate front and
rear level adjustments. The input sensitivity
of these adjustments range from 200mv up
to 5Vrms on the RCA inputs. This allows easy
integration from any source unit either with
RCA outputs or speaker outputs. Refer to
the Testing the System and the Adjusting
the Sound of the System sections for
detailed instructions on setting up the level
controls.

page 31

CHOOSING MOUNTING LOCA TIONS

12V+ GND

SPEAKER OUTPUTS

REM BRIDGED

RIGHT LEFT

REM
GAIN

REMOTEFUSE POWER

1" Minimum

The location of your XTREME amplifier will depend on several important issues. Due to the low profile size of the XTREME 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 mounting surface. As with any amplifier, there are several
possible mounting locations and configurations that can be optimal. We will cover the most obvious of situations.

PASSENGER COMPARTMENT
If you are going to mount the amplifier in the passenger compartment, make sure you have
adequate room for ventilation. XTREME amplifiers have been designed to make possible under seat
mounting. When mounting your amplifier under a seat or similar area, keep a minimum of 1” of
clearance around the amplifier for adequate cooling.

TRUNK COMPARTMENT
Mounting XTREME amplifier in the trunk provides excellent performance as long as you do not
mount the amplifier upside down or restrict the airflow around the heatsink of the amplifier. For
optimal results, mount the amplifier with the cooling fins in the vertical position. This type of

SPEAKER OUTPUTS

GAIN

12V+ GND

REM

REMOTEFUSE POWER

REMOTEFUSE POWER

RIGHT LEFT

REM BRIDGED

REM BRIDGED

REM

RIGHT LEFT

SPEAKER OUTPUTS

12V+ GND

GAIN

mounting will yield the best cooling due to the convection effect of the amplifier chassis.

POWER

FUSE

12V+ GND

REMOTE

REM
GAIN

RIGHT LEFT

SPEAKER OUTPUTS

REM BRIDGED

ENGINE COMPARTMENT MOUNTING
Do not mount XTREME amplifier in the engine compartment. The amplifier was not designed to
endure the harsh environment of the exterior elements.

page 32

GENERAL PRECAUTIONS AND INSTALLATION TIPS

Caution: 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 the XTREME amplifier unmounted. Failing to securely mount the amplifier can result in damage or injury, particularly in the event of

an accident. An unmounted amplifier acts like a heat-seeking missile in the event of a crash. Never mount a XTREME amplifier where it might
get wet. Mount the XTREME 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, ideally 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 XTREME amplifier, replace the fuse with the same size ATC 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
current fuse may result in damage to the XTREME amplifier which is not covered under warranty.

NOTE: Make sure all the equipment in the system is turned off when making or breaking connections to the XTREME input RCAs or speakers
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 XTREME amplifier can be supplied by most any automotive electrical system. Systems with multiple amplifiers
may require a higher capacity battery, alternator or the use of a storage capacitor. WE strongly recommend the use of both a Transient Storage
Capacitor and a MBR70 with an extra battery in larger stereo systems.

XTREME amplifiers generate a certain amount of heat as part of normal operation. Be sure the area around the cooling fins is unobstructed to
allow adequate air circulation. Remember, beach blankets, last weeks laundry, school books and homework papers located on top of the
amplifier, do not improve air flow.

page 33

STEP BY STEP INSTALLATION

Step 1 Determine the location for the amplifier . Refer to the Mounting Locations section in this manual for detailed information.
Step 2 Decide on the system configuration for your amplifier. For system suggestions, refer to the System Planning section of this manual.
Step 3 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

Step 4 Pre-drill amplifier mounting holes. Be sure to "think before you drill". Gas tanks, fuel lines, and other obstructions have a nasty way of

Step 5 Mount the amplifier . Make sure the amplifier is mounted on a flat surface. If this is not possible, do not over tighten the screws such that

Step 6 Turn the vehicle’s key switch on the off position.
Step 7 Disconnect the vehicle’s battery ground terminal.
Step 8 Connect the RCA and speaker wires to the amplifier. Check the quality of your speakers and signal connections. This will determine the

Step 9 Connect power wires to the amplifier. At this time do not connect the fuse at the main battery.
Step 10 Reconnect the ground terminal to the battery.
Step 11 Set crossovers. Refer to the Internal Crossover Sections of this manual for detailed instructions.
Step 12 Once satisfied that all connections and settings are correct, install the fuse at located near the vehicle’s battery and proceed to the testing

WARNING! Never exceed the recommended fuse size of this amplifier. Failure to do so will result in the void of your warranty.

run RCAs, power and speaker wires away from factory electrical wires and system as they pose a great potential for induced system noise.

hiding themselves. For best results use a marking pen to mark the mounting holes and pre-drill these holes with a standard 1/8" drill bit.

the chassis of the amplifier is twisted or bent.

ultimate performance of your ORION amplifier. Refer to the Input section of this manual for correct wiring instructions.

the system section of this manual.

page 34

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 XTREME system.

Step 1 Check all the wiring connections to be sure they are correct and secure.
Step 2 Turn the signal source volume control down all the way. Set any tone controls to their flat or defeated positions. This includes the

Step 3 Turn the level controls of the amplifier to their minimum positions.
Step 4 Turn the source unit on. Check to see if the remote power LED locate on the connection side of the amplifier is lit. If not, please refer

Step 5 If using a aftermarket source unit, turn the level controls of the amplifier about one quarter of a turn. Slowly increase the volume level

Step 6 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

Step 7 If the output is clear and undistorted, continue to the adjusting the sound of the system section of this manual.

loudness control.

to the power connections section and the trouble shooting section of this manual for instructions.

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 section and the trouble shooting section of this manual to solve your installation
problems.

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 configured properly, refer to the internal crossover section of this manual and take corrective
action.

page 35

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 down all the way . Set any tone controls to their flat or defeated positions. This includes the

Step 2 Turn the level controls of the amplifier to their minimum positions.
Step 3 Choose music with high dynamic content that you like and that you are familiar with and will be most often used in the system.
Step 4 Turn the unit up to its highest undistorted output level. If you lack test equipment, this point occurs between 3/4 to full volume depend-

Step 5 While listening to your chosen dynamic music, turn up the level control corresponding to the midrange output until you hear slight

Step 6 Turn up the level control corresponding to the tweeter output until you hear slight distortion and turn back the level control slightly for

Step 7 Fine tune crossover setting and output level between midrange and tweeters. Refer to the internal crossover section of this manual for

Step 8 Repeat Steps 5-7 for the rear speakers. If you do not have rear speakers continue to Step 10.
Step 9 Set levels between the front and rear midrange and tweeters for optimum front/rear balance.
Step 10 T urn up the level control corresponding to the woofer output until you hear slight distortion and turn back the level control slightly for

Step 11 Fine tune crossover setting and output level between satellite speakers and the woofers. Refer to the internal crossover section of this

Step 12 Enjoy your awesome ORION sound system.

loudness control.

ing on the quality of your source unit. Listen for any audible distortion, 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.

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.

an undistorted output. Depending on your system the midrange and tweeter output may be on the same output channels.

detailed instructions.

an undistorted output.

manual for detailed instructions. If using an RGC-1, adjust the level to match the output of the woofer to match the sonic requirements
of the system.

page 36

page 37

TROUBLESHOOTING TIPS

SYMPTOM PROBABLE CAUSE ACTION TO TAKE
No output Low or no remote turn-on input Check remote turn-on voltage output at amplifier and fix as needed.

Fuse blown Check power wire integrity and check for speaker shorts.

Power wires not connected Check power wire and ground connections and fix or replace as needed.
Audio input not connected Check RCA connections and fix or replace as needed.
Speaker wires not connected Check speaker wires and fix or replace as needed.
Speakers are blown Check system with known working speaker and fix or replace

Audio cycles on Thermal protection engages when Make sure there is proper ventilation for amplifier and improve
and off amplifier heatsink temperature ventilation as needed .

exceeds 90°C (190°F)
Loose or poor audio input Check RCA connections and fix or replace as needed.
Loose power connections Check power wire and ground connections and fix or replace as needed.

Distorted output Amplifier level sensitivity set too high Readjust gain. Refer to Adjusting the Sound of the System

Exceeding maximum capability section of this manual for detailed instructions.
of amplifier

Impedance load to amplifier too low Check speaker impedance load, if below 2Ω stereo or 4Ω mono.

Shorted speaker wires Check speaker wires connections and fix or replace as needed.
Speaker not connected to Check speaker wiring and fix or replace as needed. Refer to the

amplifier properly Speaker Connections section of this manual for detailed instructions.

Fix as needed and replace fuse.

speakers as needed.

rewire speakers to achieve a higher impedance.

page 38

Distorted output Internal crossover not set properly Readjust crossovers. Refer to the Internal Crossover section of this

Poor bass response Speakers wired with wrong polarity Check speaker polarity and fix as needed.

Battery fuse Short in power wire or incorrect Check power and ground connections and fix or repair as needed.
blowing power connections.

Amplifier fuse Too much current being drawn Check speaker impedance load, if below 2Ω stereo or 4Ω mono rewire
blowing speakers to achieve a high impedance and replace with recommended

for speakers manual for detailed instructions.
Speakers are blown Check system with know working speakers and fix or replace as needed.

causing cancellation at low frequency
Crossover set incorrectly Reset crossovers. Refer to the Internal Crossover section of this manual

for detailed instructions.

Impedance load at amplifier is too low Check speaker impedance load, if below 2Ω stereo or 4Ω mono

rewire speakers to achieve a higher impedance.

Fuse used is smaller than recommended Replace with proper fuse size.
Too much current being drawn Check speaker impedance load, if below 2Ω stereo or 4Ω mono

rewire speakers to achieve a high impedance.
Check power and ground connections and fix or repair as needed.

size fuse.

Check power and ground connections and fix or repair as needed.
Fuse used is smaller than recommended Replace with proper fuse size.
Impedance load at amplifier too low Check speaker impedance load. If below 2Ω stereo or 4Ω mono, rewire

speakers to achieve a higher impedance.
Speaker is blown with shorted outputs Check system with known working speakers and fix or replace as needed

page 39

AUTOSOUND 2000 TROUBLESHOOTING TIPS

QUICK CHECK FOR TROUBLESHOOTING CAR AUDIO SYSTEMS
Preface:

All audio systems exhibit noise; however, if the level of noise is low enough, and the signal level high enough, noise should
not be a problem. This means that it is very important that the signal level throughout the system be optimized BEFORE
dealing with your noise problem. Using a scope (or a small portable amplifier) and Track 99 (1kHz at all high bits) of
Autosound 2000’s CD #101, or tracks 24 through 29 of Autosound 200’s CD #102, adjust the system so that when the maximum
usable signal level of the deck is fed into the system, all the preamp level components clip at the same time. However, we
recommend up to as much as a 3:1 voltage overlap with the power amplifiers; i.e. an amplifier with a 2 volt minimum sensi­tivity can be driven by up to 6 volts of signal.

Noise Overview:
Car audio electrical accessories are notorious for interfering with car audio systems. The interference commonly arises from

three areas:

1) Power line noise (5%), which can be attenuated with in-line noise filters,

2) Inadequate power supply isolation (45%), which can be cured with transformer signal coupling, additional isolated power
supplies, or changing out components, or

3) Inductive interference (45%) - Including loop area inductive noise picked up by the signal cables - which can be remedied
by relocating or rewiring components, rerouting signal cables, or using twisted cable or balanced transmission systems.

AUTOSOUND 2000 1-2-3 METHOD OF LOGICAL TROUBLESHOOTING

I. MUTE THE AMP(S). Insert a muting plug (shorted male RCA connector) into each amplifier channel. T urn up the amp sensitivity . Start the car

and turn on the headlights, air conditioning, brake lights, etc. Listen for noise in each speaker . Be very picky here!
A. If still noisy, substitute a small test speaker with short leads for the speakers, crossovers, and speaker leads in the car. If still noisy,

substitute an isolated power supply (120 VAC to 13.8 VDC bench supply or a small motorcycle battery) for the car’s alternator. If the
amplifier is noisy with the test speaker , you have a BAD amp. Send it in. It really doesn’t matter if it is quiet or noisy whil e running on the
isolated supply because you have a BAD amp. Send it in for repair and if it was quiet on the isolated supply, indicate so on the repair tag.

page 40

B. If your muted amp is quiet, you’ve just joined 99.5% of car audio. Amps are usually very clean and do NOT pick up

unwanted noise! Continue on to Step II.

II. DECK TO AMP. Using a new set of signal cables, connect one channel from the output of the deck directly into one

channel of your clean amp. Run the cables outside the car and as far away as possible from the metal of the car. (For
noise purposes, consider a 2" thick cushion of electromagnetic energy emanating from every metal surface in the car.)

A. If still noisy, congratulations, in all probability your equalizer, electronic crossover, DSP whatchamacallit, are just fine.

This means that you can’t get your deck playing quiet with your amp, right? go to Step III.

B. If all is quiet, congratulations, in all probability your deck and amplifier(s) are fine - you obviously have a problem

with your equalizer, electronic crossover, DSP, etc. Skip on down to “Time for the Processors.”

III. MOVE THE DECK. If you’re at this step, it is time to turn your system into an “amplified deck” by temporarily relocating

the deck right ON TOP of the clean amplifier. Then using very, very short signal cables, connect the output of the deck
into the input of the amp and test for noise. Play a zero bit track - silence - and make sure all is completely quiet.

A. If still noisy, you’re in a heap of trouble, We suggest that you try another deck and give us a call so that we can put

your name into the record books. It’s a bad car audio day for you.

B. If the deck is quiet, then congratulations, you’re on your way to a successful installation. It is now time to slowly,

methodically, reinstall the deck back into its final position. Test for noise each step of the way. If the noise returns,
suspect the signal cables, forget shielding because it will have only a very, minimal effect within the audio band. We
highly suggest using twisted pair cables or a balanced transmission system for cable induced noise.

TIME FOR PROCESSORS

By the end of Step III, you should have the deck playing quietly with the amp, with the quiet cables quietly routed. So it’s
time to add the signal processors - one at a time - back into the system. Simply repeat Steps II and III with the equalizer, then
the electronic crossover, etc. However, before MOVING THE SIGNAL PROCESSORS to the amplifier, we highly suggest that
you supply power to the noisy processor from an isolated power supply rather than the car’s +12 volt DC and chassis ground.
Make sure to also connect the turn-on lead to the isolated power supply. If the processor is now quiet , then it is highly

page 41

probable that the component has inadequate isolation. Solutions include, changing components or permanently adding an
external isolated power supply (Call Autosound 2000 at 209-465-3450 for info on isolated power supplies).

SUMMATION

During the design stage of your vehicles, try to avoid using extra batteries and high output alternators. Extra batteries are
nothing but loads as soon as the engine is started and high output alternators usually make more noise than stock alterna­tors. Also, extra batteries installed in the trunk of a car will ALWAYS force extra ripple current to flow over the car.

Install Transient Storage as close to the power supply input of your amplifier as possible. The big caps will feed the switching
power supplies of your amps and minimize the inductive losses in your power wiring. Plus, they will help your peak system
response.

In problem cases, we highly recommend the use of twisted pair cable rather than coaxial cable for RCA leads. This practice
will greatly minimize cable induced noise - especially in four channel amps!

Don’t forget that your system is only as good as its worst component. Do NOT use components with inadequate power supply
isolation or you will be asking for problems.

The best electrical ground on a car is the CHASSIS of the car. Do NOT run ground leads up to th
e case of the alternator or the negative battery post. Keep ALL ground leads as short as possible.
With properly isolated components, it does NOT matter where the component is grounded. With inadequately isolated

components, it matters! With poorly isolated components, different grounds can cause different noises.
The deck is the signal reference ground for the entire sound system. The deck usually has THREE connections to the car’s

chassis: The black ground lead, the base of the antenna, and the metal-to-metal bond between the case of the deck and the
chassis of the car. With three grounds, there is usually NO cause to worry about the ground of a deck.

Amplifiers are usually designed with adequate power supply isolation. This means that it should not matter where a deck is
grounded. (Decks are grounded three times and amps float. This is car audio!)

page 42

The more components installed on a signal path, the more chances for noise to enter a system. The more electrical accessories
on a car, the more noise will be produced by the alternator.

This information was compiled from more than 20 years of working in car audio. If you would like more information on this
topic, or any other technical aspect of car audio, please call 209-465-3450 and ask for a subscription to Autosound 2000 Tech
Briefs - the monthly magazine for the technically inclined.

page 43

HIGH PERFORMANCE CAR AUDIO
AMPLIFIERS, SIGNAL PROCESSORS

AND

LOUDSPEAKERS

H

IGH PERFORMANCE

©1998 Orion Industries, Incorporated
9235 S. McKemy St., Tempe, Arizona 85284
Phone: [phone] Fax: [phone]

CAR A

UDIO

One of the ADST family of companies
Part#8900-0114 4/99