Warranty

LIMITED TWO YEAR CONSUMER WARRANTY:

Directed Electronics promises to the original purchaser, to replace this product should it prove to
be defective in workmanship or material under normal use, for a period of two years from the date
of purchase by the dealer as indicated by the date code marking of the product PROVIDED the
product was installed by an authorized Directed dealer. During this two year period, there will be
no charge for this replacement PROVIDED the unit is returned to Directed, shipping pre-paid. If
the unit is installed by anyone other than an authorized Directed dealer, the warranty period will
be 1 year from date of purchase by the dealer as indicated by the date code marking of the HCCA-D600
product. During this 1 year period, there will be no charge for this replacement PROVIDED the
unit is returned to Directed, shipping pre-paid. This warranty is non-transferable and does not
apply to any unit that has been modified or used in a manner contrary to its intended purpose,
and does not cover damage to the unit caused by installation or removal of the unit. This warranty
is void if the product has been damaged by accident or unreasonable use, neglect, improper service
or other causes not arising out of defects in materials or construction. ALL WARRANTIES
INCLUDING BUT NOT LIMITED TO EXPRESS WARRANTY, IMPLIED WARRANTY, WARRANTY
OF MERCHANTABILITY, FITNESS FOR PARTICULAR PURPOSE, AND WARRANTY OF NON-
INFRINGEMENT OF INTELLECTUAL PROPERTY ARE EXPRESSLY EXCLUDED TO THE
MAXIMUM EXTENT ALLOWED BY LAW, AND DIRECTED NEITHER ASSUMES NOR
AUTHORIZES ANY PERSON TO ASSUME FOR IT ANY LIABILITY IN CONNECTION WITH THE
SALE OF THE PRODUCT. DIRECTED HAS ABSOLUTELY NO LIABILITY FOR ANY AND ALL ACTS
OF THIRD PARTIES INCLUDING ITS AUTHORIZED DEALERS OR INSTALLERS. Unit must be
returned to Directed, postage pre-paid, with: consumer's name, telephone number, and address,
authorized dealer's name and address, and product description. IN ORDER FOR THIS WARRANTY
TO BE VALID, YOUR UNIT MUST BE SHIPPED WITH PROOF OF INSTALLATION BY AN
AUTHORIZED DIRECTED DEALER. ALL UNITS RECEIVED BY DIRECTED FOR WARRANTY
REPAIR WITHOUT PROOF OF DIRECTED DEALER INSTALLATION WILL BE COVERED BY THE
LIMITED 1 YEAR PARTS AND LABOR WARRANTY. Note: This warranty does not cover labor costs
for the removal and reinstallation of the unit.
BY PURCHASING THIS PRODUCT, THE CONSUMER AGREES AND CONSENTS THAT ALL
DISPUTES BETWEEN THE CONSUMER AND DIRECTED SHALL BE RESOLVED IN ACCORDANCE
WITH CALIFORNIA LAWS IN SAN DIEGO COUNTY, CALIFORNIA.

© 2006 Directed Electronics, All rights reserved. G47500 05-06

 CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
What’s in the Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Practice Safe Sound™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Record Your Serial Number and Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
End Panel Layouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
CEA Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Amplifier Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Signal Input and Output Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Input Gain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Phase Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Line Output Configurations (System Expansion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Low-Pass Crossover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Fine Tuning the Crossovers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Adjusting INTELLi-Bass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Infinite Baffle Example High-Pass Set at 30Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Sealed Example High-Pass Set at 20Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Sealed Example High-Pass Set at 30Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Vented Example High-Pass Set at 30Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Remote Gain Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Power Connections for the HCCA-D600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Speaker Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Bridging (strapping) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Amplifier Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Choosing Mounting Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Passenger Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Trunk Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
General Precautions and Installation Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Tools of the Trade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Step By Step Installation-amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Step By Step Installation-remote gain control (RGC-1)—option . . . . . . . . . . . . . . . . .15
Set Up and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Testing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Adjusting the Sound of the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Troubleshooting Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

© 2006 Directed Electronics—all rights reserved 1

 INTRODUCTION

Thank you for your purchase of Orion's HCCA-D600 power amplifier. Each Orion amplifier
is designed to be the leader in its class offering the most power, advanced features, and
extreme ease of use. In high-end sound systems or high SPL systems, Orion amplifiers will
give you years of trouble-free performance.

● HCCA-D600 - 600 Watt single-channel Class D amplifier with built-in fully variable
high-pass, low-pass, or band-pass crossover with INTELLi BASS. Equipped with
optional remote gain, the 600D is capable of one-channel operation with a max-
imum power of 600 Watts into 1W.

The installation of all Orion components will determine the overall performance result.
Improper installation will not only limit the performance of your Orion system but also
potentially compromise the reliability of this amplifier. To ensure proper sonic results and
component reliability, please refer to your authorized Orion dealer for installation assis-
tance or advice. If you decide to perform the installation yourself, be sure to read the entire
manual before beginning the installation.

What’s in the Box

● (1) Amplifier
● (1) Spare fuse
● (1) Allen wrench 4mm
● (1) Allen wrench 3mm
● (1) Hardware pack (screws and washers)
● (1) Amplifier installation and operation manual
● (1) Orion vinyl window sticker

PRACTICE SAFE SOUND™

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

2 © 2006 Directed Electronics—all rights reserved

 RECORD YOUR SERIAL NUMBER AND DATE

To ensure your warranty (see back cover), please record the following information regard-
ing your new amplifier.

Model: __________________________________________________
Serial Number: __________________________________________________
Date of Purchase: __________________________________________________
Purchased from: __________________________________________________

© 2006 Directed Electronics—all rights reserved 3

 END PANEL LAYOUTS

1 2 3 4 5 6 7 8 9 10

INPUT LINE OUT INTELLI

POWER
(GREEN)
L CH L CH GAIN INFRASONIC LPF REMOTE PHASE
BASS

MASTER SLAVE ON OFF

MIN MAX MIN MAX 30Hz 250Hz Oº 180º
PROTECT
(RED)

R CH R CH

1. RCA Input - accepts RCA input from a head unit, preamplifier, or equalizer.
2. RCA Line Output - provides easy connection to additional amplifiers.
3. Master/Slave Switch - controls whether the amplifier is a slave or master when
connected in combined amplifier configurations. (Refer to the Line Output
Configurations section of this guide.)
4. Gain Control - continuous adjustment for full power output.
5. Infrasonic Switch - when On cuts off extremely low bass frequencies (below the
range of human hearing, that speakers cannot effectively reproduce). Improves
efficiency of the amplifier’s power supply, improves sound reproductive perform-
ance, and reduces chances of damaging the subwoofers.
6. Intelli-Bass - adjusts the bass for up to 18dB of boost equalization.
7. LPF - this filter attenuates high frequencies and sets the high frequency limit of
the subwoofer channel (adjustable from 30 to 250 Hz).
8. Remote Bass Input - connects optional HP-RB1 remote bass control to control
the bass level from the driver’s seat.
9. Phase Control Switch - provides either 0 or 180 degree phase shift of the ampli-
fied output (speaker) with respect to the input signal to facilitate bridging of
amplifiers.
10. Power LED - when illuminated (green) indicates that the amplifier is on.
11. Protect LED - when illuminated (red) indicates that the amplifier protective
cirucitry has been activated due to thermal, output short, supply undervoltage or
supply overvoltage.

1 2 3 4 5

SPEAKER
FUSE +BAT REM GND + + - -

1. 1 ATC Fuse - this 40A fuse protects the amplifier against internal electrical dam-
age and is meant to protect the amplifier only. All other power connections
should be fused at the source.
2. +BAT - connect this terminal through a FUSE or CIRCUIT BREAKER to the positive
terminal of the vehicle battery or the positive terminal of an isolated audio sys-

4 © 2006 Directed Electronics—all rights reserved

 tem battery.
WARNING: Always protect this power wire by installing a fuse or circuit breaker of the
appropriate size within 12 inches of the battery terminal connection.

3. REM - this terminal turns on the amplifier when (+) 12 volt is applied. Connect it
to the remote turn on lead of the head unit or signal source. If a (+) 12 volt remote
turn lead is not available, a Remote Power Adapter (P/N #55000) can be used to
supply a remote turn on signal. DO NOT connect this terminal to constant (+) 12
volt.
4. GND - power return connection. Connect this terminal directly to the sheet metal
chassis of the vehicle, using the shortest wire necessary to make this connection.
Always use wire of the same gauge or larger than the (+) 12 volt power wire. The
chassis connection point should be scraped free of paint and dirt. Use only quali-
ty crimped and/or soldered connectors at both ends of this wire. DO NOT connect
this terminal directly to the vehicle battery ground terminal or any other factory
ground points.
5. Speaker - connect the speakers to these terminals. (refer to the Speaker
Connection section of this guide.)
NOTE: Make all connections to power, ground, speakers, and remote terminals before
final positioning and installation of the amplifier in the vehicle.

CEA SPECIFICATIONS

HCCA-D600

Power Output: 150 Watts RMS x 1 at 4 ohms and < 1% THD+N

Signal to Noise Ratio: -60 dBA (reference 1 Watt into 4 ohms)

Additional Power Output: 300 Watts RMS x 1 at 1 ohm at 14.4 Supply <1% THD+N

© 2006 Directed Electronics—all rights reserved 5

 SPECIFICATIONS

Amplifier Section HCCA-D600

Power Output 4W (Watts)note 1 150 x 1

Power Output 2W (Watts)note 2 200 x 1

Power Output 1W (Watts) 300 x 1

Amplifier Efficiency > 70% into 1W load at max. power

Externally Bridgeable yes

Remote Bass Function yes (optional HP-RB1 not supplied)

Distortion at Rated Power < 1.0% THD+N

Frequency Response 20Hz to 250Hz ±2.5dB

Linear Bandwidth 10Hz to 500Hz ±3dB

Damping Factor > 200

Input Sensitivity 150mV to 5V rms

Supply Voltage Range 9 to 16V

thermal, DC offset, reverse polarity,
Protection short protection, under-voltage, over-
voltage
Power 0/1 AWG, Remote 12 AWG,
Terminal Wire Gauge
Ground 0/1AWG, Speaker 12 AWG
Input Impedance 20kW

Fuse Type (1) 40 Amp ATC

Dimensions 13"x10.5"x2.3"

Weight 8 lbs.

Crossover Section

Low Pass Crossover Continuously variable (30-250Hz)

Selectable On/Off
Infrasonic Filter
24dB/Octave -6dB at 20Hz
Intelli-Bass 0–18dB boost

1. Continuous 4W load 20Hz to 250Hz, < 1% THD, with input voltage at 14.4VDC.
2. Continuous 1W load 20Hz to 250Hz, < 1% THD, with input voltage at 14.4VDC.

6 © 2006 Directed Electronics—all rights reserved

 AMPLIFIER SETTINGS

Signal Input and Output Configurations

The input section of the amplifier consists of a phase switch that sets the output configura-
tion, gain controls, and RCA inputs. The input section makes it easy to adapt this amplifier
to most system configurations.

Input Gain
The Orion HCCA D600 amplifier has a level adjustment to allow for easy integration with
any source unit. The input sensitivity can be adjusted from 150mV to 5V. Refer to Testing
the System and Adjusting the Sound of the System sections of this guide for detailed
instructions on setting the gain.

Phase Switches
● 0° - leaves output unaffected. The output signal is in phase with the input signal.
● 180° - inverts the output. The channel is 180° output of phase. This configuration
is useful for inverting the phase of subwoofers to improve staging in a vehicle.
This is also used when bridging two amplifiers into one speaker.

Line Output Configurations (System Expansion)

NOTE: When expanding your system by adding additional Orion amplifiers in the signal
chain use only the same model(s) as the first amplier in the chain.

The line outputs on Orion amplifiers offer easy, unlimited system expansion. Routing signal
from a source unit, pre-amplifier, or equalizer is a matter of connecting RCAs to the RCA
Inputs of the first Orion amplifier and then the RCA line outputs to the next Orion amplifi-
er’s RCA line inputs in the signal chain. Then the Master/Slave switch on each of the amplif-
ers is set as follows:

The first amplifier in the signal chain will have its Master/Slave switch set to the MASTER
position. In effect this first amplifier will set the gain for the remainder of the amplifiers in
the signal chain.

The remaining amplifiers following in the signal chain will have their Master/Slave switch
set to the SLAVE position. This allows the signal to be input directly, bypassing the subse-
quent amplifiers gain control. The audio level is set and supplied by the output of the mas-
ter amplifier at its gain setting.

Internal Crossover Configurations

The crossover section of the Orion HCCA D600 amplifier is continuously variable and
extremely flexible.

When using Orion loudspeakers, minor deviations from the recommended frequency
ranges can provide superior results depending on your speaker locations and your vehicle
acoustics. Setting crossover frequencies higher than recommended will not cause damage
and may provide superior sonic results depending on your system's performance goals.
Refer to your loudspeaker owner's manual for assistance in choosing the proper crossover
frequencies for your system.

WARNING! DO NOT set crossover frequencies lower than the speakers recommended

© 2006 Directed Electronics—all rights reserved 7

 operating range. This can cause driver failure that is not covered by the man-
ufacturer's warranty.

Low-Pass Crossover
The low-pass crossover adjusts the upper crossover of the filter and is continuously variable
from 30Hz to 250Hz.

Fine Tuning the Crossovers

The low-pass and high-pass crossover sections are each marked at four frequency points for
ease of system adjustment. The low-pass crossover section is marked at 30Hz, 50Hz, 150Hz,
and 250Hz. The high-pass crossover section is marked at 20Hz, 33Hz, 90Hz and 150Hz.
Specific crossover points can be chosen based on the recommended operational bandwidth
of your speakers.

Adjusting INTELLi-Bass
INTELLi-Bass on the rear channels maximizes the performance of a subwoofer and allows
for continuous adjustment of low frequency boost on the rear channels. INTELLi-Bass can be
adjusted from 0dB to 18dB of boost centered at 45Hz. Initially the Q is very low (wide). As
INTELLi-Bass is added, the Q rises (narrows). This allows the amplifier to overcome acoustic
deficiencies in your vehicle. The type of enclosure used, the sub-woofer's excursion capabil-
ity, personal preference, and attitude determine acceptable boost levels.

WARNING! Exercise caution when setting INTELLi-Bass. Maximum boost can potentially
cause woofer damage due to overexcursion.

Enclosure Type Boost Levels

0dB +3dB +6dB +10dB
Infinite Baffle Tune above High X-Max Not Not
Fs of woofer Drivers--Tune Recommended Recommended
above Fs of
woofer

Sealed Tune above Tune above High X-Max Not

Fs of woofer Fs of woofer Drivers--Tune Recommended
above Fs of
woofer

Vented Tune to port Tune to port Tune to port High X-Max

frequency frequency frequency Drivers--Tune to
port frequency

Sealed Band-pass Tune above Tune above High X-Max Not

Fs of woofer Fs of woofer Drivers--Tune Recommended
above Fs of
woofer

Vented Band-pass Tune to port Tune to port Tune to port High X-Max
frequency frequency frequency Drivers--Tune to
port frequency

Aperiodic Set crossover Set crossover Set crossover Not

to Fs of to Fs of to Fs of Recommended
woofer woofer woofer

8 © 2006 Directed Electronics—all rights reserved

 Infinite Baffle Example High-Pass Set at 30Hz
By removing low frequency signal that the woofer cannot produce, the woofer can play its
capable range louder. The first example is an infinite baffle situation. The left graph displays
the frequency response of a 12-inch woofer in an infinite baffle application without the
high-pass filter, with the filter and with the filter and the INTELLi Q set to +3dB. As you can
see, with +3dB of boost and the high pass filter set to 30Hz, the woofer has more output
down to 25Hz and less overall excursion when compared to the non-high-pass response.
Maximum physical excursion capability of the woofer is 15mm.

NOTE: The left graph is the response; the right graph is the driver excursion. These des-
ignations apply to the following graphs as well.

© 2006 Directed Electronics—all rights reserved 9

 Sealed Example High-Pass Set at 20Hz
This sealed example is the same 12-inch woofer in the recommended sealed enclosure. Up
to 6 dB of boost is capable if 20 Hz was used. With +6dB of boost, the woofer has more out-
put down to 15 Hz.

Sealed Example High-Pass Set at 30Hz

In this example, the frequency has been increased to 30 Hz. Up to 6 dB of boost is capable
at this frequency. With +6dB of boost, the woofer has more output down to 23 Hz. The
overall usable output is increased.

Vented Example High-Pass Set at 30Hz

Vented enclosures benefit most from the INTELLi Q. Up to 10 dB of boost is capable at the
box tuning frequency of 30 Hz. With +10dB of boost, the woofer has more output down to
22 Hz. The excursion below the tuning frequency has been greatly reduced.

10 © 2006 Directed Electronics—all rights reserved

 Remote Gain Operation
NOTE: Do not use the Remote Gain control when you have an expanded system installed
(see Line Ouput Configurations). The Slave amplifier(s) gain will not be controlled.

The remote gain port provides easy remote access to the internal gain structure of the HCCA
power amplifier. The RGC-1 plugs into the amplifier via the 1/8" mini jack plug. The RGC-1
can be installed in the front of the vehicle to control the amplifier gain level. The RGC-1 can
be used as a bass level control when used on an amplifier dedicated to subwoofers.

AMPLIFIER WIRING
Power Connections for the HCCA-D600
● Orion Fuse Size: 1 x 30 AMP ATC
● Power connections accept up to 0 AWG wire.
● 0/1 AWG power and ground wire recommended for optimal performance.
● Connect 12V+ to the battery through a fuse holder. This connection provides +12V
main power to the amplifier.
● Power wire must be fused no more than 18" from battery.
● Ground amplifier to a good chassis ground as close as possible to the amplifier.
● Connect REM terminal to remote turn-on lead from source unit. This connection
provides +12V power to turn-on the amplifier.
● Add extra ground wire between the negative terminal of the battery and the
chassis.

NOTE: The addition of a ground wire from the battery to the chassis of the vehicle
improves the ability of the battery to supply power to the amplifier. This is recom-
mended because the current delivery of the factory electrical system was designed
only to accommodate electronics supplied by the auto manufacturer.

Speaker Connections
The Orion HCCA-600D amplifier offer two positive and two negative output terminals for
ease of connecting the speakers to the amplifier. Since this is a mono amplifier, the speak-
er connectors are paralleled internally. The amplifier is stable to 1W.

MASTER SLAVE

© 2006 Directed Electronics—all rights reserved 11

 Bridging (strapping)
For bridging into a single speaker load, this amplifier has the ability to be bridged with
another amplifier (must be the same model). To do this you must utilize the MASTER/SLAVE
and PHASE switch settings. On the master amplifier, set the switch setting to MASTER. The
signal is then routed through RCA Line Out to the RCA Line In on the other (slave) amplifi-
er. The slave amplifier must have the MASTER/SLAVE switch set to the SLAVE position. On
the master amplifier make sure the PHASE swtich is set to the 0 position (factory default).
On the slave amplifier set the PHASE switch to 180, exactly opposite of the master amp.
Refer to the Phase Switches section of this guide.

On the slave amplifier be sure to turn the Intelli-Bass control to 0 (zero). For the speaker
connections, connect the positive (+) speaker lead from the speaker to the positive (+)
speaker terminal of the master amplifier. On the negative (-) speaker connection, take the
negative (-) speaker terminal of the master amplifier and connect it directly to the negative
(-) speaker terminal of the (slave) amplifier. The remaining positive (+) speaker terminal of
the (slave) amplifier must be connected to the negative (-) speaker lead from the speaker.
The impedance of the speaker must not exceed 1W.

NOTE: For best results, connect both negative speaker terminals on the master amp to
both negative terminals on the slave amp using at least 12 AWG cable.

MASTER AMPLIFIER SLAVE AMPLIFIER

PHASE PHASE

MASTER SLAVE 0° 180° MASTER SLAVE 0° 180°

AMPLIFIER INSTALLATION

Choosing Mounting Locations

The location of your amplifier will depend on several important issues. Due to the low pro-
file size of the Orion amplifiers, there are many possible installation locations that will yield
satisfactory amplifier performance. Always mount the amplifier in a place that protects the
amplifier from the elements. In addition, mount the amplifier on a stable, flat surface.

12 © 2006 Directed Electronics—all rights reserved

 NOTE: The wiring connections to the power, remote and speaker terminals should be
accomplished before the amplifier is mounted.

NOTE: Mounting amplifiers upside down is not recommended and may cause premature
thermal shutdown.

WARNING! Do not mount any amplifier in the engine compartment. Amplifiers are not
designed to endure the harsh environment of the exterior elements.

Passenger Compartment
If you are going to mount the amplifier in the passenger compartment, make sure you have
adequate room for ventilation. The amplifiers have been designed to make under-seat
mounting possible. When mounting your amplifier under a seat or similar area, keep a min-
imum of 1" of clearance around the amplifier for adequate cooling.

Trunk Compartment
Mounting your amplifier in the trunk provides excellent performance as long as you do not
restrict the airflow around the heatsink of the amplifier. For optimal results, mount the
amplifier with as much clearance as possible. This type of mounting will yield the best cool-
ing due to the convection effect of the amplifier chassis.

General Precautions and Installation Tips

WARNING! Be careful not to cut or drill into gas tanks, fuel lines, brake lines, hydraulic
lines, vacuum lines, or electrical wiring when working on your vehicle.

Disconnect the vehicle's ground wire at the battery before making or breaking connections
to the audio system's power supply terminals.

WARNING! Do not use this amplifier unmounted. Failing to securely mount the amplifi-
er can result in damage or injury, particularly in the event of an accident. An
unmounted amplifier becomes a dangerous projectile in the event of a crash.
Never mount the amplifier where it might get wet. Mount the amplifier so
the wire connections will not be pulled. Route the wires where they will not
be scraped, pinched or damaged in any fashion.

The +12V power supply wire must be fused as close as possible to the battery terminal, ide-
ally within 12". Use the recommended fuse size or circuit breaker listed in the Power
Connections section of this manual.

If you need to replace the fuse plugged into the side of the amplifier, replace the fuse with
the same size 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 cur-
rent fuse may result in damage to the amplifier that is not covered under warranty.

NOTE: Make sure all the equipment in the system is turned off when making or break-
ing connections to the input RCAs or speaker terminals. Turn on the system and
slowly turn up the volume control only after double checking all wire connections.

Power for systems with a single amplifier can be supplied by most automotive electrical sys-
tems. Systems with multiple amplifiers may require a higher capacity battery, alternator or
the use of a storage capacitor. We strongly recommend the use of a Directed Audio
Essentials power capacitor with an extra battery in larger stereo systems.

© 2006 Directed Electronics—all rights reserved 13

 Orion amplifiers generate a certain amount of heat as part of normal operation. Be sure the
area around the amplifier is unobstructed to allow adequate air circulation. Remember,
beach blankets, last week's laundry, school books and homework papers located on top of
the amplifier do not improve air flow and may become damaged.

Tools of the Trade

Listed below are the majority of the tools required to perform an installation. Having the
proper tools will make the installation that much easier. Some of these tools are necessities;
some will just make the job easier.

● Allen Wrenches (2.5mm and 3mm) supplied

● DMM or VOM
● Electric drill with assorted drill bits
● Grommets
● Heat shrink tubing
● Marking pen
● Nylon tie straps
● Phillips and flat blade screw drivers
● Pliers (standard and needle nose)
● Reference CD with 1 kHz Sine Wave at 0dB level (all bits high)
● RTA (real time analyzer)
● Soldering iron and solder
● Utility knife
● Wire brush or sandpaper for chassis grounding
● Wire crimper
● Wire cutters
● Wire strippers

Step By Step Installation-amplifier

Step 1 Determine the location for the amplifier. Refer to the Choosing Mounting
Locations section of this guide for detailed information.
Step 2 Decide on the system configuration for your amplifier. For system sugges-
tions, refer to the Speaker Connections section of this guide.
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 run RCAs and
power and speaker wires away from factory electrical wires and system as
they pose a great potential for induced system noise.
Step 4 Pre-drill amplifier mounting holes. Be sure to "think before you drill." Gas
tanks, fuel lines, and other obstructions have a nasty way of hiding them-
selves. For best results use a marking pen to mark the mounting holes and
pre-drill these holes with a standard 1/8" drill bit.
Step 5 Turn the vehicle's key switch to the off position.
Step 6 Disconnect the vehicle's battery ground terminal.
Step 7 Connect power wires to the amplifier (ground first, then 12 V(+) and REM).
Step 8 Connect the RCA and speaker wires to the amplifier. Check the quality of
your speakers and signal connections. This will determine the ultimate per-
formance of your Orion amplifier. Refer to the Signal Input and Output Level

14 © 2006 Directed Electronics—all rights reserved

 Controls and Speaker Connections sections of this guide for correct wiring
instructions.
Step 9 Mount the amplifier. Make sure the amplifier is mounted on a flat surface. If
this is not possible, do not over tighten the screws so that the chassis of the
amplifier is twisted or bent.
Step 10 Reconnect the ground terminal to the battery after power, speaker, and RCA
connections are completed.
Step 11 Set LPF crossover. Refer to the Internal Crossover Configuration section of this
manual for detailed instructions.
Step 12 Once satisfied that all connections and settings are correct, install the fuse
located near the vehicle's battery and proceed to either mounting the
remote bass control section or proceed to the Testing the System section of
this manual.

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

Step By Step Installation-remote gain control (RGC-1)—option

Step 1 Locate a convient location (under the dashboard on the driver’s side) for
mounting the RGC-1.
Step 2 Plug the remote bass cable into the amplifer.
Step 3 Run the remote bass cable from the amplifier location to the RGC-1. Do not
plug into the rear of the RGC-1 at this time.
Step 4 Pre-drill RGC-1 mounting holes. Be sure to "think before you drill." Electrical
lines, and other obstructions have a nasty way of 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.
Step 5 Mount the RGC-1 with the provided screws.
Step 6 Set the bass control on the RGC-1 to minimum.
Step 7 Connect the remote bass cable to the jack on the rear of the RGC-1.

SET UP AND TROUBLESHOOTING

Testing the System
After you have completed the installation, you need to test the system. This will help ensure
years of trouble-free operation. Please refer to the listed steps below when testing the
sound of your Orion system.

Step 1 Check all the wiring connections to be sure they are correct and secure.
Step 2 Turn the signal source volume control all the way down. Set any tone con-
trols to their flat or defeated positions. This includes the loudness control.
Step 3 Turn the level controls of the amplifier to their minimum positions.
Step 4 Turn the source unit on. Check to see if the power LED located on the con-
nection side of the amplifier is on. If not, please refer to the Power
Connections and the Troubleshooting Tips sections of this manual for instruc-
tions.
Step 5 If using an aftermarket source unit, turn the level controls of the amplifier
about one quarter of a turn. Slowly increase the volume level of the source
unit to so that you can hear the output of the system. If no sound is heard or
if the output is distorted, turn the system off immediately. Refer to the Power

© 2006 Directed Electronics—all rights reserved 15

 Connections and the Troubleshooting Tips sections of this manual to solve
your installation problems.
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 correct from the
amplifier. When using active crossovers on midrange and tweeters, do not
use crossover frequencies lower than recommended. If the system is not con-
figured properly, refer to the Internal Crossover Configuration section of this
manual and take corrective action.
Step 7 If the output is clear and undistorted, continue to the Adjusting the Sound
of the System section of this manual.

Adjusting the Sound of the System

Once you have checked the system's operation, adjust the sound of the system. Adjusting
the sound of the system is accomplished by setting the level controls and adjusting the
internal crossovers.

Step 1 Turn the signal source volume control all the way down. Set any tone con-
trols to their flat or defeated positions. This includes the loudness control.
Step 2 Turn the level controls of the amplifier to their minimum positions.
Step 3 Choose music with high dynamic content that you like, with which you are
familiar, and will be used most often in the system.
Step 4 Turn the source unit's volume control up to its highest undistorted output
level. If you lack test equipment, this point occurs between 3/4 to full volume
depending on the quality of your source unit. Listen for any audible distor-
tion. If any distortion is audible, reduce the volume of the source unit until
you have an undistorted output. Leave the volume control at this position
during your system tuning.
Step 5 While listening to your chosen dynamic music, turn up the level control cor-
responding to the midrange output until you hear slight distortion and turn
the level control back slightly for an undistorted output. Depending on your
system, the midrange and tweeter output may be on the same output chan-
nels.
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 an undistorted
output. Depending on your system the midrange and tweeter output may be
on the same output channels.
Step 7 Fine-tune the output level between midrange and tweeters. Refer to the
Internal Crossover Configuration section of this manual for detailed instruc-
tions.
Step 8 Repeat Steps 5-7 for the rear speakers. If you do not have rear speakers con-
tinue to Step 10.
Step 9 Set levels between the front and rear midrange and tweeters for optimum
front/rear balance.
Step 10 Turn up the level control corresponding to the woofer output until you hear
slight distortion and turn back the level control slightly for an undistorted
output.
Step 11 Fine-tune the output level between satellite speakers and the woofers. Refer
to the Internal Crossover Configuration section of this manual for detailed
instructions. If using an RGC-1, adjust the level to the output of the woofer
to match the sonic requirements of the system.
Step 12 Enjoy your awesome Orion sound system.

16 © 2006 Directed Electronics—all rights reserved

 Troubleshooting Tips
Symptom Probable Cause Action To Take

No output

Low or no remote turn-on Check remote turn-on voltage

at voltage amplifier and repair
as needed.

Fuse blown Check power wire's integrity

and check for speaker shorts. Fix
as needed and replace fuse.

Power wires not connected Check power wire and ground

connections and repair or
replace as needed.

Audio input not connected Check RCA connections and

repair or replace as needed.

Speaker wires not Check speaker wires and repair

connected or replace as needed.

Speakers are blown Check system with known work

ing speaker and repair or
replace speakers as needed.

Audio cycles
on and off

Thermal protection engages Make sure there is proper venti

when amplifier heat sink lation for amplifier and improve
temperature exceeds 90°C ventilation as needed.
(190°F)

Loose or poor audio input Check RCA connections and

repair or replace as needed.

Loose power connections Check power wire and ground

connections and repair or
replace as needed.

Distorted output

Amplifier level sensitivity Readjust gain. Refer to the

set too high exceeding Adjusting the Sound of the
maximum capability of System section of this manual
amplifier for detailed instructions.

Impedance load to amplifier Check speaker impedance load,

too low if below 1W, rewire the speakers
to achieve higher impedance.

Shorted speaker wires Check speaker wire connections

and fix or replace as needed.

Speaker not connected Check speaker wiring and repair

to amplifier properly or replace as needed. Refer to
the Speaker Connections section
of this guide for detailed
instructions.

© 2006 Directed Electronics—all rights reserved 17

 Symptom Probable Cause Action To Take

Distorted output

Internal crossover not set Readjust crossovers. Refer to the

properly for speakers Internal Crossover Configuration
section of this guide for detailed
instructions.

Speakers are blown Check system with known work

ing speakers and fix or replace
as needed.

Poor bass response

Speakers wired with wrong Check speaker polarity and fix

polarity causing cancellation as needed.
at low frequencies

Crossover set incorrectly Reset crossovers. Refer to the

Internal Crossover Configuration
section of this guide for detailed
instructions.

Impedance load at amplifier Check speaker impedance load,

is too low if below 1W, rewire speakers to
achieve higher impedance.

Battery fuse
blowing

Short in power wire or Check power and ground con-

incorrect wiring nections and replace or repair as
needed.

Fuse used is smaller than Replace with proper fuse size.

recommended

Actual current exceeds fuse Check speaker impedance load.

rating If below 1W, rewire speakers to
achieve higher impedance.

Amplifier fuse
blowing

Fuse used is smaller than Replace with proper fuse size.

recommended

Impedance load at Check speaker impedance load.

amplifier too low If below 1W, rewire speakers to
achieve higher impedance.

Speaker is blown with Check system with known work

shorted outputs ing speakers and fix or replace
as needed.

Actual current exceeds Check speaker impedance load.

fuse rating If below 1W, rewire speakers to
achieve higher impedance.

18 © 2006 Directed Electronics—all rights reserved

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