Orion HCCA 225G4 User manual
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TABLE
OF
CONTENTS
INTRODUCTION
1
WARRANTY
4
SPECIFICATIONS
6
END
PANEL
LAYOUT
8
INPUT
CONFIGURATIONS
9
INPUT
GAIN
10
AUXILIARY
OUTPUT
CONFIGURATIONS
1
1
CROSSOVER
SECTION
CONFIGURATIONS
12
INTELLI
Q
16
REMOTE
GAIN
OPERATION
20
POWER
CONNECTIONS
HCCA225
AND
HCCA250
21
POWER
CONNECTIONS
HCCA275
23
SPEAKER
CONNECTIONS
25
INSTALLATION
TIPS
33
TROUBLESHOOTING
TIPS
41
AUTOSOUND
2000
TROUBLESHOOTING
TIPS
43
INTRODUCTION
Thank
you
for
your
purchase
of
ORION'S
HCCA
power
amplifier.
Each
HCCA
amplifier
is
designed
to
be
the
leader
in
its
class
offer¬
ing
the
most
power,
advanced
features
and
extreme
ease
of
use.
In
high-end
sound
systems
or
high
SPL
systems,
the
HCCA
ampli¬
fiers
will
give
you
years
of
trouble-free
performance.
•
HCCA
225G4-
25
watt
per
channel
2
channel
high
current
amplifier
with
built-in
fully
variable
high-pass,
low-pass
or
bandpass
crossover
with
INTELLLi
Q.
Equipped
with
remote
gain
capability,
the
HCCA
225G4
is
capable
of
3,
2,
or
1
chan¬
nel
operation
with
a
maximum
power
capability
of
400
watts
into
mono.
•
HCCA
250G4-
50
watt
per
channel
2
channel
high
current
amplifier
with
built-in
fully
variable
high-pass,
low-pass
or
bandpass
crossover
with
INTELLLi
Q.
Equipped
with
remote
gain
capability,
the
HCCA
250G4
is
capable
of
3,
2,
or
1
chan¬
nel
operation
with
a
maximum
power
capability
of
800
watts
into
mono.
•
HCCA
275G4-
75
watt
per
channel
2
channel
high
current
amplifier
with
built-in
fully
variable
high-pass,
low-pass
or
bandpass
crossover
with
INTELLLI
Q.
Equipped
with
remote
gain
capability,
the
HCCA
275G4
is
capable
of
3,
2,
or
1
chan¬
nel
operation
with
a
maximum
power
capability
of
1200
watts
into
IQ
mono
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
re¬
sults
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
1
ABOUT
THIS
MANUAL
This
manual
is
designed
to
answer
your
questions
about
this
product.
In
the
event
you
have
questions
not
covered
in
this
manual,
please
refer
questions
to
your
local
Authorized
ORION
Dealer.
Additionally,
you
can
call
ORION'S
Technical
Support
Staff
at
(480)
705-5600
for
assistance.
PRACTICE
SAFE
SOUND
Continuous
exposure
to
sound
pressure
levels
over
100
dB
may
cause
permanent
hearing
loss.
High
powered
automotive
sound
systems
can
generate
sound
pressure
levels
in
excess
of
130
dB.
When
playing
your
system
at
high
levels,
please
use
hearing
pro¬
tection
and
prevent
long
term
exposure.
RECORD
VOUR
SERIAL
NUMBER
AND
PATE:
MODEL:_
SERIAL
NUMBER:_
DATE
OF
PURCHASE;_
COMPANY
PURCHASED
FROM:_
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
(480)
705-5600.
In
countries
other
than
the
USA
or
Canada,
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.
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
all
warranty
and
non-warranty
service
issues,
please
refer
to
your
nearest
Authorized
ORION
Dealer
for
assistance.
If
you
require
additional
information
or
assistance
regarding
service
repair
issues,
please
call
(480)
705-5600.
Exclusion
1.
This
warranty
is
in
lieu
of
all
other
warranties
expressed
of
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
and
you
may
also
have
other
rights
which
vary
from
state
to
state.
SAVE
YOUR
RECIEPT!
page
5
SPECIFICATIONS
AMPLIFIER
HCCA
225G4
HCCA
250G4
HCCA
275G4
Power
output
4
Q
Stereo
(watts)
25
watts
50
watts
75
watts
Power
output
2
0
Stereo
(watts)’
50
watts
100
watts
150
watts
Power
output
1H
Stereo
(watts)’
too
watts
200
watts
300
watts
Power
output
0.5
Q
Stereo
(watts)’
200
watts
400
watts
600
watts
Power
output
4
Q
Mono
(watts)’
100
watts
200
watts
300
watts
Power
output
2
Mono
(watts)’
200
watts
400
watts
600
watts
Power
output
1
Q
Mono
(watts)’
400
watts
800
watts
1200
watts
Distortion
all
channels
driven
(from
20Hz
to
20kHz)
<0.1%
THD
<0.1%
THD
<0.1%
THD
Frequency
Response
20Hzto20kHz±0.2SdB
20Hzto20kHz±0.25dB
20Hzto20kHz±0.25dB
Linear
Bandwidth
6Hzto50kHz±3dB
6Hz
to
50
kHz
±3dB
6Hzto50kHz±3dB
Signal-to-noise
ratio
full
bandwidth
@
rated
output
power
>100dB
>100dB
>100dB
Dairpirg
factor
@
output
connector
full
bandwidth
>400at
output
connector
>400at
output
connector
>400at
output
connector
Slew
Rate
>30V/ms
>30V/ps
>30V/ms
SPECIFICATIONS
(CONT.)
input
sensitivity^
200MVto
SVrms
200MVto
SVrms
200MVto
SVrms
input
impedance
47kW
47kW
47kW
fuse
type
(2)
20AMPATC
(2)30
AMPATC
(6)
30
AMPATC
CROSSOVER
HCCA
225G4
HCCA
2SOG4
HCCA
275G4
low-pass
crossover^
Continuously
variable
Continuously
variable
Continuously
variable
low-pass
frequency
range
45Hz
to
5kHz
45Hz
to
5kHz
45Hz
to
5kHz
high-pass
crossover
Continuously
variable
Continuously
variable
Continuously
variable
high-pass
frequency
range
10Hz
to
1kHz,
100Hz
to
10kHz
10Hz
to
1kHz,
100Hz
to
10kHz
10Hz
to
1kHz,
100Hz
to
10kHz
INTELLi
Q
boost
range
OdB
to
lOdB
OdB
to
10dB
OdBtolOdB
DIMENSIONS
12"
X
10.25"
X
2.25“
279mm
x
260mm
x
57mm
(L
x
W
X
H)
18"
X
10.25"
X
2
.
2
5
"
457mm
x
260mm
x
57mm
(LxWxH)
25"
X
10.25"
X
2.25"
635mm
x
260mm
x
57mm
(LxWxH)
1.
All
channels
driven,
20
Hz
to
20,000
Hz,
<0.1%
THD,
power
input
voltage
at
12.0
VDC.
2.
HCCA
amplifiers
are
designed
to
accept
full
9
Volts
RMS
input
when
set
to
the
minimum
gain
position,
3.
Crossovers
produce
a
slope
rate
of
12
dB/Octave
and
a
"Q"
of
.707
END
PANEL
LAYOUT
1.
Power
LED-when
lit
indicates
that
the
amplifier
is
on.
2.
Input
Configuration
Switches-determine
the
output
configuration
of
the
amplifier
(page
9)
3.
Independent
Gain
Controls-continuously
adjust
from
200mV
to
5Vrms
for
full
power
output
(page
10)
4.
RCA
inputs-accepts
RCA
input
from
a
source
unit,
preamplifier
or
equalizer
5.
AUX
RCA
outputs-provides
easy
connection
to
additional
amplifiers
(page
11)
6.
AUX
RCA
output
control-determines
the
audio
signal
out
the
AUX
RCAs
(page
11)
7.
Low-pass
Frequency
Control-adjusts
the
frequency
of
the
low-pass
crossover
(page
12)
8.
Low-pass
Crossover
activation
switch-activates
the
low-pass
crossover
(page
12)
9.
INTELLI
Q
adjust
control-adjusts
the
"Q"
boost
of
the
high-pass
crossover
(page
16)
10.
High-pass
"x10"
frequency
range
switch-
selects
the
frequency
range
of
the
high-pass
crossover
(page
14)
11.
High-pass
frequency
control-
adjusts
the
frequency
of
the
high-pass
crossover
(page
14)
12.
High-pass
Crossover
activation
switch-
aaivates
the
high-pass
crossover
(page
14)
13.
REM
Remote
turn-on
input-turns
on
the
amplifier
when
fed
12
V+
(page
21,
23)
14.
Speaker
Connections-allows
up
to
12
gauge
speaker
wire.
15.
Remote
Gain
Control
Port-allows
dashboard
remote
gain
control
(page
20«2)
16.
Fuses-Protects
the
amplifier
from
over
current
situations.
17.
Power
Connections-allows
up
to
4
gauge
power
and
ground
cables
(page
21,
23)
INPUT
CONFIGURATION
amplifier
consists
of
separate
phase
switches
that
set
output
configuration,
separate
left
and
right
gain
controls
and
RCA
inputs.
The
input
section
makes
it
easy
to
adapt
this
amplifier
to
most
system
configurations.
^
^
PHASE
SWITCHES
I
I
P
IPO
motto
RIGHT
PHASE
??
0
0
1
RIGHT
tf/T
1
GAIN
GAIN
LEFT
PHASE
□
□
0
MONO
rao
_J
mosw
RIGHT
PHASE
LEFT
PHASE
CH
1
1
0
tto
L_
0
0
RIGHT
LEFT
GAIN
GAIN
iZI
0
MONO
_J
The
HCCA
amplifier
has
separate
left
and
right
phase
control
switches.
There
are
six
different
setting
combinations.
Setting
1
is
the
factory
configuration.
Both
left
and
right
channels
are
in
Phase.
Both
left
and
right
gain
controls
are
active.
This
setting
is
used
for
typical
two
channel
stereo
operation
(page
25).
Setting
2
inverts
the
output
of
the
left
channel.
The
left
channel
is
180°
out
of
phase
from
the
right
channel.
Both
left
and
right
gain
controls
are
active.
When
one
pair
of
RCA's
are
available
as
the
input,
this
setting
is
used
to
sum
mono
the
imput
for
bridging
the
amplifier
to
a
mono
load
(page
27).
This
configuration
is
also
useful
for
Tri-mode
operation
(page
31).
Additionally,
when
in
stereo
mode
(page
25),
inverting
one
channel
of
satellite
speakers
can
focus
imaging.
Setting
3
inverts
the
output
of
the
right
channel.
The
right
channel
is
180°
out
of
phase
from
the
left
channel.
page
9
lUSUlm
HtGHTtWKSE
UfTPHAS£
RCA
Setting
4
inverts
the
output
of
both
the
left
and
right
channels.
Both
left
and
right
gain
controls
are
active.
This
configuration
is
useful
for
inverting
one
set
of
speakers
like
rear
speakers
in
front/rear
system
to
improve
staging
in
a
vehicle
(page
25).
IZI
LBFTPHASE
190
J
INPUT
RIGHT
PHASE
LEFT
PHASE
rqA
IIMPUT
GAIN
Setting
5
inverts
the
output
of
the
left
channel.
The
left
channel
is
180®
out
of
phase
from
the
right
channel.
Only
the
right
gain
control
is
active.
This
is
the
"MONO
BRIDGED"
output
configuration
(page
29).
This
setting
is
to
be
used
when
using
a
single
RCA
as
a
mono
Input.
Right
Phase
control
determines
the
phase
of
the
output.
When
the
Right
Phase
control
is
in
the
0“
position,
the
bridged
output
is
in
phase
with
the
rest
of
the
system.
Setting
6
inverts
the
output
of
the
bridged
output.
The
mono
bridged
input
is
180®
out
of
phase
from
the
rest
of
the
system.
Only
the
right
gain
control
is
active.
This
is
the
"MONO
BRIDGED"
output
configuration
(page
29).
Right
Phase
control
determines
the
phase
of
the
output.
When
the
Right
Phase
control
is
in
the
180®
position,
the
bridged
output
is
out
of
phase
with
the
rest
of
the
system.
OZ)
I
I
Q
RiGHTPHASf.
MZ3
HCCA
amplifiers
have
separate
left
and
right
level
adjustments.
The
input
sensitivity
of
these
adjustments
range
from
200mV
up
to
5Vrms
to
easily
integrate
with
any
source
unit
both
after
market
and
OEM
(Original
Equipment
Manufacturer)
Refer
to
the
"Test¬
ing
the
System"
(page
38)
and
the
"Adjusting
the
Sound
of
the
System"
(page
39)
for
detailed
instructions
on
setting
the
gain.
AUX
AUX
RCA
AUX
AUX
RCA
AUX
AUX
RCA
AUXIUARY
OUTPUT
CON
FIG
U
RATION
The
auxiliary
outputs
on
ORION
amplifiers
offer
easy,
unlimited
system
expansion.
Routing
signal
from
a
source
unit,
pre-amplifier
or
equalizer
is
a
matter
of
routing
RCAs
to
the
RCA
Inputs
and
out
the
AUX
outputs
to
the
next
XTREME
or
HCCA
amplifier
in
the
signal
chain.
When
the
switch
is
in
the
"COPY"
position,
the
AUX
RCAs
output
is
an
identical
copy
of
the
input
signal.
The
signal
passes
through
a
buffer
stage
so
that
an
infinite
number
of
HCCA
amplifiers
can
be
daisy
chained
without
signal
loss
or
overloading
of
the
source
unit.
This
maximizes
the
signal
output
and
minimizes
the
potential
for
system
noise.
When
the
switch
is
in
the
"GAIN"
position,
the
AUX
RCA
outputs
are
buffered
through
the
gain
stage
of
the
amplifier.
When
the
first
amplifier
in
the
signal
chain
is
set
this
way,
a
remote
gain
controller
can
be
installed
in
the
amplifier
and
act
as
a
"PRE-AMP"
controlling
the
overall
level
of
the
system.
Following
amplifiers
can
be
configured
in
either
the
"COPY"
configuration
with
their
gains
set
to
zero
as
the
"GAIN"
amp
is
now
controlling
the
gain
level
for
all
subsequent
amps.
This
eliminates
the
need
to
"gain
match"
multiple
amplifiers.
When
the
switch
is
in
the
"MASTER"
position,
the
AUX
RCA
outputs
are
buffered
through
the
gain
stage
of
the
amplifier
and
filtered
through
the
crossover
sec¬
tions
of
the
amplifier.
When
set
this
way,
the
amplifier's
gain
and
crossover
set¬
tings
are
sent
to
other
amplifiers
down
the
signal
chain.
This
can
be
useful
for
configuring
multiple
subwoofer
amplifiers
easily
in
a
large
SPL
system.
All
subse¬
quent
amplifiers
after
the
master
amp
will
be
in
the
"COPY"
position
and
have
their
gains
set
to
zero
and
all
crossovers
turned
off.
The
master
amplifier
will
con¬
trol
all
the
functions
of
the
slave
amps
via
the
"MASTER"
AUX
OUT
signal.
In
ad¬
dition,
one
RGC-1
gain
module
can
be
used
to
control
the
level
of
an
entire
sub
system
by
plugging
it
into
the
"MASTER"
amp
page
11
INTE
RN
AL
CROSSOVE
R
CO
N
FIG
U
RATI
O
N
The
crossover
section
of
the
HCCA
amplifier
is
continuously
variable
and
ex¬
tremely
flexible.
There
are
eight
different
crossover
configurations
possible
al¬
lowing
high-pass,
low-pass
and
band-pass
configurations.
The
high-pass
crossover
utilizes
the
INTELLi
Q
feature.
This
circuit
is
designed
to
optimize
the
performance
of
ORION
subwoofers
in
all
types
of
enclosures.
When
using
ORION
loudspeakers,
minor
deviations
from
the
recommended
frequency
ranges
can
provide
superior
results
de¬
pending
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
operating
range.
This
can
cause
driver
failure
that
is
not
covered
by
manufacturer's
warranty.
LOW-PASS
CROSSOVER
600Hz
5kHz
^
17S
LPON
—
LPOFF
m
OdB
3SH7
HP
iQH
Z
HP
ON
—
When
the
push
button
is
in
the
"out"
position,
the
low-pass
crossover
is
bypassed
When
the
push
button
is
in
the
"in"
position,
the
low-pass
crossover
is
active.
The
low-pass
crossover
is
continuously
variable
from
45
Hz
to
5
kHz.
FINE
TUNING
THE
LOW-PASS
CROSSOVER
600HZ
5kHz
The
crossover
section
is
marked
at
four
frequency
points
for
ease
of
system
adjustment.
These
points
are
45
Hz,
175
Hz,
600
Hz
and
5,000
Hz.
Specific
crossover
points
can
be
chosen
based
on
the
recommended
operational
bandwidth
of
your
speakers.
There
are
three
small
dots
on
the
frequency
range
dial.
These
dots
represent
commonly
used
ORION
crossover
fre¬
quencies.
These
crossover
frequencies
are
85
Hz,
2,500
Hz
and
3,500
Hz
respectively.
page
13
HIGH-PASS
CROSSOVER
MID
AND
TWEETERS
HIGH-PASS
WOOFERS
When
both
push
buttons
are
in
the
"out"
position,
the
high-pass
crossover
is
bypassed.
When
both
push
buttons
are
in
the
"in"
position,
the
high-pass
crossover
is
active
in
the
"HIGH"
frequency
range.
The
high-pass
crossover
is
continuously
variable
from
100
Hz
to
10
kHz.
This
setting
is
used
for
crossing
over
midrange
and
tweeter
speak¬
ers.
Set
the
INTELLi
Q
level
to
"0
dB."
NOTE:
When
the
high-pass
crossover
is
in
the
"HIGH"
frequency
range,
the
frequency
indicators
represent
1/10
of
the
crossover
frequency.
For
example,
35Hz
=
350Hz.
WARNING!!!
When
using
the
crossover
in
the
"HIGH"
range,
it
is
not
recommended
to
use
the
INTELLi
Q
as
it
may
potentially
damage
your
midrange
or
tweeter
speakers.
When
only
the
push
button
to
activate
the
high-pass
crossover
is
in
the
"in"
position,
the
high-pass
crossover
is
active
in
the
"LOW"
frequency
range.
The
high-pass
cross¬
over
is
continuously
variable
from
10
Hz
to
1
kHz.
The
high-pass
crossover
is
now
opti¬
mized
for
use
as
a
subsonic
filter
for
subwoofers.
Additionally,
boost
can
be
added
at
the
high-pass
crossover
frequency
for
improved
bass
output
while
still
protecting
the
woofer
from
excessive
excursion.
The
INTELLi
Q
adjustment
allows
up
to
10
dB
of
boost
at
the
selected
crossover
frequency.
Care
must
be
taken
when
setting
the
INTELLi
Q
at
or
near
the
maximum
boost.
1,200
Hz
10
kHz
120Hz
1kHz
35Hz
10Hz
350
Hz
100
Hz
The
crossover
section
is
marked
at
four
frequency
points
for
ease
of
system
adjustment.
These
points
are
10
Hz,
35
Hz,
120
Hz
and
1
kHz.
Specific
crossover
points
can
be
to
be
chosen
based
on
the
recommended
operational
bandwidth
of
your
speakers.
Note:
When
the
high-pass
crossover
is
set
in
the
"HIGH"
fre¬
quency
range,
the
corner
frequencies
are
100
Hz,
350
Hz,
1.2
kHz
and
10
kHz
respectively.
page
15
ADJUSTING
INTELLI
Q
Boost
Levels
OdB
+3dB
+6dB
+10dB
Enclosure
Type
:
Infinite
Baffle
Acceptable,
No
Problems.
Tune
above
Fs
of
woofer.
High
X-Max
Drivers.
Tune
above
Fs
of
woofer.
Not
Recommended
Not
Recommended
Sealed
Acceptable,
No
Problems.
Tune
above
Fs
of
woofer.
Acceptable,
No
Problems.
Tune
above
Fs
of
woofer.
High
X-Max
Drivers.
Tune
above
Fs
of
woofer.
Not
Recommended
Vented
Acceptable,
no
Problems.
Tune
to
Port
frequency.
Acceptable
No
Problems.
Tune
to
Port
frequency.
Acceptable
No
Problems.
Tune
to
Port
frequency.
High
X-Max
Drivers.
Tune
to
port
frequency.
Sealed
Bandpass
Acceptable,
no
Problems.
Tune
above
Fs
ofwoofer.
Acceptable
No
Problems.
Tune
above
Fs
of
woofer.
High
X-Max
Drivers
Drivers.
Tune
above
Fs
subfwoofer.
Not
Recommended
Vented
Bandpass
Acceptable,
no
Problems.
Tune
to
port
frequency.
Acceptable,
no
Problems.
Tune
to
port
frequency.
Acceptable,
no
Problems.
Tune
to
port
frequency.
High
X-Max
Driver.
Tune
to
port
frequency.
Aperiodic
Set
crossover
to
Fs
of
woofer.
Set
crossover
to
Fs
of
woofer.
Set
crossover
to
Fs
of
woofer.
Not
Recommended
6dB
lOdB
3dB
OdB
Incorporated
in
the
high-pass
crossover,
INTELLi
Q
maximizes
the
performance
of
a
subwoofer.
The
high-pass
subsonic
filter
removes
unwanted
bass
output
from
the
woofer,
increasing
the
output
of
a
subwoofer
by
as
much
as
3
dB
due
to
the
increased
mechanical
power
handling.
Depending
on
the
enclosure,
using
INTELLi
Q
can
increase
the
low
frequency
response
by
an
additional
lOdBM!
The
boost
level
is
identified
by
the
corner
markings.
Acceptable
boost
levels
are
determined
by
the
type
of
enclosure
used
and
the
woofer's
excursion
capability.
Listed
below
are
recommended
boost
levels
for
different
enclosure
designs.
"Q"
BOOST
FILTER
RESPONSE
On
the
left
is
a
frequency
response
of
the
high-pass
filter
set
to
30
Hz.
On
the
right
frequency
response
of
the
high-pass
filter
set
to
20Hz.
INTELLi
Q
levels
of
OdB,
3dB,
6dB
and
lOdB
are
displayed
respectively.
page
17
INFINITE
BAFFLE
EXAMPLE
HIGH-PASS
SET
@
30Hz
By
removing
low
frequency
signal
which
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.
Maxi¬
mum
physical
excursion
capability
of
the
woofer
is
15mm.
SEALED
EXAMPLE
HIGH-PASS
SET
@
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
output
down
to
15
Hz.
SEALED
EXAMPLE
HIGH-PASS
SET
@
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.
Overall
usable
output
is
increased.
VENTED
EXAMPLE
HIGH-PASS
SET
@
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.
page
19
REMOTE
GAIN
OPERATION
REMOTE
REM
GAIN
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
am¬
plifier
gain
level.
The
RGC-1
can
be
used
as
a
bass
level
control
when
used
on
an
amplifier
dedicated
to
subwoofers.
In
addition,
one
RGC-1
can
be
used
on
multiple
sub
amplifiers.
Plug
the
RGC-1
into
the
first
amp
which
will
have
its
AUX
OUT
selection
switch
in
the
"MASTER"
posi¬
tion,
The
RGC-1
information
will
now
be
sent
to
subsequent
amps
via
the
"MAS¬
TER
"
signal.
For
more
information
on
setting
the
AUX
OUT
function
see
page
13.
POWER
CONNECTIONS
HCCA
225G4
AND
HCCA
250G4
wr
Z)/
1
/
SRiEAKBR
OUTRUTS
LEFT
R/GHT
REM
+
-
-
+
MONO
+
BRIDGED
REMOTE
FUSE
ROWER
REM
GAIN
Connect
to
remote
tum-on
lead
of
source
unit
Amplifier
Fuse
Size
HCCA
225G4
(2)
30
AMP
HCCA
250G4
(2)
40
AMP
Vehicles
Battery
¥
page
21
•
Power
connections
made
through
a
large
4
gauge
removable
terminal
connector.
•
Minimum
4
gauge
power
and
ground
wire
recommended
for
optimal
performance.
•
Connect
12V+
to
the
battery
through
fuse
holder.
This
connection
provides
+12V
main
power
to
the
amplifier.
•
Power
wire
must
be
fused
no
more
than
18“
from
battery.
•
Ground
amplifier
to
a
good
chassis
ground
as
close
as
possible
to
the
amplifier.
•
Connect
REM
terminal
to
remote
turn-on
lead
from
source
unit.
This
connection
provides
+12V
power
to
turn-on
the
amplifier.
•
Add
Extra
Ground
wire
between
the
negative
terminal
of
the
battery
and
the
chassis.
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.
POWER
CONNECTIONS
HCCA
275G4
Cbririecttorernoteturri-C)ri
lead
of
source
unit
Amplifier
Fuse
Size
HCCA
275G4
(6)
30
AMP
iQ:
iQ:
+
Vehicles
Battery
oaae
23
•
Power
connections
made
through
dual
large
4
gauge
removable
terminal
connector.
•
Dual
4
gauge
power
and
ground
wire
required
for
proper
performance.
•
Connect
12V+
to
the
battery
through
power
distribution
and
fuse
holder.
This
connection
provides
+12V
main
power
to
the
amplifier.
•
Power
wires
must
be
fused
no
more
than
18"
from
battery.
•
Terminate
both
grounds
of
the
amplifier
to
a
good
chassis
ground
as
close
as
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
an
extra
ground
wire
between
the
negative
terminal
of
the
battery
and
the
chassis.
Either
dual
4
gauge
or
single
1/0
gauge.
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.
WARISHNCi:
The
HCCA
275G4
has
two
seperate
4
gauge
power
and
ground
inputs.
Both
pairs
of
connections
must
use
4
gauge
power
wire
for
proper
operation.
Failure
to
do
this
may
damage
the
amplifier
and
is
not
covered
under
warranty.
age
25
•
Lowest
Recommended
Impedance
is
0.5Q
Stereo
•
RCA
inputs
are
connected
to
both
left
and
right
channels
•
Left
Phase
switch
set
to
0®
(page
11)
•
Right
Phase
switch
set
to
0®
(page
11)
•
Gain
controls
can
be
set
together
or
independently
of
each
other
•
Output
can
be
configured
for
high-pass,
low-pass,
band-pass
or
full
range
operation
(page
14)
•
Output
is
configured
for
stereo
operation
TUNING
NOTE:
The
phase
switches
can
be
individually
switched
for
improved
sound
quality.
Try
different
phase
switch
positions
for
best
sonic
results.
The
high-pass
crossover
can
be
used
as
a
subsonic
filter
with
INTELLi
Q
(page
18).
Configure
the
high-pass
crossover
for
"LOW"
frequency
range
operation
and
set
according
to
instructions
explained
in
the
High-pass
Crossover
Configuration
section
in
this
manual
(page
16).
SUMMED
BRIDGED
CONFIGURATION
1
ohm
minimum
•
Lowest
Recommended
Impedance
is
^Q.
bridged
mono
•
RCA
inputs
are
connected
to
both
left
and
right
channels
•
Right
Phase
switch
set
to
0°
(page
9)
•
Left
Phase
switch
set
to
180®
(page
9)
•
Gain
controls
must
be
set
identically
for
both
left
and
right
channels
•
Output
can
be
configured
for
high-pass,
low-pass,
band-pass
or
full
range
operation
•
Output
is
configured
summed
bridged
which
is
ideal
for
subwoofer
applications
TUNING
NOTE:
The
phase
switches
can
be
individually
switched
for
improved
sound
quality.
In
the
summed
bridged
configura¬
tion
the
left
and
the
right
phase
must
be
set
opposite
from
each
other
in
order
to
operate
correctly.
The
high-
pass
crossover
can
be
used
as
a
subsonic
filter
with
INTELLi
Q
(page
18).
Configure
the
high-pass
crossover
for
"LOW"
frequency
range
operation
and
set
according
to
instructions
explained
in
the
"High-pass
Crossover
Configuration”
section
in
this
manual
(page
16).
age
29
•
Lowest
Recommended
Impedance
is
bridged
mono
•
Only
the
Right
RCA
input
is
used
•
Right
Phase
switch
set
to
0®
(page
12)
•
Left
Phase
switch
set
to
"MONO
BRIDGED"
(page
12)
\
•
Right
Gain
control
sets
the
level
for
the
amplifier
output
•
Output
can
be
configured
for
high-pass,
low-pass,
band-pass
or
full
range
operation
(page
14)
•
Output
is
configured
mono
bridged
which
is
ideal
for
separate
left
or
right
channel
subwoofer
applications
TUNING
NOTE:
In
the
"MONO
BRIDGED"
configuration,
the
Right
Phase
control
can
be
used
to
change
the
phase
of
the
amplifier
output.
The
right
phase
switches
can
be
Individually
switched
for
improved
sound
quality.
Try
different
phase
switch
positions
for
best
sonic
results.
The
high-pass
crossover
can
be
used
as
a
subsonic
filter
with
INTELLi
Q
(page
18).
Configure
the
high-pass
crossover
for
"LOW"
frequency
range
operation
and
set
according
to
instructions
explained
in
the
"High-pass
Crossover
Configuration"
section
in
this
manual
(page
16).
•
Lowest
Recommended
Impedance
is
0.5Q
stereo
and
1Q
bridged
mono
•
RCA
inputs
are
connected
to
both
left
and
right
channels
•
Right
Phase
switch
set
to
0°
(page
12)
•
Left
Phase
switch
is
set
to
180°,
Speaker
polarity
on
the
right
front
speaker
must
be
inverted
to
maintain
proper
speaker
polarity
(page
9)
•
Gain
controls
must
be
set
identically
for
both
left
and
right
channels
•
Output
must
be
configured
for
full
range
operation
•
Passive
crossover
frequencies
must
not
overlap.
WARNING:
Failure
to
do
so
may
result
in
damage
to
the
amplifier.
•
Output
is
configured
summed
bridged,
which
is
ideal
for
single
subwoofer
applications
TUNING
NOTE:
The
phase
switches
can
be
individually
switched
for
improved
sound
quality.
In
the
Tri-mode
configu¬
ration
the
left
and
the
right
phase
must
be
set
opposite
from
each
other
in
order
to
operate
correctly
(page
12).
The
high-pass
crossover
can
be
used
as
a
subsonic
filter
with
INTELLi
Q
(page
18).
Configure
the
high-pass
crossover
for
"LOW"
frequency
range
operation
and
set
according
to
instructions
ex¬
plained
in
the
"High-pass
Crossover
Configuration"
section
in
this
manual
(page
16).
INSTALLATION
TIPS
TOOLS
OF
THE
TRADE
Listed
are
the
majority
of
the
tools
required
to
perform
the
installation.
Having
the
proper
tools
will
make
the
installation
that
much
easier.
Some
of
these
tools
are
necessities.
Some
make
the
job
much
easier.
marking
pen
electric
drill
with
assorted
drill
bits
utility
knife
Phillips
and
flat
blade
screw
drivers
pliers
(standard
and
needle
nose)
wire
brush
or
sandpaper
for
chassis
grounding
solder
iron
and
solder
grommets
heat
shrink
tubing
nylon
tie
straps
volt-ohm
meter
(optional)
wire
cutters
wire
crimpers
wire
strippers
RTA
(real
time
analyzer)
Reference
CD
with
1
kHz
Sine
Wave
at
OdB
level
(all
bits
high)
page
33
MOUNTING
THE
HCCA
AMPLIFIER
The
HCCAG4
amplifiers
have
a
unique
mounting
system
that
can
be
configured
for
different
install
situations.
By
placing
the
removable
mounting
rails
in
the
"in”
or
"out”
positions
the
look
of
the
amplifier
mounting
can
be
changed
to
suit
personal
tastes
or
installation
requirements.
In
the
"in”
position,
you
will
not
see
the
amplifier
mounting
screws
and
the
amp
will
”float”
above
the
mounting
screws.
The
amp
can
also
be
mounted
in
a
”standard”
manner
using
the
"out"
position.
FIGURE
A
225G4-12"(279mm)
-250G4-18"(457mm)-
275G4
-
25"(635mm)
FIGURE
B
FIGURE
A:
This
figure
shows
the
mounting
feet
of
the
amplifier
in
the
"in"
position.
To
mount
the
amplifier
in
this
manner
you
must
mount
just
the
two
feet
to
the
mounting
surface
before
screwing
them
to
the
amp.
The
distance
needed
between
the
vertical
sides
of
each
foot
is
noted
in
the
figure
to
the
left.
Simply
measure
the
dis¬
tance,
mount
the
feet,
then
mount
the
amplifier
to
the
feet.
FIGURE
B:
This
figure
shows
the
mounting
feet
in
the
"out”
postion.
This
method
can
be
accomplished
by
using
the
same
procedure
as
above
or
by
simply
mounting
the
feet
to
the
amplifier
and
mounting
the
amplifier
to
the
surface
as
you
would
a
"normal"
amp.
CHOOSING
MOUNTING
LOCATIONS
The
location
of
your
HC(^
amplifier
will
depend
on
several
important
issues.
Due
to
the
low
profile
size
of
the
HCCA
amplifiers
^
I
possible
installation
locations
that
will
yield
satisfactory
amplifier
performance.
Always
mount
the
amplifier
in
a
p
ace
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
obvi-
ous
of
situations.
PASSENGER
COMPARTMENT
MOUNTING
If
you
are
going
to
mount
the
amplifier
in
the
passenger
compartment,
make
sure
you
have
ad¬
equate
room
for
ventilation.
The
HCCA
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
Mounting
the
HCCA
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
ampli¬
fier.
For
optimal
results,
mount
the
amplifier
with
the
cooling
fins
in
the
vertical
position.
This
type
of
mounting
will
yield
the
best
cooling
due
to
the
convection
effect
of
the
amplifier
chassis.
ENGINE
COMPARTMENT
MOUNTING
Do
not
mount
the
HCCA
amplifier
in
the
engine
compartment.
The
amplifier
was
not
designed
to
endure
the
harsh
environment
of
the
exterior
elements.
page
35
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
HCCA
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
HCCA
amplifier
where
it
might
get
wet.
Mount
the
HCCA
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
HCCA
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
HCCA
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
HCCA
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
HCCA
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.
HCCA
amplifiers
generate
a
certain
amount
of
heat
as
part
of
their
normal
operation.
Be
sure
the
area
around
the
cooling
fins
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
does
not
improve
air
flow.
STEP
BV
STEP
INSTALLATtON
_
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
run
RCAs,
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
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
amplifier.
Make
sure
the
amplifier
is
mounted
on
a
flat
surface.
If
this
is
not
possible,
do
not
over
tighten
the
screws
such
that
the
chassis
of
the
amplifier
is
twisted
or
bent.
Step
6
Turn
the
vehicle's
key
switch
to
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
ultimate
performance
of
your
ORION
amplifier.
Refer
to
the
Installation
Quick
Reference
section
of
this
manual
for
correct
wiring
instructions.
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
crossover
and
signal
routing
configurations.
Refer
to
the
"Input
Configurations"
and
the
“Internal
Crossover
Configuration"
sections
of
this
manual
for
detailed
instructions.
Step
12
Once
satisfied
that
all
connections
and
settings
are
correct,
install
fuse
at
location
near
the
vehicle's
battery
and
proceed
to
the
"Testing
the
System"
section
of
this
manual.
WARNING!!
11
Never
exceed
the
recommended
fuse
size
of
this
amplifier.
Failure
to
do
so
will
result
in
voiding
of
your
warranty.
page
37
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