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 [phone]. 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 [phone].
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