Orion ORC5V Original operating instructions

ORC5V 5FARAD
ORC10V 10FARAD
HYBRID CAPACITOR
Installation
& Operation
© 2009 Directed Electronics. ORC5V 2009-11

© 2009 Directed Electronics. All rights reserved.
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I NTRODUCTION
T ABLE OF C ONTENTS
Thank you for purchasing the ORION Hybrid Capacitor.The ORION Hybrid Capacitors, also known as
Electric Double Layer Capacitors (EDLC) or Super Capacitors, are passive electrostatic energy storage devices.They
are state of the art technology that allows you to put massive power storage in a very small space
What are ORION Hybrid Capacitors good for?
Some of the most promising applications that have been found for ORION Hybrid Capacitors are battery and
large audio system performance enhancement. Even the very best batteries, that present day technology has to
offer, have performance limitations determined by the laws of physics and chemistry that govern their operation.
ORION Hybrid Capacitors supply their energy much faster than a battery. A properly installed ORION Hybrid
Capacitor can deliver the instantaneous power (Amps) that are commonly demanded by today's large audio
systems.
What makes ORION Hybrid Capacitor Cells so special?
The electrode forming process, which produces ultra-dense yet porous hybrid electrodes, and the continuous
operating voltage of 2.7 volts (per cell) give the ORION Hybrid Capacitor the highest energy storage capacity and
power density of any other commercially available components of comparable size and weight.
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Instructions . . . . . . . . . . . . . . . . . . . 3
Contents of Carton. . . . . . . . . . . . . . . . . . . 3
Design Features. . . . . . . . . . . . . . . . . . . . . . 4
Safety Features. . . . . . . . . . . . . . . . . . . . . . . . 4
NOTE: Review each section for more detailed information.
If, after reading your manual, you still have questions regarding this product, we recommend
that you see your ORION dealer.
Installation . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Installation Considerations . . . . . . . . . . . . . . 4
Mounting Locations. . . . . . . . . . . . . . . . . . . . 5
Wiring the System. . . . . . . . . . . . . . . . . . . . . 5
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 8
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2009 Directed Electronic. All Rights Reserved.

© 2009 Directed Electronics. All rights reserved. 3
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SAFETY INSTRUCTIONS
This symbol with “WARNING” is intended to alert the user to the
presence of important instructions. Failure to heed the instructions
will result in severe injury or death.
This symbol with “CAUTION” is intended to alert the user to the
presence of important instructions. Failure to heed the instructions
can result in injury or unit damage.
CAUTION: To prevent injury and damage to the unit, please read and follow the
instructions in this manual.We want you to have enjoyment from this
system, not a headache.
CAUTION: If you feel unsure about installing this system yourself, have it installed by a
qualified ORION technician.
CAUTION: Before installation, disconnect the battery negative (-) and positive (+)
terminal to prevent damage to the unit, fire and/or possible injury.
WARNING:To prevent serious personal injury, fire and/or damage, ensure the capacitor
has been properly discharged before servicing the vehicle and/or system
components.
CAUTION: Failure to observe the following safety precautions could result in damage
to the capacitor, vehicle and/or personal injury.
sDO NOT allow metal objects, such as screwdrivers or other tools, to touch both
capacitor terminals at the same time.The result may cause arcing and
possible fire.
sDO NOT use capacitor cells that have signs of damage, including cracks, leaks, or
swelling.
sDO NOT expose capacitor cells to flames, sparks or heat at any time.
sDO NOT immerse capacitor cells in water or allow water to come into contact with
them at any time.
sDO NOT remove the electrolyte filling bolt from the top of a capacitor cell at any
time.
sDO NOT connect the positive (+) wire from the battery to the negative (–) terminal
of the capacitor.
sDO NOT connect the negative (–) wire from the battery to the positive (+) terminal
of the capacitor.
sDO NOT make any connections to a capacitor if the connecting polarity cannot be
properly identified.Applying reversed polarity will damage capacitor cells.
CONTENTS OF CARTON
A model ORC5V ORC10V Hybrid Capacitor Module
Installation & Operation Manual Charging Bulb

© 2009 Directed Electronics. All rights reserved.
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I NSTALLATION
INSTALLATION CONSIDERATIONS
The following is a list of tools needed for installation:
Volt/Ohm Meter
Wire strippers
Wire crimpers
Wire cutters
Felt-tip pen or center punch
#2 Phillips screwdriver
3/16” Allen wrench
5/32” Allen wrench
Battery post wrench
Hand held drill w/assorted bits
Electrical tape
Rubber or snap grommets
Nylon tie straps
Assorted connectors
Adequate Length—Red Power Wire
Adequate Length—Black Grounding Wire
D ESIGN F EATURES
The following features are the results of the unique patented manufacturing process that enables the
DEI Hybrid Capacitor to deliver many charge and discharge cycles with greater energy and power
per unit weight and volume.
High Energy
The amazingly high specific capacitance and lower weight of ORION's Hybrid Capacitor yields an energy
per kilogram figure that is twice that of any other commercially available Electric Double Layer Capacitor
(EDLC).
More Power
Both the 'per weight' and 'per volume' power density of ORION's Hybrid Capacitor exceeds that of
other hybrid capacitors in production today.The extremely low internal resistance (ESR) characteristic of
ORION's Hybrid Capacitor enables them to supply large amounts of instantaneous peak power, when
demanded by the load.
Long Life
ORION's Hybrid Capacitor has a very long life span as well.They have been subjected to more than
500,000 charge and discharge cycles and only show a small typical loss of capacitance (less than 20%) and
an even smaller than typical increase in ESR (less than 2X).The long life span of the ORION's Hybrid
Capacitor means that it may never need to be replaced.
Excellent Low Temperature Performance
ORION's Hybrid Capacitors show very little loss of effective capacitance or ESR, even at temperatures as
low as -°40F (-°40C).
SAFETY FEATURES
LED Display
The display at the top of the ORION Hybrid Capacitor will show the current voltage at the capacitor.
Warning Buzzer
The warning buzzer will sound if the ORION Hybrid Capacitor has been wired to a reverse polarity.
Safety Vent
The safety vent ruptures when the internal pressure of capacitor cell has reached 5 ~ 10 kg/cm2.
CAUTION: To prevent injury due to hazardous chemicals, do not touch the capacitor
if the safety vent has ruptured. Have the system looked at by a qualified
technician for repair and/or disposal.
ATTENTION: Safety vent ruptures caused by improper wiring is not covered under
warranty.

© 2009 Directed Electronics. All rights reserved. 5
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INSTALLATION
This section focuses on some of the vehicle considerations for installing your new ORION
Hybrid Capacitor. Pre-planning your system layout and best wiring routes will save installation time.
When deciding on the layout of your new system, be sure that each component will be easily accessible
for making adjustments.
CAUTION: If you feel unsure about installing this system yourself, have it installed by
a qualified ORION technician.
CAUTION: Before installation, disconnect the battery negative (-) and positive (+)
terminals to prevent damage to the unit, fire and/or possible injury.
Before beginning any installation, follow these simple rules:
1. Be sure to carefully read and understand the instructions before attempting to install the unit.
2. For safety, disconnect the negative lead from the battery prior to beginning the installation.
3. For easier assembly, we suggest you run all wires prior to mounting your unit in place.
4. Route all of the high current wires close together and away from any RCA cables.
5. Use high quality connectors for a reliable installation and to minimize signal or power loss.
6. Think before you drill! Be careful not to cut or drill into gas tanks, fuel lines, brake or hydraulic lines,
vacuum lines or electrical wiring when working on any vehicle.
7. Never run wires underneath the vehicle. Running the wires inside the vehicle provides the best
protection.
8. Avoid running wires over or through sharp edges. Use rubber or plastic grommets to protect any
wires routed through metal, especially the firewall.
9. ALWAYS protect the battery and electrical system from damage with proper fusing. Install the
appropriate fuse holder and fuse on the +12V power wire within 18” (45.7 cm) of the battery
terminal.
10. When grounding to the chassis of the vehicle, scrape all paint from the metal to ensure a good, clean
ground connection. Grounding connections should be as short as possible and always be connected to
metal that is welded to the main body, or chassis, of the vehicle.
MOUNTING LOCATIONS
Select a dry location that will provide good ventilation around the ORION Hybrid Capacitor.We
recommend that you mount the capacitor on the floor of the trunk or in a location where
it will be protected from water damage.
sMount in a location free from grease, water, flames, sparks or heat. Preferably in the trunk of the
vehicle.
sThe capacitor should be mounted with the supplied screws as close to the amplifier as possible
keeping the wire runs short. It is recommended that runs be kept less than 24 inches, as this will
help to reduce voltage loss in the cables.
sMark the location where the capacitor is to be mounted.After wiring the system, mount the
capacitor into place.
WIRING THE SYSTEM
CAUTION: If you do not feel comfortable with wiring your new unit, please see your
local Authorized ORIION Dealer for installation.
CAUTION: Before installation, disconnect the battery negative (-) and positive (+)
terminals to prevent damage to the unit, fire and/or possible injury.
CAUTION: Avoid running power wires near the low level input cables, antenna, power
leads, sensitive equipment or harnesses.The power wires carry substantial
current and could induce noise into the audio system.
CAUTION: Improper wiring connections can seriously damage the capacitor and/or
your vehicle. Be sure to carefully follow the connection instructions in this
manual. Improper wiring will void warranty.

© 2009 Directed Electronics. All rights reserved.
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ATTENTION: Make sure the battery and all other power sources are disconnected.
ATTENTION: When installing high voltage audio equipment, such as capacitors and
amplifiers, we recommend using “full-spec” AWG (American Wire Gauge)
type wire for your power and ground wires.
CAUTION: Ensure correct polarity during the following connections. Failure to do
so may cause damage to the unit when power is applied.
NOTE:If a reverse polarity has been connected to the capacitor, a warning buzzer will sound when
power is applied. Immediately disconnect the capacitor from power, ensure it has been
discharged and reconnected to correct polarity.
1. Attach the ground wire to the negative terminal block of the capacitor.The negative terminal is
marked with a (–) Negative Connections.Attach the other end of the ground wire to the chassis
of the car, ensure there is good metal to metal contact. Ensure that no stray wires are visible.
Ensure all wires are secured. Loose connections will affect the performance of your capacitor,
possibly leading to failure.
2. Attach a fused Power wire to the positive terminal of the capacitor.The positive terminal is the
platinum colored block marked with a (+) Positive Connections. Ensure that no stray wires are
visible. Ensure all wires are secured. Loose connections will affect the performance of your capacitor,
possibly leading to failure.
3. To hook up your amplifier or distribution block, use the available 1/0 AWG and/or 4 AWG
connections.
4. Mount the unit securely in the location decided upon.
Charging and connecting the Hybrid Capacitor to the battery
ATTENTION: Charging your capacitor will ensure that the battery and capacitor voltage
are equalized.This will help prevent arcing when the initial power connection
to the capacitor is made.
Overcharging cells will reduce their useful life span. HINT: Charging cells at an ambient temperature
of less than +77°F (+25°C) will minimize the deterioration of their useful life span (keeping it near their
500,000 cycle expectation).
INSTALLATION
NOTE:If a reverse polarity has been connected to the capacitor, a warning buzzer will sound when
power is applied. Immediately disconnect the capacitor from power, ensure it has been
discharged and reconnected to correct polarity.
1. Connect the capacitor Negative (-) and battery Negative (-) to chassis ground of vehicle.
2. Connect one bulb end through fuse to capacitor Positive (+). It is highly suggested that you place a
fuse before the capacitor.
3. Connect the other bulb end to battery Positive (+).
4. When connection is made, the charging is started.
5. Once a full charge has been reached and the capacitor module reads the same voltage as the
battery. See Fig. 1. Remove the bulb.
6. Connect the power wire leading to capacitor module to the positive (+) battery post. Attention,
small sparks may occur. See Fig. 2.
7. Make sure all power and ground connections are made and secure at the capacitor module.
8. The ORION Hybrid Capacitor is now ready for use.

© 2009 Directed Electronics. All rights reserved. 7
7
INSTALLATION
OPERATION
Discharging the Hybrid Capacitor
WARNING:To prevent serious personal injury, fire and/or damage, ensure the capacitor
has been properly discharged before servicing the vehicle and/or system
components.
1. Disconnect the power wire going to the
capacitor module from the battery.
2. Connect one blub end to the
capacitor Negative(-) through fuse.
3. Connect the other one bulb end to the
capacitor Positive(+).
4. When connection is made, the capacitor
is discharging
5. When the voltage meter readout is close
to zero, the capacitor is discharged .
On the top of the Hybrid Capacitor is a blue LED display
that will show the current voltage of the system while it is
on.
Voltage Display
Capacitor is discharged
when voltage is Zero
Connect to
chassis ground
of vehicle.
Bulb
Keep Grounds
as short as
Bulb
possible.
Connect to
chassis ground
of vehicle.
Connected to
Amplifier or System
Distribution Block
Can be used as
Ground
Distribution Block
Connected to
Amplifier or System
Distribution Block
Can be used as
Ground
Distribution Block
CHARGING CAPACITOR
Capacitor is charged
when voltage is equal
FINAL CONNECTION
Connect to
chassis ground
of vehicle.
Keep Grounds
as short as
possible.
Fig. 1 Fig. 2

© 2009 Directed Electronics. All rights reserved.
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SPECIFICATIONS
MODEL- 5/10 Farad Hybrid Capacitor
Rated Capacitance– 77°F (25°C) 5 Farad10 Farad
(Constant Current Discharge (5A) 15.0v–>3.0v)
Capacitance Tolerance
Rated Voltage,VR
Surge Voltage
Maximum Internal Resistance (ESR):
Operating Temperature Range*
Storage Temperature Range
Input/Output Connections
(AWG-American Wire Gauge)
Dimensions:
thgieH
htdiW
htgneL
Weight:
*Prolonged operation above the operating temperature limit of a cell will greatly reduce its useful life
span. Exposure to temperatures below the operating temperature will reduce the ability of the cell to
easily accept a charge.
Specifications subject to change without notice
INSTALLATION
DISPOSING OF HYBRID CAPACITOR CELLS
A ORION Hybrid Capacitor cell contains hazardous material, such as Acetonitrile (ACN).You must
follow federal, state, and local laws when disposing of failed or aged cells. For more information, contact
the Customer Support department of Directed Electronics. Capacitor modules that have
reached their end-of-life can be recycled. Directed Electronics. will take back capacitor modules that need to
be recycled. Directed does not pay for shipping of returned capacitor modules that are to be recycled.
CAUTION: To prevent injury due to hazardous chemicals, do not touch the capacitor if
the safety vent has ruptured. Have the system looked at
by a qualified technician for repair and/or disposal.
ORC5V ORC10V
±10%
16.0 Volts
18.0 Volts
<6.5m
-40 to 140°F
(-40 to 60°C)
-40 to 158°F
(-40 to 70°C)
(6) 1/0 AWG and/or 4 AWG
(8.0 cm)3.15"
(23.2 cm)9.13"
4.05 lbs. (1.8kg)
(16.71 cm)6.6"

LIMITED 90-DAY ACCESSORY/1-YEAR CAPACITOR WARRANTY
This product is sold with a LIMITED 90-day accessory/1-year capacitor manufacturer’s warranty.
Directed Electronics (“Directed”) promises to the original purchaser that the product (“Product”) will be
free from defects in materials and workmanship under normal use and condition for a period of ninety
(90) days for accessories/ one (1) year for capacitors after the date of purchase. A sales receipt and/or
warranty registration card is required to provide proof of date of purchase of the Product.
Product defect occurring within the first 90 days for accessories or 1-year for capacitors after
retail purchase by the end consumer will be repaired or replaced with new or reconditioned part(s), at
Directed’s sole election. To obtain warranty service, the Product must be returned, postage pre-paid ad-
dressed to Directed, along with a legible copy of the receipt and the following information: Consumer’s
name, telephone number and address, authorized dealer/purchase location name and address and prod-
uct description. ALL PRODUCTS RECEIVED BY DIRECTED FOR WARRANTY REPAIR WITHOUT PROOF OF
PURCHASE WILL BE DENIED. Note: This warranty does not cover labor costs for the removal or reinstal-
lation of the Product. Product must be returned to the following address: ATTN: WARRANTY DEPART-
MENT, Directed Electronics, 1 Viper Way, Vista, CA 92081.
This warranty is non-transferable and does not apply to any Product that has been modified or
used in a manner contrary to its intended purpose, and does not cover damage to the Product caused by
installation or removal of the Product. This warranty is VOID if the Product has not been purchased from
Directed or an authorized Directed dealer, or if the Product has been damaged by accident, unreason-
able use, negligence, acts of God, neglect, improper service or other causes not arising out of defect in
materials or construction. This warranty does not cover the elimination of externally generated static or
noise, or any installation problems related to speakers, accessories, electrical systems, cosmetic damage
or damage due to negligence, misuse, abuse, failure to follow operating instructions, accidental spills or
customer applied cleaners, damage due to environmental causes such as floods, airborne fallout, chemi-
cals, salt, hail, windstorms, lightning or extreme temperatures, damage due to accidents, road hazards,
fire, theft, loss or vandalism, damage due to improper connection to equipment of another manufacturer,
modification of existing equipment, or Product which has been opened or tampered with for any reason
or which has been damaged due to alteration or service performed by anyone other than Directed. This
warranty is only valid for sale of Product within the United States of America. Product sold outside of the
United States of America is sold “AS IS,” and shall have NO WARRANTY, express or implied.
THIS LIMITED WARRANTY IS THE ONLY WARRANTY FOR THIS PRODUCT. ALL OTHER WARRAN-
TIES, 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 LI-
ABILITY IN CONNECTION WITH THE SALE OF THE PRODUCT. DIRECTED HAS ABSOLUTELY NO LIABILITY
FOR ANY AND ALL ACTS OF THIRD PARTIES INCLUDING ITS LICENSED DEALERS OR INSTALLERS. IN
NO EVENT WILL DIRECTED BE LIABLE FOR ANY INCIDENTAL, SPECIAL OR CONSEQUENTIAL DAM-
AGES (INCLUDING LOSS OF PROFITS). 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.
Some states do not allow limitation on how long an implied warranty lasts. In such states, the
limitations or exclusions of this Limited Warranty may not apply. Some states do not allow the exclusion
or limitation of incidental or consequential damages. In such states, the exclusion or limitation of this
Limited Warranty may not apply to you. This Limited Warranty gives you specific legal rights, and you may
have other rights which vary from state to state.
For more information on Orion products please visit www.orioncaraudio.com 920 0011 2009-11