Orion BLACK COIL HCCA Series User manual

High Performance
Competition Subwoofers
HCCA102
HCCA104
HCCA122
HCCA124
HCCA152
HCCA154

ATTENTION
FOR ANY QUESTIONS,
ISSUES, RETURNS OR WARRANTY
DO NOT contact the retailer, we recommend that
you contact our service department for any and all
assistance at [email protected].
We will do our best to resolve any problem in a
professional and timely manner.
Thank you for purchasing this Orion product. Orion products
are specifically engineered and designed for the mobile audio
environment. This manual contains important information about
installation, set-up procedures and integrating your new Orion
product into your vehicle. With proper care and installation, your
new product will provide you with many years of high performance
listening enjoyment. We recommend having an Authorized Orion
Dealer install your new product for optimal performance. Before
installing your new product, please read through the manual to fully
understand the application.
Before making any electrical connections, make sure that you
disconnect the battery’s ground cable to prevent the possibility
of short circuits or damage to your electronic equipment. If your
vehicle’s stereo (head unit) comes with an Anti-theft code, DO NOT
disconnect the battery. If you have the access code for the stereo
(head unit), please refer to the vehicle’s owner’s manual.
!!
WARNING: This product can expose you
to chemicals including DEHP which is known
to the State of California to cause cancer, birth
defects or other reproduction harm. For more
information go to www.P65warnings.ca.gov.

INTRODUCTION............................................................................................................2
FEATURES.............................................................................................................3
SPECIFICATION..........................................................................................4-5
WIRING CONFIGURATION..................................................................................6-12
BUILDING AN ENCLOSURE....................................................................................13
ENCLOSURE DETAILS...............................................................................................14
ENCLOSURE RECOMMENDATION................................................................15-26
WARNING & DISCLAIMER......................................................................................27
TROUBLESHOOTING.............................................................................................28
WARRANTY.........................................................................................................29-30
TABLE OF CONTENTS
WHAT’S IN THE BOX
1 x HCCA Subwoofer
1 x Mounting Template
1 x Owner’s Manual
1 x Window Sticker

FEATURES
3
21
4
3
5
6
7
8
9
10
13
14
16
15
17
18
19
20
21
12 11
1Polypropylene dust cap - moisture and UV resistant.
2Tall, wide, balanced, NBR Foam (high density expanded polyester foam) surround for
linear controlled long excursion using a Tri Radius symmetrical edge design optimized
on non-linear FEA.
3Paper cone - moisture and UV resistant.
4Custom Cast Aluminum frame.
5Spider ring attachment screws. Part of re-cone feature (8 hex screws)
6aluminum voice coil former (10” uses 3” voice coil former, 12 & 15 use a 4” voice coil former)
7Venting in Voice coil former. Part of the enhanced voice coil cooling system (forced
convection)
811mm Steel front plate.
9Large 3 stack ceramic magnets (10” 264 oz 12/15” 445 oz)
10 11mm Steel back plate/pole piece T yoke assembly
11 1.25” vent. Part of the enhanced voice coil cooling system (forced convection - aluminum
heat sinking - shorting rings to reduce inductive heating)..
12 Voice coil gap vents. Part of the enhanced voice coil cooling system (forced convection -
aluminum heat sinking -shorting rings to reduce inductive heating).
13 Cast aluminum rear pole piece heat sink with ns and vent holes. Part of the enhanced
voice coil cooling system (forced convection - aluminum heat sinking)
14 High temperature (Polyester Amide Resin Coated) Copper clad Aluminum voice coil
wound on an aluminum former (10” uses 3” voice coil, 12 & 15 use a 4” voice coil) Dual 2
and 4 ohm voice coils available
15 Screen meshed areas to allow venting below spider to and keep foreign object out of the
voice coil gap.
16 Cast aluminum top pole piece heat sink with ns and vent hole. Part of the enhanced
voice coil cooling system (forced convection-aluminum heat sinking-shorting rings to
reduce inductive heating).
17 Bottom at interlaced Conex spider with stitched and looped tinsel leads attached.
18 Custom allen head screw terminals. A pair on each side (one pair for each voice coil).
19 Spider spacer and spider mounting ring assembly part of eld re-cone kit attachment
method. (eight allen head screws).
20 Top at interlaced Conex spider.
21 Surround clamp ring, part of eld re-cone kit attachment method. (eight allen head
screws).

SPECIFICATIONS
4
Model Number HCCA102 HCCA104 HCCA122 HCCA124 HCCA152 HCCA154
Size 10” 10” 12” 12” 15” 15”
Fs (free-air resonance, Hz) 42.51 44.3 32.3 33.2 28.13 30.02
Vas (equivalent compliance, cu.
ft.)
0.31029 0.31699 0.89274 0.93157 2.95746 2.82259
Vas (equivalent compliance,
liters)
8.79 8.98 25.29 26.39 83.78 79.96
Qms (Q, mechanical) 7.16 5.99 5.08 4.16 5.17 4.38
Qes (Q, electrical) 0.48 0.52 0.5 0.54 0.55 0.61
Qts (total driver Q) 0.45 0.48 0.45 0.48 0.5 0.54
Re (DC resistance, ohms) 3.9 7.4 47.4 47.3
Z (nominal impedance, ohms) 2x2 4x2 2x2 4x2 2x2 2x2
Le (inductane, mh) 1.93 2.93 2.61 3.67 2.59 3.68
Efciency (1W @ 1M, db) 86.51 83.66 84.22 83.38 87.2 87.4
Xmas (one way linear excursion,
in.)
1.01948 1.01948 1.18939 1.18939 1.18939 1.18939
Xmas (one way linear excursion,
mm)
25.89 25.89 30.1875 30.18 30.18 30.18
RMS POWER WATTS 2000 2000 2500 2500 2500 2500
NOMINAL POWER WATTS 4000 4000 5000 5000 5000 5000
MAX MUSIC POWER WATTS 8000 8000 10000 10000 10000 10000
Mms (total moving mass, grams) 250 225 425 386 500 460
Cms (mechanical compliance,
m/N)
0.000056 0.000057 0.000057 0.00006 0.00005 0.000061
BI (motor strength, Tesla-M) 23.3 29.86 26.27 33.2 25.34 32.21
Sd (effective radiating area, sq.
cm.)
333.29 333.29 559.9 559.9 962.11 962.11
Sd )effective radiating area, sq.
in.)
51.66 51.66 86.78 86.78 149.13 149.13
Frequency Range (Hz) 32-100 33-100 24-100 25-100 21-100 22-100
Energy Bandwidth Product
(EBP)**
89 85 65 61 51 49

SPECIFICATIONS
5
Model Number HCCA102 HCCA104 HCCA122 HCCA124 HCCA152 HCCA154
Physical Dimensions
Speaker Displacement (cu ft) 0.1268 0.1268 0.28931 0.28931 0.37704 0.37704
Speaker Outer Diameter (inches/
mm)
238 238 292 292 383 383
Mounting hole diameter (inches/
mm)
9.37 9.37 11.5 11.5 15.079 15.079
Mounting depth (inches/mm) 8.425/214 8.425/214 10.28/261 10.28/261 11.575/294 11.575/294
Magnet Weight (Oz) 263.7 263.7 444.98 444.98 444.98 444.98
Recommended Enclosures
Typical sealed enclosure (cu. ft.) 0.9 0.9 2 2 3.64 3.64
Vented enclosure (cu. ft.) *** 0.75 0.75 1.5 1.5 3.05 3.05
Port tuning frequency (Hz) 42 42 40 40 38 38
Port square equivalent (inches) 2.5x2.5 2.5x2.5 14x2 14x2 16x3 16x3
Port length (inches) 10.95 10.95 30.33 31.33 26.62 26.62

6
WIRING CONFIGURATION
RE-CONE KIT
A re-cone kit is available for these speakers and can be obtained from your dealer.
The part number for each model is listed below.
Model/Part# Description
HCCA102RK ORION HCCA 10” 2 OHM Re-Cone Kit
HCCA104RK ORION HCCA 10” 4 OHM Re-Cone kit
HCCA122RK ORION HCCA 12” 2 OHM Re-Cone Kit
HCCA124RK ORION HCCA 12” 4 OHM Re-Cone Kit
HCCA152RK ORION HCCA 15” 2 OHM Re-Cone Kit
HCCA154RK ORION HCCA 15” 4 OHM Re-cone Kit
WIRING CONFIGURATIONS
The following illustrations provide guidelines on properly connecting your HCCA
Orion woofer to an amplier for maximum power and performance using common
parallel, and series/parallel wiring congurations.
Recommended Amplier Power
1 woofer 1,200 to 4,000 Watts
2 woofer 2,400 to 8,000 Watts
3 woofer 3,600 to 12,000 Watts
4 woofer 4,800 to 16,000 Watts

7
WIRING CONFIGURATION
2 ohm
+ +
- -
+
-
2 ohm
Series - One Speakers (Dual 2 ohm voice coils)
One dual 2 ohm voice coil woofer with voice coils in connected in series
results in a 4 ohm load to the amplifier.
2 ohm
+ +
- -
+
-
2 ohm
Parallel - One Speakers (Dual 2 ohm voice coils)
One dual 2 ohm voice coil woofer with voice coils in parallel
results in a 1 ohm load to the amplifier.

8
WIRING CONFIGURATIONWIRING CONFIGURATION
4 ohm
+ +
- -
+
-
4 ohm
Parallel - One Speakers (Dual 4 ohm voice coils)
One dual 4 ohm voice coil woofer with voice coils in parallel
results in a 2 ohm load to the amplifier.
4 ohm 4 ohm
++
- -
4 ohm 4 ohm
++
- -
+
-
-
h
Parallel - Two Speakers (Dual 4 ohm voice coils)
Two dual 4 oh voice woofers with voice coils in
parallel results in a 1 ohm to the amplifier.

9
WIRING CONFIGURATION
Series-Parallel - Two Speakers (Dual 2 ohm voice coils)
Two dual 2 ohm voice coil woofers with voice coils in series and then
parallel the two series woofers results in a 2 ohm load to the amplifier.
2 ohm 2 ohm
++
- -
2 ohm 2 ohm
++
- -
+
-
4 ohm 4 ohm
++
- -
4 ohm 4 ohm
++
- -
4 ohm 4 ohm
++
- -
+
-
m
m
m
Series-Parallel - Three Speakers (Dual 4 ohm voice coils)
Three dual 4 ohm voice coil woofers with voice coils of each woofer wired
in series and then parallel the three woofers for resulting 2.67 ohm load to
the amplifier.

10
WIRING CONFIGURATION
Series-Parallel - Four Speakers (Dual 4 ohm voice coils)
Four dual 4 ohm voice coil woofer should be wired with the voice coils
on each woofer in series and then parallel the four woofers for a
resulting 2 ohm load to the amplifier.
4 ohm 4 ohm 4 ohm 4 ohm 4 ohm 4 ohm 4 ohm 4 ohm
+
-
++
- -
++
- -
++
- -
++
- -
m
m
m
m
m
m
m
2 ohm 2 ohm 2 ohm 2 ohm 2 ohm 2 ohm 2 ohm 2 ohm
+
-
++
- -
++
- -
++
- -
++
- -
oh
m
m
h
oh
h
oh
Series-Parallel—Four Speakers (dual 2 ohm voice coils)
Four dual 2 ohm voice coil woofers should be wired with the voice
coils on each woofer in series and then parallel the four woofers for
a resulting 1 ohm load to the amplifier.

WIRING CONFIGURATION
11
2 Amplifiers - One Speaker (dual 2 ohm coils)
One dual 2 ohm voice coil woofer with each voice coil connected
to an individual amplifier, resulting in a 2 ohm to each amplifier.
2 ohm
2 ohm
+ +
- -
+
-
+
-

WIRING CONFIGURATION
12
4 ohm
4 ohm
+ +
- -
+
-
+
-
2 Amplifiers - One Speaker (dual 4 ohm coils)
One dual 4 ohm voice coil woofer with each voice coil connected
to an individual amplifier, resulting in a 4 ohm to each amplifier.

13
If you’re planning to build your own enclosure and are confused
in what type of enclosure best suits your needs this page will
help you choose what enclosure best fits your needs. There are
many different types of enclosures. The two most common used
enclosures are sealed and vented enclosure. This page will show
the advantages and disadvantages of the two enclosures.
ADVANTAGES OF A SEALED ENCLOSURES
•High power handing capability
•Great transient response
•Tolerant of minor enclosure size variation
•Easy to construct
•Smooth roll off (12dB/octave)
DISADVANTAGES OF A SEALED ENCLOSURES
•Requires a woofer with a long excursion for better low bass
frequency response.
•Can have lower sensitivity than ported enclosures.
•When using high power and small enclosures, the woofer is not in an ideal
cooling environment.
•Lower bass as compared to a properly tuned vented enclosure
above the ported tuning frequency.
ADVANTAGES OF A VENTED ENCLOSURE
•Increased output around vented tuning
•Higher power handling above the port tuning frequency
•Extended frequency response
•Magnet is in a good cooling environment
•Handles higher bass frequencies with less distortion
DISADVANTAGES OF A VENTED ENCLOSURE
•Vented enclosure transient response is not as good as sealed
boxes because of the resonant effect of the vent tuning
•Midrange sound coming from inside the enclosure through the vent
can produce unpleasant sound coloration.
•Loss of cone movement control below vent tuning, which can re
sult in high distortion and mechanical failure of the driver.
•Lower power handling below the port tuning frequency
BUILDING AN ENCLOSURE

14
ENCLOSURE DETAILS
ENCLOSURE DETAILS
1. Parameters listed are for conventional applications only, for further help
please call Sound Pros Tech Support.
2. At least 0.75” MDF (Medium Density Fiberboard) is recommended for any
enclosure.
3. Recommended enclosures are NET box volumes, speaker and port
displacement are calculated into the volume of the enclosure, you will need
to add these volumes to calculate GROSS volume for the enclosure.
NOTES
* Due to the high power capabilities and long excursion of the HCCA woofers,
the Thiele/Small Parameters were calculated and measured using Klippel
analyzer system.
** Energy Bandwidth Product (EBP) is determined by the following formula Fs/
Qes=EBP. EBP values of 50 and lower suggest a sealed enclosure is best, 50 to
90 means the subwoofer versatile and 90 and above mean vented Enclosure is
recommended.
*** Subsonic lter should always be used and adjusted specically for vented
box designs.
ENCLOSURE DESIGN
This section gives the basic description for a sealed enclosure. Orion HCCA
woofers are designed for sealed enclosures and vented enclosures. Sealed
enclosures are generally considered the most versatile for all music types and
are the easiest to build. They will also give high power handling with a wider
range of frequencies. The enclosure must be absolutely air tight. Use a high
quality wood glue for all seams of the enclosure. The enclosure should also
be screwed together. The enclosure should be no less than 3/4” on sides. The
bafe board (woofer mounting plate) should be no less than 1”. If the woofer
mounting is to be recessed then a minimum of two 3/4” plates together
should be used. As MDF is a porous material it is best to also seal the inside of
the enclosure.
NOTE: The woofer must face up or down only, specially in sealed enclosures.
NOTE: Refer to the website www.orioncaraudio.com for updated enclosure
data for your woofer application.

15
HCCA102 & HCCA104 SEALED ENCLOSURE
ENCLOSURE RECOMMENDATION
c
b
—Box Parts—
Box Shape – Square Prism
1 Top, 1 Bottom
depth (c) = 14 in. (356 mm)
width (b) = 14 in. (356 mm)
thickness = 1.0 in. (25.4mm)
1 Front, 1 Back
height (a) = 12 in. (305 mm)
width (d) = 12 in. (305 mm)
thickness = 1.0 in. (25.4mm)
2 Sides
height (a) = 12 in. (305 mm)
depth (c) = 14 in. (356 mm)
thickness = 1.0 in. (25.4mm)
— Driver Mounting —
Mounting: Front
Top &
Bottom
a
d
Front &
Back
c
Sides
A
B
C
— External Dimensions —
A = 14 in (356 mm)
B = 14 in (356 mm)
C = 14 in (356 mm)
— Internal Dimensions —
A = 12 in (305 mm)
B = 12 in (305 mm)
C = 12 in (305 mm)
— Wall Thickness —
Front = 1 in. (25.4mm)
Sides = 1 in. (25.4mm)
Box Properties
— Description —
Type: Closed Box
Shape: Prism, Square
— Box Parameters —
Vb = 0.913 cu.ft
V(total) = 1 cu.ft
Qtc = 0.537
QL = 20
F3 = 67.85 Hz
Fill = none

16
ENCLOSURE RECOMMENDATION
HCCA102 & HCCA104 VENTED 800 TO 1500 WATTS INPUT
c
b
—Box Parts—
Box Shape – Square Prism
1 Top, 1 Bottom
depth (c) = 16 in. (406 mm)
width (b) = 20 in. (508 mm)
thickness = 1 in. (25.4mm)
1 Front, 1 Back
height (a) = 14 in. (356 mm)
width (d) = 18 in. (457 mm)
thickness = 1 in. (25.4mm)
2 Sides
height (a) = 14 in. (356 mm)
depth (c) = 16 in. (406 mm)
thickness = 1 in. (25.4mm)
— Driver Mounting —
Mounting: Front
Top &
Bottom
a
d
Front
& Back
c
Sides
A
B
— External Dimensions —
A = 16 in. (406 mm)
B = 20 in. (508 mm)
C = 16 in (406 mm)
— Internal Dimensions —
A = 14 in
B = 18 in. (457 mm)
C = 14 in (356 mm)
— Wall Thickness —
Front = 1 in. (25.4mm)
Sides = 1 in. (25.4mm)
Box Properties
— Description —
Type: Vented Box
Shape: Prism, Square
— Box Parameters —
Vb = 1.785 cu.ft
V(total) = 2.042 cu.ft
Fb = 38 Hz
QL = 7
F3 = 32.05 Hz
Fill = none
— Vents —
No. of Vents = 1
Vent shape = rectangle
Vent ends = one flush
Hv = 3.75 in. (95 mm)
Wv = 3.75 in. (95 mm)
Lv = 11.67 in. (296 mm)
h
e
h
g
— Vent Parts —
1 Top, 1 Bottom
width (e) = 5.25 in (133 mm)
length (h) = 11.67 in. (296 mm)
thickness = 0.75 in. (19 mm)
2 Sides
height (g) = 3.75 in. (95 mm)
length (h) = 11.67 in. (296 mm)
thickness = 0.75 in. (19 mm)
C

ENCLOSURE RECOMMENDATION
17
HCCA102 & HCCA104 VENTED 1500+ WATTS INPUT
c
b
—Box Parts—
Box Shape – Square Prism
1 Top, 1 Bottom
depth (c) = 15.16 in. (385 mm)
width (b) = 13.5 in. (343 mm)
thickness = 1 in. (25.4mm)
1 Front, 1 Back
height (a) = 11.5 in. (292 mm)
width (d) = 11.5 in. (292 mm)
thickness = 1 in. (25.4mm)
2 Sides
height (a) = 11.5 in. (292 mm)
depth (c) = 15.16 in. (385 mm)
thickness = 1 in. (25.4mm)
— Driver Mounting —
Mounting: Front
Top &
Bottom
a
d
Front
& Back
c
Sides
A
B
C
— External Dimensions —
A = 13.5 in. (343 mm)
B = 13.5 in. (343 mm)
C = 15.16 in. (385 mm)
— Internal Dimensions —
A = 11.5 in. (292 mm)
B = 11.5 in. (292 mm)
C = 13.16 in. (334 mm)
— Wall Thickness —
Front = 1 in. (25.4mm)
Sides = 1 in. (25.4mm)
h
e
h
g
— Vent Parts —
1 Top, 1 Bottom
width (e) = 4 in. (102 mm)
length (h) = 10.95 in. (278 mm)
thickness = 0.75 in. (19 mm)
2 Sides
height (g) = 2.5 in. (64 mm)
length (h) = 10.95 in. (278 mm)
thickness = 0.75 in. (19 mm)
Box Properties
— Description —
Type: Vented Box
Shape: Prism, Square
— Box Parameters —
Vb = 0.75 cu.ft
V(total) = 1.007 cu.ft
Fb = 42 Hz
QL = 7
F3 = 35.53 Hz
Fill = none
— Vents —
No. of Vents = 1
Vent shape = rectangle
Vent ends = one flush
Hv = 2.5in. (64 mm)
Wv = 2.5in. (64 mm)
Lv = 10.95 in. (278 mm)

ENCLOSURE RECOMMENDATION
HCCA102 & HCCA104 VENTED SPL ENCLOSURE ONLY
18
c
b
—Box Parts—
Box Shape – Square Prism
1 Top, 1 Bottom
depth (c) = 17.41 in. (442 mm)
width (b) = 15 in. (381 mm)
thickness = 1 in. (25.4 mm)
1 Front, 1 Back
height (a) = 13 in. (330 mm)
width (d) = 13 in. (330 mm)
thickness = 1 in. (25.4 mm)
2 Sides
height (a) = 13 in. (330 mm)
depth (c) = 17.41 in. (442 mm)
thickness = 1 in. (25.4 mm)
— Driver Mounting —
Mounting: Front
Top &
Bottom
a
d
Front
& Back
c
Sides
A
B
— External Dimensions —
A = 15 in. (381 mm)
B = 15 in. (381 mm)
C = 17.41 in. (442 mm)
— Internal Dimensions —
A = 13 in. (330 mm)
B = 13 in. (330 mm)
C = 15.41 in. (391 mm)
— Wall Thickness —
Front = 1 in. (25.4 mm)
Sides = 1 in. (25.4 mm)
Box Properties
— Description —
Type: Vented Box
Shape: Prism, Square
— Box Parameters —
Vb = 1.25 cu.ft
V(total) = 1.507 cu.ft
Fb = 57 Hz
QL = 7
F3 = 44.65 Hz
Fill = none
— Vents —
No. of Vents = 1
Vent shape = rectangle
Vent ends = one flush
Hv = 4.5 in.(114 mm)
Wv = 4.5 in.(114 mm)
Lv = 9.45 in. (240 mm)
h
e
h
g
— Vent Parts —
1 Top, 1 Bottom
width (e) = 6 in. (152 mm)
length (h) = 9.45 in. (240 mm)
thickness = 0.75 in. (19 mm)
2 Sides
height (g) = 4.5 in. (114 mm)
length (h) = 9.45 in. (240 mm)
thickness = 0.75 in. (19 mm)
C

19
ENCLOSURE RECOMMENDATION
HCCA122 & HCCA124 SEALED ENCLOSURES
c
b
—Box Parts—
Box Shape – Square Prism
1 Top, 1 Bottom
depth (c) = 11.71 in. (297 mm)
width (b) = 27.42 in. (697 mm)
thickness = 1 in. (25.4 mm)
1 Front, 1 Back
height (a) = 15.71 in. (399 mm)
width (d) = 25.42 in. (645.7 mm)
thickness = 1 in. (25.4 mm)
2 Sides
height (a) = 15.71 in. (399 mm)
depth (c) = 11.71 in. (297 mm)
thickness = 1 in. (25.4 mm)
— Driver Mounting —
Mounting: Front
Top &
Bottom
a
d
Front &
Back
c
Sides
A
B
C
— External Dimensions —
A = 17.71 in. (450 mm)
B = 27.42 in. (697 mm)
C = 11.71 in. (297 mm)
— Internal Dimensions —
A = 15.71 in. (399 mm)
B = 25.42 in. (645.7 mm)
C = 9.709 in. (247 mm)
— Wall Thickness —
Front = 1 in. (25.4 mm)
Sides = 1 in. (25.4 mm)
Box Properties
— Description —
Type: Closed Box
Shape: Prism, Square (optimum)
— Box Parameters —
Vb = 2 cu.ft
V(total) = 2.244 cu.ft
Qtc = 0.952
QL = 12.95
F3 = 32.93 Hz
Fill = none