Orion HCCA102 User manual

Subwoofer
MODEL
HCCA102
HCCA104
HCCA122
HCCA124
HCCA152
HCCA154
OWNER'S MANUAL

INSTALLATION
The performance of these HCCA subwoofers is directly proportional to the quality of
installation. Care taken during the installation process will be rewarded with years of
satisfying performance. If you are unsure about your installation capabilities, please
refer to your local Authorized Orion Dealer for technical assistance. Orion dealers are
trained professionals dedicated to extracting the maximum performance out of your
Orion system. If you decide to install this speaker system yourself, please read the
entire section on sealed and vented enclosures before starting your installation.
Please Note: Due to the extremely long excursion and high temperature possibilities
of this woofer, it is recommended that when the woofer is installed it be positioned
so that the cone either faces upward or downward only.
FINDING SPEAKER MOUNTING LOCATIONS
Choosing the correct speaker locations will have the greatest effect on the sound
quality of the system. There are many different considerations needed when choosing
the locations that best suit your needs. The locations must be large enough for the
speakers to fit. Care is needed to ensure that the location you have chosen will not
affect any of the mechanical or electrical operations of the vehicle.
Determining the best location for the speakers will depend on your cosmetic needs
and your vehicle’s interior. Usually the woofers are installed in the trunk, rear seat,
or rear of the vehicle.
FEATURES
1 2
21
20
19 3
18 4
17 5
16 6
15 7
8
14 9
10
13
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.
9 ,ARGE3STACKCERAMICMAGNETS(10v264OZ 12/15v445OZ)
10 11MM3TEELBACKPLATE/POLEPIECE4 YOKEASSEMBLY
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 fins 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 fins and vent hole. Part of
the enhanced voice coil cooling system (forced convection-aluminum heat
sinking-shorting rings to reduce inductive heating).
17 Bottom flat 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 field re-cone kit
attachment method. (eight allen head screws).
20 Top flat interlaced Conex spider.
21 Surround clamp ring, part of field re-cone kit attachment method. (eight
allen head screws).

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
HCCA102ck ORION HCCA 10” 2 OHM Re-Cone Kit
HCCA104ck ORION HCCA 10” 4 OHM Re-Cone Kit
HCCA122ck ORION HCCA 12” 2 OHM Re-Cone Kit
HCCA124ck ORION HCCA 12” 4 OHM Re-Cone Kit
HCCA152ck ORION HCCA 15” 2 OHM Re-Cone Kit
HCCA154ck ORION HCCA 15” 4 OHM Re-Cone Kit
WIRINGCONFIGURATIONS
The following illustrations provide guidelines on properly connecting your HCCA
Orion woofer to an Orion amplifier for maximum power and performance using
COMMON PARALLEL, AND SERIES/PARALLEL WIRING CONFIGURATIONS.
Recommended Amplifier Power
1 woofer 1,200 to 4,000 watts
2 woofers 2,400 to 8,000 watts
3 woofers 3,600 to 12,000 watts
4 woofers 4,800 to 16,000 watts

+
-
2 ohm 2 ohm
Series—One Speaker (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.
- -
+ +
Figure 2
Figura 2
Abbildung 2
+
-
1. Connect the woofer in series by connecting the negative (-) of one terminal to the
positive (+) terminal of the other coil.
2. Wire the positive (+) terminal of the first coil to the positive (+) terminal on the
amplifier. Wire the negative (-) terminal of the second coil to the negative (-) terminal
on the amplifier.

2 ohm
2 oh
Parallel—One Speaker (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.
- -
+ +
Figure 3
Figura 3
Abbildung 3
+
-
1. Connect the speaker in parallel by connecting the two positive (+) terminals
together and the two negative (-) terminals together.
2. Wire the positive (+) terminals of the woofer to the positive (+) terminal on the
amplifier. Wire the negative (-) terminals of the woofer to the negative (-) terminal
on the amp.

4 ohm 4 ohm
Parallel—One Speaker (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.
- -
+ +
Figure 4
Figura 4
Abbildung 4
+
-
1. Connect the speaker in parallel by connecting the two positive (+) terminals
together and the two negative (-) terminals together.
2. Wire both positive (+) terminals of the woofer to the positive (+) terminal on the
amplifier. Wire both negative (-) terminals of the woofer to the negative (-) terminal
on the amplifier.

4 ohm 4 oh 4 ohm
4 ohm
Parallel—Two Speakers (dual 4 ohm voice coils)
Two dual 4 ohm voice coil woofers with voice coils in parallel and the two woofers in
parallel results in a 1 ohm load to the amplifier.
- - - -
+ + + +
+
Figure 5 -
Figura5
Abbildung 5
1. Connect the speaker in parallel by connecting the four positive (+) terminals
together and the four negative (-) terminals together.
2. Wire the positive (+) terminals of the woofers to the positive (+) terminal on the
amplifier. Wire the negative (-) terminals of the woofers to the negative (-) terminal
on the amplifier.

2 ohm 2 ohm 2 ohm 2 ohm
Series-Parallel—Two Speakers (dual 2 ohm voice coils)
Note: Verify and ensure that the woofer wiring is connected as shown with
the negative connection from the first woofer coil connected to the positive
connection of the second woofer coil.
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.
- - - -
+ + + +
+
Figure 6 -
Figura6
Abbildung 6
1. Connect each woofer in series by connecting the negative (-) of the first coil to the
positive (+) terminal of the second coil.
2. Wire the positive (+) terminal of the first coil on each woofer to the positive (+)
terminal on the amplifier. Wire the negative (-) terminal of the second coil on each
woofer to the negative (-) terminal on the amplifier.

4 ohm 4 ohm 4 ohm
4 ohm 4 oh 4 ohm
Series-Parallel—Three Speakers (dual 4 ohm voice coils)
Note: Verify and ensure that the woofer wiring is connected as shown with
the negative connection from the first woofer coil connected to the positive
connection of the second woofer coil.
Three dual 4 ohm voice coil woofer with voice coils of each woofer wired in series and
then parallel the three woofers for a resulting 2.67 ohms.load to the amplifier.
- - - - - -
+ + + + + +
Figure 7
Figura 7
Abbildung 7
+
-
1. Connect each woofer in series by connecting the negative (-) of the first coil to the
positive (+) terminal of the second coil.
2. Wire the positive (+) terminal of each woofer’s first coil to the positive (+) terminal
on the amplifier. Wire the negative (-) terminal of each woofer’s second coil to the
negative (-) terminal on the amplifier.

4 ohm 4 ohm 4 ohm 4 ohm 4 ohm 4 ohm 4 ohm 4 ohm
Series-Parallel—Four Speakers (dual 4 ohm voice coils)
Note: Verify and ensure that the woofer wiring is connected as shown with
the negative connection from the first woofer coil connected to the positive
connection of the second woofer coil.
Four dual 4 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 2 ohm load to the
amplifier.
- - - - - - - -
+ + + + + + + +
+
Figure 8 -
Figura8
Abbildung 8
1. Connect each woofer in series by connecting the negative (-) of the first coil to the
positive (+) terminal of the second coil.
2. Wire the positive (+) terminals of the first coil of each woofer to the positive (+)
terminal on the amplifier. Wire the negative (-) terminal of the second coil of each
woofer to the negative (-) terminal on the amplifier.

2 ohm 2 ohm 2 ohm 2 ohm 2 ohm 2 ohm 2 ohm 2 ohm
Series-Parallel—Four Speakers (dual 2 ohm voice coils)
Note: Verify and ensure that the woofer wiring is connected as shown with
the negative connection from the first woofer coil connected to the positive
connection of the second woofer coil.
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.
- - - - - - - -
+ + + + + + + +
+
Figure 9 -
Figura9
Abbildung 9
1. Connect each woofer in series by connecting the negative (-) of the first coil to the
positive (+) terminal of the second coil.
2. Wire the positive (+) terminals of the first coil of each woofer to the positive (+)
terminal on the amplifier. Wire the negative (-) terminal of the second coil of each
woofer to the negative (-) terminal on the amplifier.

2
ohm
2
oh
2 Amplifiers—One Speaker (dual 2 ohm voice coils)
One dual 2 ohm voice coil woofer with each voice coil connected to an individual
amplifier, resulting in a 2 ohm load to each amplifier.
- -
+ +
+
-
+
Figure 10
Figura 10
Abbildung 10
-
1. Connect one of the speaker’s voice coils to the first amplifier by connecting the
positive (+) terminal and the negative (-) terminal from the speaker to the respective
positive (+) terminal and the negative (-) terminal from the first amplifier.
2. Connectthe other of the speaker’s voice coils to the second amplifier by connecting
the positive (+) terminal and negative (-) terminal from the speaker to the respective
positive (+) terminal and the negative (-) terminal from second amplifier.

4
ohm
4
oh
2 Amplifiers—One Speaker (dual 4 ohm voice coils)
One dual 4 ohm voice coil woofer with each voice coil connected to an individual
amplifier, resulting in a 4 ohm load to each amplifier.
- -
+ +
+
-
+
Figure 11
Figura 11
Abbildung 11
-
1. Connect one of the speaker’s voice coils to the first amplifier by connecting the
positive (+) terminal and the negative (-) terminal from the speaker to the respective
positive (+) terminal and the negative (-) terminal from the first amplifier.
2. Connectthe other of the speaker’s voice coils to the second amplifier by connecting
the positive (+) terminal and negative (-) terminal from the speaker to the respective
positive (+) terminal and the negative (-) terminal from second amplifier.

SPECIFICATIONS
Model/Part Number HCCA102 HCCA104 HCCA122
Size 10” 10” 12”
Thiele/Small Parameters
Fs (free-air resonance, Hz) 42.51 44.3 32.3
Vas (equivalent compliance, cu. ft.) 0.31029 0.31699 0.89274
Vas (equivalent compliance, liters) 8.798.9825.29
Qms (Q, mechanical) 7.165.995.08
Qes (Q, electrical) **** 0.480.520.5
Qts(total driver Q) **** 0.450.480.45
Re (DC resistance, ohms) **** 3.9 7.4 4
Z (nominalimpedance, ohms) 2 x 2 4 x 4 2 x 2
Le (inductance, mh) **** 1.932.932.61
Efficiency (1W @ 1M, dB) 86.51 83.66 84.22
Xmax (one way linear excursion, in.) 1.01948 1.01948 1.18939
Xmax (one way linear excursion, mm) 25.89 25.89 30.1875
Pe (continuous power handling, watts) 150015002000
Peakpower handling (music, watts) * 300030004000
Mms (total moving mass, grams) 250 225 425
#MS (MECHANICAL COMPLIANCE, MM/.)
0.000056 0.000057 0.000057
Bl (motor strength, Tesla-M) **** 23.329.86 26.27
Sd (effective radiating area, sq. cm.) 333.29 333.29 559.9
Sd (effective radiating area, sq. in.) 51.66 51.66 86.78
Frequency range (Hz) 32 - 100 33 - 100 24 - 100
Energy Bandwidth Product (EBP) ** 89 85 65
Driver Physical Dimension
Speaker Displacement (cu ft) 0.1268 0.1268 0.28931
3PEAKER/UTER$IAMETER(INCHES/MM) 238 238 292
-OUNTING HOLE DIAMETER (INCHES/MM)
9.379.3711.5
-OUNTINGDEPTH(INCHES/MM) 8.425/214 8.425/214 10.28/261
MagnetWeight (Oz) 263.7 263.7 444.98
"ASKETDIAMETER(INCHES/MM)
Recommended Enclosures
Typical sealed enclosure (cu. ft.) 0.9 0.9 2
Vented enclosure (cu. ft.) *** 0.750.751.5
Porttuning frequency (Hz) 424240
Port square equivalent (inches) 2.5 x 2.5 2.5 x 2.5 14 x 2
Port length (inches) 10.95 10.95 30.33
Specifications are subject to change without notice.

SPECIFICATIONS
Model/Part Number HCCA124 HCCA152 HCCA154
Size 12” 15” 15”
Thiele/Small Parameters
Fs (free-air resonance, Hz) 33.2 28.13 30.02
Vas (equivalent compliance, cu. ft.) 0.93157 2.95746 2.82259
Vas (equivalent compliance, liters) 26.39 83.78 79.96
Qms (Q, mechanical) 4.165.174.38
Qes (Q, electrical) **** 0.540.550.61
Qts(total driver Q) **** 0.480.5 0.54
Re (DC resistance, ohms) **** 7.4 47.3
Z (nominalimpedance, ohms) 4 x 4 2 x 2 4 x 4
Le (inductance, mh) **** 3.672.593.68
Efficiency (1W @ 1M, dB) 83.38 87.287.4
Xmax (one way linear excursion, in.) 1.18939 1.18939 1.18939
Xmax (one way linear excursion, mm) 30.18 30.18 30.18
Pe (continuous power handling, watts) 200020002000
Peakpower handling (music, watts) * 400040004000
Mms (total moving mass, grams) 386 500 460
#MS (MECHANICAL COMPLIANCE, MM/.)
0.00006 0.00005 0.000061
Bl (motor strength, Tesla-M) **** 33.225.34 32.21
Sd (effective radiating area, sq. cm.) 559.9 962.11 962.11
Sd (effective radiating area, sq. in.) 86.78 149.13 149.13
Frequency range (Hz) 25 - 100 21 - 100 22 - 100
Energy Bandwidth Product (EBP) ** 61 51 49
Driver Physical Dimension
Speaker Displacement (cu ft) 0.28931 0.37704 0.37704
3PEAKER/UTER$IAMETER(INCHES/MM) 292 383 383
-OUNTING HOLE DIAMETER (INCHES/MM)
11.515.079 15.079
-OUNTINGDEPTH(INCHES/MM) 10.28/261 11.575/294 11.575/294
MagnetWeight (Oz) 444.98 444.98 444.98
"ASKETDIAMETER(INCHES/MM)0
Recommended Enclosures
Typical sealed enclosure (cu. ft.) 23.643.64
Vented enclosure (cu. ft.) *** 1.5 3.053.05
Porttuning frequency (Hz) 403838
Port square equivalent (inches) 14 x 2 16 x 3 16 x 3
Port length (inches) 31.33 26.62 26.62
Specifications are subject to change without notice

ENCLOSURE DETAILS
1. Parameters listed are for conventional applications only, for further help please
call Tech Audio Support
2. 1” MDF is recommended.
3. Recommended enclosures are NET Box Volumes, speaker and port displacement
are calculated into the volume of the enclosure, you will not need to add these
volumes to calculate GROSS volume for the enclosure.
NOTES:
* Due to the high power capabilities and long excursion of these woofers, the
4HIELE/3MALL 0ARAMETERS WERE CALCULATED AND MEASURED USING A +L IPPEL ANALYZER
system.
** %NERGY "ANDWIDTH 0RODUCT (%"0) IS DETERMINED BY THE FOLLOWI NG FORMULA &S/
Qes = EBP. EBP values of 50 and lower suggest a sealed enclosure is best 50 to
91 means the subwoofers versatile and 90 and above mean vented enclosure is
recommended.
*** Sub-sonic filters should always be used and adjusted specifically for vented box
designs.
**** Electrical Parameters were calculated in series.
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
ENCLOSURESHOULDBENOLESSTHAN3/4vONSIDES.4HEBAFFLEBOARD(WOOFERMOUNTING plate)
should be no less than 1”. If the woofer mounting is to be recessed then a
MINIMUM OFTWO 3/4v PLATESTOGETHER SHOULD BE USED. !S -$& IS A POROUSMATERIAL it is best
to also seal the inside of the enclosure.
NOTE: The woofer must face up or down only, especially in sealed enclosures.
NOTE: Refer to the website www.orioncaraudio.com for updated enclosure data for
your woofer application.

EXPLANATION OF ENCLOSURE SPECIFICATIONS
There are many different factors that help determine the best style of enclosure for
you or your vehicle. Listed below are some factors that should be considered.
The size of the enclosure is directly proportional to the efficiency and power handling
of that speaker. A woofer in a smaller enclosure will handle more power than the
same woofer in a larger enclosure. The exact opposite is true for efficiency, a larger
enclosure will play lower frequencies at a higher volume with less power than a
smaller enclosure.
The sealed enclosure design following is best for overall sound quality. The enclosure
size to use will depend on the power and type of vehicle that it will be placed in.
Larger enclosures are best suited if you have smaller amounts of power (25% to 50%
of speaker’s power handling), have a larger vehicle or looking for greater output. A
smaller enclosure should be utilized if you have recommended power (50% to 100%
of speaker’s rated power handling), have a smaller (high gain) vehicle or are looking
for more accurate sound reproduction. The smaller sealed enclosure will yield more
control, this audible translates into faster and more accurate bass.
A vented enclosure will offer greater efficiency and stronger low bass output
compared to a sealed design. A vented enclosure uses the back wave (sound from the
back side of the cone) to reinforce the output from the speaker. A properly tuned
enclosure will yield gain across the entire bandwidth of the subwoofer system and
offer more cone control than a sealed enclosure. A low tuning will yield less overall
gain but greater extension (low bass). A high tuned enclosure will offer more gain but
limit the low end response of the system. One of the advantages of having a vented
enclosure is because it is tunable to a specific frequency and that tuning frequency is
known as the “Fb”. Another important box specification is “F3”, which is the rolloff
frequency at which the driver’s response is down 3dB. This is an important number
when it comes to setting your a highpass filter or your ORION IntelliQ. The IntelliQ
should be set at the same frequency as the “F3”as this will keep the speaker from
damaging or what is know as overloading.
Good planning and proper construction will assure the best response from your
system. The next pages will outline many different enclosures and designs that allow
the HCCA subwoofers to perform best. As always, if you have any questions on
enclosure construction or design, call Technical Support 1-800-753-0800.

HCCA102 & 104 Sealed Enclosure
Note: These Enclosures are designed for sound quality and offer very low tuning
frequencies. If you are building a system where the goal is to listen to music, these
are the enclosures to build. They offer the best low frequency performance of all the
designs.
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
— External Dimensions —
A = 14 in (356 mm)
B = 14 in (356
mm)
C = 14 in (356 mm)
— Internal Dimensions
—
A = 12 in (305 mm)
A B = 12 in (305
mm)
C = 12 in (305
mm)
C — Wall Thickness
—
Front = 1 in. (25.4mm)
B Sides = 1 in.
(25.4mm)
c Top
&
Bottom
b
d
—Box
Parts—
Box Shape – Square
Prism
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)
c thickness = 1.0 in.
(25.4mm)
2
Sides
Front &
a
Back
Sides
height (a) = 12 in. (305
mm)
depth (c) = 14 in. (356 mm)
thickness = 1.0 in. (25.4mm)
— Driver Mounting —
Mounting: Front

HCCA102 & 104 Vented 800 to 1500 Watts Input
Note: These enclosures will deliver higher sound pressure levels than sealed enclosures.
The perceived loudness will be lower than a sealed enclosure, although the metered
number will be higher. WARNING: proper setting of the IntelliQ is critical or woofers
may become damaged from over excursion!
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)
— External Dimensions —
A = 16 in. (406 mm)
B = 20 in. (508
mm)
C = 16 in (406 mm)
— Internal Dimensions
—
A = 14
in
A B = 18 in. (457
mm)
C = 14 in (356
mm)
C — Wall Thickness
—
Front = 1 in. (25.4mm)
B Sides = 1 in.
(25.4mm)
Top &
c
Bottom
b
d
—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)
c thickness = 1 in.
(25.4mm)
2
Sides
Front
a &
Back
e
h
Sides
height (a) = 14 in. (356
mm)
depth (c) = 16 in. (406 mm)
thickness = 1 in. (25.4mm)
— Driver Mounting —
Mounting: Front
— 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)
h 2
Sides
g
height (g) = 3.75 in. (95 mm)
length (h) = 11.67 in. (296 mm)
thickness = 0.75 in. (19 mm)