HCCA 225R, 250R & 275R OWNER'S MANUAL HIGH PERFORMANCE CAR AUDIO
TABLE OF CONTENTS INTRODUCTION 3 WARRANTY 6 SPECIFICATIONS 8 TECHNICAL DESIGN FEATURES 10 SYSTEM PLANNING 12 POWER CONNECTIONS 20 SPEAKER CONNECTIONS 24 INPUT SECTION 32 INTERNAL CROSSOVER SECTION 34 INTELLI Q 38 AUXILIARY OUTPUT SECTION 42 REMOTE GAIN SECTION 43 INSTALLATION TIPS 44 TROUBLESHOOTING TIPS 50 AUTOSOUND 2000 TROUBLESHOOTING TIPS 52 page 2
INTRODUCTION Thank you for your purchase of ORION’s HCCA power amplifier. Each HCCA amplifier is designed to be the leader in its class offering the most power, advanced features and extreme ease of use. In high-end sound systems or high SPL systems, the HCCA amplifiers will give you years of trouble-free performance. • HCCA 225R- 25 watt per channel 2 channel high current amplifier with built-in fully variable high-pass, low-pass or bandpass crossover with INTELLLi Q.
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 Hotline at 1800 315-2052 or (480) 705-5600 for assistance. PRACTICE SAFE SOUND Continuous exposure to sound pressure levels over 100 dB may cause permanent hearing loss.
WHAT’S IN THE BOX QTY DESCRIPTION 1 HCCA power amplifier 2 2 conductor 4 gauge power connector 1 5 conductor 12 gauge speaker connector 4 #8 Phillips Pan Head Screws 1 HCCA Reference Manual page 5
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.
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 1-800-350-9726 or (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.
SPECIFICATIONS AMPLIFIER SECTION HCCA 225R HCCA 250R HCCA 275R Power output 4 Ω Stereo (watts) 25 watts 50 watts 75 watts Power output 2 Ω Stereo (watts)1 50 watts 100 watts 150 watts Power output 1 Ω Stereo (watts)1 100 watts 200 watts 300 watts Power output 0.
input sensitivity3 200 mV to 5 Vrms 200 mV to 5 Vrms 200 mV to 5 Vrms input impedance 47kΩ 47kΩ 47kΩ fuse type (2) 20 AMP ATC (2) 30 AMP ATC (6) 30 AMP ATC low-pass crossover4 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 1
TECHNICAL DESIGN FEATURES page 10
AMPLIFIER CALL OUTS 1. Power LED-when lit indicates that the amplifier is on. 2. Output Configuration Switches-determine the output configuration of the amplifier 3. Independent Gain Controls-continuously adjust from 200mV to 5Vrms for full power output 4. RCA inputs-accepts RCA input from a source unit, preamplifier or equalizer 5. AUX RCA outputs-provides easy connection to additional amplifiers. 6. AUX RCA output control-determines the audio signal out the AUX RCAs 7.
SYSTEM PLANNING The easiest way to maximize the performance for your ORION HCCA amplifier is to properly plan your system. By planning your system, you can avoid situation where the performance of the reliability of your system is compromised. Your Authorized ORION dealer has been trained by ORION Industries on how to maximize your system’s sonic potential. Authorized ORION dealers are a valuable resource in helping you with your system de-sign and installation.
SYSTEM 2 adds an additional amplifier to drive the subwoofers. A RGC-1 (Remote Gain Control) has been added to the subwoofer amplifier for dash mounted subwoofer level control. AMPLIFIER 1 • Output is configured for high-pass operation. • Left Phase switch set to 0° • Right Phase switch set to 0° • Gain controls can be set together or independently of each other AMPLIFIER 2 • Output is configured for band-pass operation. • The high-pass crossover is used as a sub sonic filter with INTELLi Q.
SYSTEM 3 page 14
SYSTEM 3 adds an additional amplifier and another set of satellites to SYSTEM 2 for a front rear fade system. AMPLIFIER 1 & 2 • Output is configured for high-pass operation. • Left Phase switch set to 0° • Right Phase switch set to 0° • Gain controls can be set together or independently of each other AMPLIFIER 3 • Output is configured for band-pass operation. • The high-pass crossover is used as a subsonic filter with INTELLi Q.
SYSTEM 4 SYSTEM 4 adds an amplifier to system 3 to the front satellites for more power and control. AMPLIFIER 1 & 3 • Output is configured for high-pass operation.
AMPLIFIER 2 • Output is configured for bandpass operation. AMPLIFIER 4 • Output is configured for band-pass operation. • Left Phase switch set to 0° • The high-pass crossover is used as a subsonic filter with INTELLi Q.
SYSTEM 5 page 18
SYSTEM 5 has one amplifier driving front satellites, one amplifier running as a Master Amplifier and additional amplifiers running as Slave amplifiers to the master. The subwoofer amplifiers are configured in a Master/ Slave configuration for absolute crossover and level matching. AMPLIFIER 1 • Output is configured for high-pass operation. • Left Phase switch set to 0° AMPLIFIER 2 • Output is configured for band-pass operation. AMPLIFIER 3, 4 & 5 • Output is configured for full range operation.
POWER CONNECTIONS Amplifier Fuse Size XTREME 400 (2) 20 AMP XTREME 800 (2) 30 AMP XTREME 1200 (6) 30 AMP page 20
• Power connections made through a large 4 gauge removable terminal connector. (Dual 4 gauge connectors of the HCCA 275R) • 4 Gauge power and ground wire recommended for optimal performance. (Dual 4 gauge connectors of the HCCA 275R) • Minimum 8 Gauge power and ground cable is recommended for acceptable performance. (Use only 4 gauge power wire on the HCCA 275R). • Connect 12V+ to the battery through fuse holder. This connection provides +12V main power to the amplifier.
POWER CONNECTIONS HCCA 275R Amplifier Fuse Size HCCA 275R (6) 30 AMP page 22
• 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 less than 18” from battery. • Terminate both grounds for amplifier to a good chassis ground as close as possible to the amplifier.
TWO CHANNEL STEREO CONFIGURATION INPUT AUX RIGHT PHASE LEFT PHASE LOW-PASS HIGH-PASS AUX RCA INPUT RCA 600Hz 5kHz POWER 6dB 10dB 3dB 0dB 120Hz 1kHz R 0 180 0 RIGHT LEFT GAIN GAIN MONO BRIDGE COPY MASTER GAIN 45Hz 35Hz 10Hz 180 LP ON LP OFF L SPEAKER OUTPUTS LEFT 175Hz REMOTE FUSE HP x 10 HP x 1 HP ON HP OFF POWER RIGHT REM BRIDGED REM GAIN + + _ _ 12V+ GND page 24
• Lowest Recommended Impedance is 0.5Ω Stereo. • RCA inputs are connected to both left and right channels • Left Phase switch set to 0° • Right Phase switch set to 0° • 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. • Output is configured either for stereo operation. TUNING NOTE: The phase switches can be individually switched for improved sound quality.
SUMMED BRIDGED CONFIGURATION page 26
• Lowest Recommended Impedance is 1Ω bridged mono. • RCA inputs are connected to both left and right channels • Left Phase switch set to 0° • Right Phase switch set to 180° • 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..
SINGLE CHANNEL BRIDGED CONFIGURATIONS page 28
• Lowest Recommended Impedance is 1Ω bridged mono. • Only the Right RCA input is used • Right Phase switch set to 0° • Left Phase switch set to “MONO BRIDGED” • 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. • Output is configured mono bridged which is ideal for separate left or right channel subwoofer applications..
TRI-MODE THREE CHANNEL CONFIGURATION page 30
• Lowest Recommended Impedance is 0.5Ω stereo and 1Ω bridged mono. • RCA inputs are connected to both left and right channels • Left Phase switch set to 0° • Right Phase switch is set to 180°, Speaker polarity on the right channel must be inverted to maintain proper speaker polarity. • 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.
INPUT SECTION The input section of the 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 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.
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. 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. Right Phase control determines the phase of the output.
INTERNAL CROSSOVER SECTION The crossover section of the HCCA amplifier is continuously variable and extremely flexible. There are eight different crossover configurations possible allowing high-pass, low-pass and band-pass configurations. New for ORION amplifiers is the INTELLi Q feature on the high-pass crossover. This circuit is designed to optimize the performance of ORION subwoofers in all types of enclosures.
FINE TUNING THE LOW-PASS CROSSOVER 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 to 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 frequencies. These crossover frequencies are 85 Hz, 2,500 Hz and 3,500 Hz respectively.
HIGH-PASS CROSSOVER When both push buttons are in the “out” position, the high-pass crossover is bypassed. MID AND TWEETERS 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 speakers. Set the INTELLi Q level to “0 dB.
FINE TUNING THE HIGH-PASS CROSSOVER “HIGH RANGE” 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” frequency range, the corner frequencies are 100 Hz, 350 Hz, 1.2 kHz and 10 kHz respectively.
ADJUSTING INTELLI Q Boost Levels 0dB +3dB +6dB +10dB 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.
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 10dB!!! The boost level is identified by the corner markings.
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.
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 enclosure 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.
AUXILIARY OUTPUT SECTION The auxiliary outputs offer ORION amplifiers easy unlimited system expansion . Routing signal from a source unit, pre-amplifier or equalizer is a matter of routing RCAs into 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 RCA is an identical copy of the RCA inputs.
Remote Gain Section 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 amplifier gain level.
INSTALLATION TIPS TOOLS FOR 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.
CHOOSING MOUNTING LOCATIONS The location of your HCCA amplifier will depend on several important issues. Due to the low profile size of the HCCA amplifiers, there are many possible installation locations that will yield satisfactory amplifier performance. Always mount the amplifier in a place that protects the amplifier from the elements. In addition, mount the amplifier on a stable, flat mounting surface.
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.
STEP BY STEP INSTALLATION 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.
TESTING THE SYSTEM After you have completed the installation, you need to test the system. This will help ensure years of trouble free operation. Please refer to the listed steps below when testing the sound of your ORION HCCA system. Step 1 Check all the wiring connections to be sure they are correct and secure. Step 2 Turn the signal source volume control down all the way. Set any tone controls to their flat or defeated positions. This includes the loudness control.
Step 2 Turn the level controls of the amplifier to their minimum positions. Step 3 Choose music with high dynamic content that you like, that you are familiar with and will be most often used in the system. Step 4 Turn the unit up to its highest undistorted output level. If you lack test equipment, this point occurs between 3/4 to full volume depending on the quality of your source unit.
TROUBLE SHOOTING TIPS SYMPTOM PROBABLE CAUSE ACTION TO TAKE No output Low or no remote turn-on input Check remote turn-on voltage output at amplifier and fix as needed Fuse blown Check power wire integrity and check for speaker shorts.
SYMPTOM PROBABLE CAUSE ACTION TO TAKE Distorted output continued... Speaker not connected to properly Check speaker wiring and fix or replace as needed. Refer to the amplifier speaker connections section of this manual for detailed instructions Internal crossover not set properly Readjust crossovers.
AUTOSOUND 2000 TROUBLESHOOTING TIPS QUICK CHECK FOR TROUBLESHOOTING CAR AUDIO SYSTEMS Preface: All audio systems exhibit noise; however, if the level of noise is low enough, and the signal level high enough, noise should not be a problem. This means that it is very important that the signal level throughout the system be optimized BEFORE dealing with your noise problem.
B. II. DECK TO AMP. Using a new set of signal cables, connect one channel from the output of the deck directly into one channel of your clean amp. Run the cables outside the car and as far away as possible from the metal of the car. (For noise purposes, consider a 2" thick cushion of electromagnetic energy emanating from every metal surface in the car.) A. B. III. If your muted amp is quiet, you’ve just joined 99.5% of car audio.
SUMMATION: During the design stage of your vehicles, try to avoid using extra batteries and high output alternators. Extra batteries are nothing but loads as soon as the engine is started and high output alternators usually make more noise than stock alternators. Also, extra batteries installed in the trunk of a car will ALWAYS force extra ripple current to flow over the car. Install Transient Storage as close to the power supply input of your amplifier as possible.
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HIGH PERFORMANCE CAR AUDIO AMPLIFIERS, SIGNAL PROCESSORS AND LOUDSPEAKERS HIGH PERFORMANCE CAR AUDIO ©1998 Orion Industries, Incorporated 9235 S. McKemy Street , Tempe, Arizona 85284 Phone: 480.705.5600 Fax: 480.705.5788 One of the ADST family of companies.
