Orion HCCA10002, HCCA10004 Owner's Manual

OWNER'

S MANUAL

Amp

lifie

r

MODEL

HCC

A10002

HCC

A10004

BRIDGE

4

OHM

B

RIDGE

4

OHM

END PANEL

LAYOUTS

HCC

A10002

1

2 3 4

ESP

5 6

REMOTE

Figure 1
Figura

1

Abbil

dung

1

2.

Speakers (Left channel) -Connect the speakers to these terminals.

(HCCA10002 only, refer to the Speaker Connections section of
this guide.)

3. Input - Accepts RCA input from a head unit, preamplifier, or
equalizer (HCCA10002 only).

4. RCA Line Output - Provides easy connection to additional ampli-
fiers, the RCA inputs and RCA output are the same signal and are
not affected by any amplifier functions.

5. Speakers (right channel) - HCCA10002 only see item

2

L R L R

GAIN

I

NPUT

INPU

T OUTPUT

O

UT

PUT

HCCA

10004

L CH

R

CH

BRIDGE 4 OHM

6. Remot

e Gain Input - Connects optional RGC2 remote gain control

to control the gain level from the driver’s seat.

7. GAIN RANGE - Selects the input sensitivity range to either High
(for high power head units) or Low (for line level head units).

1

7 8

9 4

10

11

12

13 6

8. Sp

eakers (Left Front and Right Front below) -Connect the speak-
ers to these terminals. (HCCA10004 only, refer to the Speaker
Connections section of this guide.)

LF L LR

GAI

N

RANGE LF

HIGH

INPU

T OUTPUT

INPUT

CH LINE

REMOTE

LR MODE OUT

GAIN

2 CH

F/R SUM

9. Input (Le

ft Front and Right Front below) - Accepts RCA input from

a head unit, preamplifier, or equalizer (HCCA10004 only).

ESP

LOW

4 CH PASS

RF

RF

R RR

RR

10.

11.

Figure

2

12.

Figura 2

Abbildung

2

13.

I

nput (L

e

ft Rear and Right Rear below) - see item 9

Speakers (Right Rear and Left Rear below) -see item 8
2/4 Channel Switch - 2ch setting will allow 4 channel output with

a signal only present on the front inputs. 4 ch will allow a 4 chan­nel output when signal is present on the front and rear inputs.

Front/Rear Sum Switch - Allows you to sum the front and rear
channels together before sending the signal out the RCA line out.

1. ESP - Allows connection of a MD Audio Engineering ESP
controller, like the

Bitwriter.

If the switch is not engaged, then only the front left and front
right signals are sent to the RCA line out.

1

2 3 4

ground

terminal or any other factory ground points.

4. Top cover lock - Use the key provided or the 3mm hex key to
unlock and remove the top cover.

Figure 3
Figura

3

A

bbil

dung

3

B+

Insulated

Wire

L

REM

GND

POWER

Recommended

wire stripping lengths

(L):

L (for Power wires): 1.0” (25

mm)

L (for Speaker wires): 0.5” (13

mm)

L (for Remote wires): 0.5” (13

mm)

NOTE: M

ake all connections to power, ground, speakers, and remote
terminals before final positioning and installation of the amplifier in
the vehicle. The top cover needs to be removed to fasten some of the
connections. These connections once made are secured by tightening
the set screws with the Allen wrench provided. These fastening set
screws are labeled and located on top of the amplifier at either end,
directly above their associated connectors.

1. +BAT

- connect this terminal through a FUSE or CIRCUIT BREAKER
to the positive terminal of the vehicle battery or the positive ter­minal of an isolated audio system battery.

WARNING: Always protect this power wire by installing a fuse or
circuit breaker of the appropriate size within 12 inches of the battery
terminal connection.

2. REM - this terminal turns on the amplifier when (+) 12 volt is
applied. Connect it to the remote turn on lead of the head unit
or signal source. If a (+) 12 volt remote turn lead is not available,

4/0

0ANEL

,AYOUT

NO

TE: T

op

cover must be removed to access the following controls
(Refer to the Removing the Top Cover section of this manual). These
controls are duplicated for the HCCA10004 (a separate set of controls
for Front and Rear channels).

1

2 3

4

X-OVER

a Remote Po

wer Adapter (P/N ORRPA) can be used to supply a
remote turn on signal. DO NOT connect this terminal to constant
(+) 12 volt.

HIG

H

PASS

ALL

SLO

PE

LOW

HIGH

24dB

LOW
PASS

3. GND -

power return connection. Connect this terminal directly

to the sheet metal chassis of the vehicle, using the shortest wire
necessary to make this connection. Always use wire of the same

50

2K

HZ HZ

HIGH

12dB

OFF

50

2K

HZ HZ

MIN

MAX LOW

15

60

ON

0 10

20 200

gauge or

larger than the (+) 12 volt power wire. The chassis con-

HZ

HZ

GAIN GAI

N

dB dB HZ HZ

nect

ion point should be scraped free of paint and dirt. Use only
quality crimped and/or soldered connectors at both ends of this
wire. DO NOT connect this terminal directly to the vehicle battery

Figure

4
Figura 4
Abbildung 4

RANGE

10 9

Q FREQ

INFRA

SONIC INTELLI-Q

8 7 6

5

1. HIGH PASS -

Adjusts the lower crossover frequency of the ampli-

fier.

2. CROSSOVER SELECTION - ALL is the full range setting, LOW is the
low pass setting and HIGH is the high pass setting.

3. SLOPE - Selects the crossover roll off between 12db and

24d

b

per o

ctave.

4. LOW PASS - Adjusts the upper crossover frequency of the ampli­fier.

5. FREQ - Adjusts the center frequency of the Intelli-Q between 20
and 200 Hz.

6. Q - Continuously adjusts the “Q” boost of the high-pass crossover
from 0 to 10dB of boost.

REMOVING THE TOP COVER

Top C

over

Figure 5
Figura

5

Abbil

dung

5

Lock

Key

7. ON/OF

F - Turns the Intelli-Q on or off.

8. Infrasonic (Subsonic) Switch - When On cuts off extremely low
bass frequencies (below the range of human hearing that speak­ers cannot effectively reproduce). The high pass filter is engaged
when the infrasonic switch is On. This improves efficiency of the
amplifier’s power supply, improves sound reproductive perfor­mance, and reduces chances of damaging the subwoofers.

1. Inser

t key into lock.

2. Turn the key counterclockwise.

3. Slide the top cover away from the key while the key is still turned.
The cover only needs to slide approximately 0.25” before it can
be lifted up and removed from the amplifier.

9.

10.

GAIN RANGE

- Selects the input sensitivity range to either High

(for high power head units) or Low (for line level head units).

GAIN - Continuous adjustment for full power output.

NOTE: Whe

n installing cover, line up the pins on the bottom side of
the cover with the holes in the top of the amplifier. Slide toward the
power connectors. When the top cover shuts, it automatically locks
and does not require the key to complete.

NOTE: The top cover plate is designed to be reversible however the
LED color orientation will also appear changed when the cover is
reversed (see Amplifier Visual Troubleshooting section).

Amplif

ier Section

HCCA

10002

HCCA

10004

Power O

utput 4Ω (Watts

rms) *

250 x 2

125 x 4

P

owe

r O

utput 2Ω (Watts

rms) **

500 x 2

250 x 4

Power O

utput 4Ω (Watts

rms) Bridged

1000

x

1

500 x 2

Ampl

ifier Efficiency

> 6

0% in

to

2Ω load

at max. power

> 55% in

to

2

Ω load

at max. power

Signa

l to Noise ratio at
rated output power and
lowest impedance

>100

dB

>100

dB

Remot

e Gain Function

Yes (RGC2 opt

ional)

Yes (RGC2 opt

ional)

Distor

tion at Rated Power

0.05% T

HD+N

0.05% T

HD+N

Fre

quency Response

20Hz to 20

kHz

+/-

2.5dB

20Hz to 20

kHz

+/-

2.5dB

Linea

r Bandwidth

10Hz

to

150kHz

+/-

3dB

10Hz

to

150kHz

+/-

3dB

Dampi

ng Factor

>

200

>

200

Input Se

nsitivity Selection

Switch

Yes

Yes

Input Se

nsitivity

200mV-4V

/ 400mv-8V

200mV-4V

/ 400mv-8V

Supply V

oltage Range

9 to

16V

9 to

16V

CEA SPECIFICATIONS SPECIFICATIONS

HCC

A10002

Powe

r Output: 250 Watts RMS x 2 at 4 ohms and
< 1% THD+N
Signal to Noise Ratio: >70 dBA (reference

1

Watt

i

nto 4 ohms)

Addit

ional Power: 500 Watts RMS x 2 at 2 ohm
at 14.4 Supply

<

1% THD+N

HCCA

10004

Power

Output: 125 Watts RMS x 4 at 4 ohms and
< 1% THD+N
Signal to Noise Ratio: >70 dBA (reference

1

Watt

i

nto 4 ohms)

Addit

ional Power: 250 Watts RMS x 4 at 2 ohm

at 14.4 Supply

<

1%

THD+N

SPECIFICATIONS (continued)

Amplif

ier Section

HCCA

10002

HCCA

10004

Prot

ection

The

rmal, DC offset, short protection, under-

voltage, over-voltage

Term

inal Wire Gauge

Power 4 AWG

Remot

e 12 - 16

AWG

Ground 4 AWG

Spe

aker 8 - 12

AWG

Power 4 AWG

Remot

e 12 - 16

AWG

Ground 4 AWG

Spe

aker 8 - 12

AWG

Input Im

pedance,

Balanced line

20 k

Ω

20 kΩ

Fuse Size

100 Amp

100 Amp

Balan

ced Line Inputs

Yes

Yes

Dimensions (L x W x H)

19.75”x 10.3”x

2.5” 19.75”x 10.3”x

2.5”

Cross

over Section

High P

ass Crossover

Continuous

ly variable

(50-2kHz)

Continuous

ly variable

(50-2kHz)

Low P

ass Crossover

Continuous

ly variable

(50-2kHz)

Continuous

ly variable

(50-2kHz)

Inte

lli-Q

0-10dB

0-10dB

* Continuous

4Ω load 20Hz to 20kHz, < 1% THD, with input voltage at 14.4 VDC.

** Continuous 2Ω load 20Hz to 20kHz, < 1% THD, with input voltage at 14.4 VDC.

AMPLIFIER SETTINGS

3IGNAL)NPUT

AND

/UT

PUT

#ONFI

GURATIONS

The

input section of the amplifier consists of gain controls, high pass
and low pass crossovers controls, Intelli-Q control and RCA inputs and
outputs. The input section makes it easy to adapt this amplifier to
most system configurations.

)NPUT'AIN

These

Orion amplifiers have level adjustments to allow for easy inte­gration with any source unit. The input sensitivity is a push button
adjustment, with the depressed (in) position giving you a range from
400

mV

to 8V while in

the out position this range is 200mV to 4V. Refer
to Testing the System and Adjusting the Sound of the System sections
of this guide for detailed instructions on setting the gain.

!DJUST

ING

)NT

ELLI-1

Incor

porated 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 type of enclosure
used and the woofer’s excursion capability determine acceptable
boost levels. Listed next are recommended boost levels for different
enclosure designs.

Enclosure

Type

Boost Levels

0dB +3dB +6dB

+10dB

Infinite

Baffle

Tune above Fs

of woofer

High X-Max
Drivers - Tune
above Fs of

woofer

Not

Recommended

Not

Recommended

Sealed Tune above Fs

of woofer

Tune above Fs

of woofer

High X-Max
Drivers - Tune
above Fs of

woofer

Not

Recommended

Vented Tune to port

frequency

Tune to port

frequency

Tune to port fre-

quency

High X-Max
Drivers -Tune to

port frequency

Sealed

Band-pass

Tune above Fs

of woofer

Tune above Fs

of woofer

High X-Max
Drivers - Tune
above Fs of

woofer

Not

Recommended

Vented

Band-pass

Tune to port

frequency

Tune to port

frequency

Tune to port fre-

quency

High X-Max
Drivers -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

pass

, and band-pass operation. This circuit is designed to optimize the

performance of subwoofers in all types of enclosures.
When using Orion loudspeakers, minor deviations from the recom-

mended frequency ranges can provide superior results depending 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 the manufacturer’s warranty.

#ROS

SOVER3WITCH

Con

trols the type of filter for the onboard active crossover. The
HCCA10004 has two switches, the upper switch is for channels 1/2, the
lower switch is for channels

3/4.

,INE/UT

PUT

#ONFI

GURATIONS

The line o

utputs on Orion amplifiers offer easy system expansion and
can be used to route signal from the RCA line outputs to the next
Orion amplifier’s RCA line inputs in the signal chain.

)NTE

RNAL

#ROS

SOVER

#ONFI

GURATIONS

The

crossover section of the Orion HCCA10002 and HCCA10004 ampli­fiers are continuously variable and extremely flexible. There are eight
different crossover configurations possible allowing high-pass, low-

All position does not attenuate any frequencies and is for full
range speaker systems.

High attenuates low frequencies and is used for mid-range speak­ers and tweeters.

Low attenuates high frequencies and is used for subwoofer
speakers.

,OW-0ASS

#ROS

SOVER

When

the switch is in the middle (ALL position), the low-pass crossover
is bypassed. When the switch is to the left (LOW position), the low­pass crossover is active. The low-pass crossover is continuously variable
from 50Hz to

2kHz.

(IGH-0ASS#ROS

SOVER

When t

he switch is in the middle (ALL position), the high-pass cross­over is bypassed. When the switch is to the right (HIGH position), the
high-pass crossover is active. The high-pass crossover is continuously
variable from 50Hz to

2kHz.

2EMOT

E'AIN/PERATION(OPTIONAL)

The rem

ote gain port provides easy remote access to the internal gain
structure of the HCCA power amplifier. The optional RGC2 plugs into
the amplifier via the 1/8” mini jack plug. The RGC2 can be installed
in the front of the vehicle near the driver’s position to control the
amplifier gain level. On HCCA10004, it only affects the rear channels
by default.

)NFI

NITE

"AF

FLE

%XAMPLE(IGH-0ASS

SETAT20(Z

By re

moving low frequency signal that 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. As you can see, with +3dB of boost and the high
pass filter set to 30Hz, the woofer has more output down to 25Hz and
less overall excursion when compared to the non-high-pass response.
Maximum physical excursion capability of the woofer is

15mm.

Figure

6
Figura 6
Abbildung 6

Figure 7
Figura

7
Abbil

dung

7

NOTE: The fi

rst graph is the response; the second graph is the driver

excursion. These designations apply to the following graphs as well.

3EA

LED

%XAMPLE(IGH-0ASS3ETAT20(Z

This

sealed example is the same 12-inch woofer in the recommended
sealed enclosure. Up to 6 dB of boost is capable if 20 Hz was used.
With +6dB of boost, the woofer has more output down to 15 Hz.

Figure

8
Figura 8
Abbildung 8

Figure

9
Figura 9
Abbildung 9

3EA

LED

%XAMPLE(IGH-0ASS3ETAT30(Z

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. The overall usable output is
increased.

Figure 10
Figura

10

Abbil

dung 10

Figure 11
Figura

11

Abbil

dung

11

6EN

TED

%XAMPLE(IGH-0ASS3ETAT30(Z

Vent

ed enclosures benefit most from the Intelli-Q. Up to 10 dB of

boost is capable at the box tuning frequency of 30 Hz. With

+10d

B

of boost

, the woofer has more output down to 22 Hz. The excursion

below the tuning frequency has been greatly reduced.

Figure 12
Figura

12

Abbil

dung

12

Figure 13
Figura

13

Abbil

dung

13

AMPLIFIER WIRING

0OWER

#ONNE

CTIONS

s Ori

on HCCA10002 Fuse Size: 100 Amp.

s Orion HCCA10004 Fuse Size: 100 Amp.
s Power connections accept up to 4 AWG wire.
s 4 AWG power and ground wire must be used for optimal per-

formance.

s Connect 12V+ to the battery through a fuse holder. This connec-

tion provides +12V main power to the amplifier.

s Power wire must be fused no more than 12” from battery.
s Ground amplifier to a good chassis ground as close as possible to

the amplifier.

s Recommended fuse is 100A for both amplifiers.
s Connect REM terminal to remote turn-on lead from source unit.

This connection provides +12V power to turn-on the amplifier.

s Add extra ground wire between the negative terminal of the

battery and the chassis.

NOTE: Th

e addition of a ground wire from the battery to the chassis
of the vehicle improves the ability of the battery to supply power to
the amplifier. This is recommended because the current delivery of the
factory electrical system was designed only to accommodate electron­ics supplied by the auto manufacturer.

3PEAKER

#ONNECTIONS(##!10002

The Or

ion HCCA10002 amplifier offer one positive and one negative
output terminal for ease of connecting channel 1(L CH) and/or 2(R CH)
outputs to the speakers. The amplifier is stable to 2Ω per channel. See
diagrams below.

One Channe

l/Two Channel Configuration

s Lowe

st recommended impedance is 2Ω stereo.

s Outputs can be configured for high-pass, low-pass, or full range

operation.

Three Channe

l (L Channel, R Channel, Bridged)

s Left

and Right are configured for two-channel stereo operation.

s Lowest recommended impedance is 2Ω stereo.
s The third output is configured for a single channel bridged out-

put.

s The bridged outputs lowest recommended impedance is

4Ω.

s Outp

uts are configured for high-pass, low-pass, or full range

operation.

Figure 14
Figura

14

Abbil

dung

14

L CH R CH

L CH R CH

Bridge

Configuration

Bridgi

ng allows one speaker to be driven at a higher power level from
the amplifier.
s The bridged outputs lowest recommended impedance is

4Ω.

Figure 16
Figura

16

A

bbi

l

dung

16

Figure 15
Figura

15
Abbil

dung

15

L CH R CH

NO

TE:

To ge

t full output in this configuration, band limiting filters as
shown in this diagram may need to be used to prevent the impedance
from dropping too low and engaging protection circuits.

3PEAKER

#ONNECTIONS(##!10004

The Or

ion HCCA10004 amplifier offers four positive and four negative

output terminals for ease of connecting channel 1(LF), 2(RF),

3(RR),

and 4

(LR) outputs to the speakers. The amplifier is stable to 2Ω per

channel. See diagrams below for possible configurations.

Four Ch

annel Stereo Configuration

s Chan

nel 1/2 and channel 3/4 lowest recommended impedance is

2Ω stereo.

s Crossover mode, output, and gain configurations are indepen-

dently adjustable between the front and rear channels.

s Two-channel or four-channel input can be used for this configu-

ration. For source unit fading, use the four-channel input mode.

s Channels 1/2 and channels 3/4 outputs can be individually config-

ured for high-pass, low-pass, or full range operation.

Three

Channel Configuration

s Channe

ls 1/2 are configured for 2-channel stereo operation.

s Channel 1/2 lowest recommended impedance is 2Ω stereo.
s Channels 3/4 are configured for a single channel bridged out-

put.

s Channel 3/4 lowest recommended bridged impedance is

4Ω.

s Cross

over mode, output, and gain configurations are indepen-

dently adjustable between channels 1/2 and

3/4.

s Two-c

hannel or four-channel input can be used for this configu-

ration. For source unit fading, use the four-channel input mode.

s Channel 1/2 and 3/4 outputs can be configured for high-pass, low-

pass, or full range operation.

s Channel 3/4 outputs are configured for summed bridged opera-

tion for subwoofer.

LF LR

LF LR

RF

Figure 17
Figura

17

Abbil

dung

17

RR

RF RR

Figure 18
Figura

18

Abbil

dung

18

Five Ch

annel Configuration

s Channe

ls 1/2 are configured for 2-channel stereo operation.

s Channel 1/2 lowest recommended impedance is 2Ω stereo. Lowest

recommended impedance is 2Ω stereo and 4Ω bridged mono.

s Rear outputs must be set for full range operation.
s Passive crossovers must be used on all components and frequen-

cies must not overlap.

Tri-

Mode Six Channel Configuration

s Lowe

st recommended impedance is 2Ω stereo and 4Ω bridged

mono.

s Front and rear outputs must be set for full range operation.
s Passive crossovers must be used on all components and frequen-

cies must not overlap.

WARNING! Failure to observe these requirements may result in dam­age to the amplifier.

LF

LR

RF

RR

LF LR

RF

RR

Figure 19
Figura

19

Abbil

dung

19

NOTE: To g

et full output in this configuration, band limiting filters as
shown in this diagram may need to be used to prevent the impedance
from dropping too low and engaging protection circuits.

Figure

20
Figura 20
Abbildung 20

NOTE: To ge

t full output in this configuration, band limiting filters as
shown in this diagram may need to be used to prevent the impedance
from dropping too low and engaging protection circuits.

AMPLIFIER INSTALLATION

#HOO

SING

-OUNT

ING

,OCAT

IONS

The lo

cation of your amplifier will depend on several important issues.
Due to the low profile size of the Orion 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 surface.

NOTE: Mounting amplifiers upside down is not recommended and
may cause premature thermal shutdown.

WARNI

NG! Do not mount any amplifier in the engine compartment.

Amplifiers are not designed to endure the harsh environment of the
exterior elements.

0ASS

ENGER

#OMP

ARTMENT

If y

ou are going to mount the amplifier in the passenger compart­ment, make sure you have adequate room for ventilation. The amplifi­ers have been designed to make under-seat mounting possible. When
mounting your amplifier under a seat or similar area, keep a minimum
of 1” of clearance around the amplifier for adequate cooling.

4RUNK

#OMP

ARTMENT

Mounti

ng your amplifier in the trunk provides excellent performance
as long as you do not restrict the airflow around the heatsink of the
amplifier. For optimal results, mount the amplifier with as much clear-

ance as possible. This type of mounting will yield the best cooling due
to the convection effect of the amplifier chassis.

'ENE

RAL

0RE

CAUTIONS

AND

)NS

TALLATION

4IPS

WARNI

NG! 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 this amplifier unmounted. Failing to securely mount the
amplifier can result in damage or injury, particularly in the event of
an accident. An unmounted amplifier becomes a dangerous projectile
in the event of a crash. Never mount the amplifier where it might get
wet. Mount the amplifier so the wire connections will not be pulled.
Route the wires where they will not be scraped, pinched or damaged
in any fashion.

The +

12V power supply wire must be fused as close as possible to
the battery terminal, ideally within 12”. Use the recommended fuse
size or circuit breaker listed in the Power Connections section of this
manual.

If you need to r

eplace the fuse plugged into the side of the amplifier,
replace the fuse with the same size and type fuse that came with the
amplifier. If you are not sure as to the correct value, refer to the Power
Connections section of this manual for details. Using a higher current
fuse may result in damage to the amplifier that is not covered under
warranty.

NOTE: Make s

ure all the equipment in the system is turned off when
making or breaking connections to the input RCA’s or speaker termi­nals. Turn on the system and slowly turn up the volume control only
after double checking all wire connections.

Powe

r for systems with a single amplifier can be supplied by most
automotive electrical systems. Systems with multiple amplifiers may
require a higher capacity battery, alternator or the use of a storage
capacitor. We strongly recommend the use of an Orion Wired power
capacitor with an extra battery in larger stereo systems.

Orio

n amplifiers generate a certain amount of heat as part of normal
operation. Be sure the area around the amplifier is unobstructed to
allow adequate air circulation. Remember, beach blankets, last week’s
laundry, school books and homework papers located on top of the
amplifier do not improve air flow and may become damaged.

You mus

t first remove the top cover (see Removing the Top Cover
section) then end caps to mount the amplifier (mounting holes are
within). (1) Remove the screws first, (2) lift the end cap straight up
to detach from unit and then (3) pull away from the amplifier. Once
mounted replace end caps by following this process in reverse.

3

4OOLSOFTHE

4RADE

List

ed below are the majority of the tools required to perform an
installation. Having the proper tools will make the installation that
much easier. Some of these tools are necessities; some will just make
the job easier.

s Allen Wr

enches (3mm and 4mm)

s DMM or VOM
s Electric drill with assorted drill bits
s Grommets
s Heat shrink tubing
s Marking pen
s Nylon tie straps
s Phillips and flat blade screw drivers
s Pliers (standard and needle nose)
s Reference CD with

1

kHz Sine

Wave at 0dB level (all bits high)

s RTA (real time analyzer)

s

Sold

ering iron and solder

s Utility knife
s Wire brush or sandpaper for chassis grounding
s Wire crimper

Figure 21
Figura

21

Abbil

dung

21

2

1

s
s

Wire cu

tters

Wire strippers

3TEP"

Y3TEP)NSTALLATION

NOTE: Conne

ct all input, power and speaker connections to amplifier

before mounting the amplifier in its final location.

1. Determine the location for the amplifier. Refer to the Choosing
Mounting Locations section of this guide for detailed informa­tion.

2. Decide on the system configuration for your amplifier. For system
suggestions, refer to the Speaker Connections section of this
guide.

3. Run all the wires from the amplifier location to the speakers,
source unit, and battery. Do not connect the battery at this time.
Be sure to run RCA’s and power and speaker wires away from
factory electrical wires and system as they pose a great potential
for induced system noise.

4. Remove end caps before mounting the amplifier.

5. Pre-drill amplifier mounting holes. Be sure to “think before you
drill”. Gas tanks, fuel lines, mechanical/electrical systems and/or
other obstructions may be hidden beneath mounting location.
For best results use a marking pen to mark the mounting holes

10.

11.

12.

13.

14.

15.

Connec

t the RCA and speaker wires to the amplifier. Check the
quality of your speakers and signal connections. This will deter­mine the ultimate performance of your Orion amplifier. Refer
to the Signal Input and Output Configurations and Speaker
Connections sections of this guide for correct wiring instruc­tions.

Reconnect the ground terminal to the battery after power,
speaker, and RCA connections are completed.

Set crossovers. Refer to the Internal Crossover Configuration sec­tion of this manual for detailed instructions.

Set gain control to a low level before turning on the amplifier.
Adjust gain control as needed after the system is playing. (see
adjusting the sound of the system)

Once satisfied that all connections and settings are correct, install
the fuse located near the vehicle’s battery and proceed to the
Testing the System section of this manual.

After all connections and adjustments are made, install end caps
if they are to be used.

and pre-drill these holes with a standard 1/8” drill bit.

6. Mount the amplifier. Make sure the amplifier is mounted on a
flat surface. If this is not possible, do not over tighten the screws
so that the chassis of the amplifier is twisted or bent.

7. Turn the vehicle’s key switch to the off position.

8. Disconnect the vehicle’s battery ground terminal.

9. Connect power wires to the amplifier (ground first, then 12 V(+)
and REM). Power wire must be fused near the battery. Be sure to
remove the fuse from the fuse holder at this time.

WARNING! Never exceed the recommended fuse size of this amplifier.
Failure to do so will result in the voiding of your warranty and possible
damage to the amplifier.

SETUP AND TROUBLESHOOTING

4ESTING

THE

3YSTEM

After y

ou 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
system.

1. Check

all the wiring connections to be sure they are correct and

secure.

2. Turn the signal source volume control all the way down. Set any

tone controls to their flat or defeated positions. This includes the
loudness control.

3. Turn the level controls of the amplifier to their minimum posi-

tions.

4. Turn the source unit on. Check to see if the power LED located

on the top of the amplifier is on. If not, please refer to the Power
Connections and the Troubleshooting Tips sections of this manual
for instructions.

5. If using an aftermarket source unit, turn the level controls of

the amplifier about one quarter of a turn. Slowly increase the
volume level of the source unit until you can hear the output of
the system. If no sound is heard or if the output is distorted, turn
the system off immediately. Refer to the Power Connections and
the Troubleshooting Tips sections of this manual to solve your
installation problems.

6. Check to make sure the output for each channel is correct. If the

active crossovers are used, check to make sure that each output is

correct from the amplifier. When using active crossovers on mid­range and tweeters, do not use crossover frequencies lower than
recommended. If the system is not configured properly, refer to
the Internal Crossover Configuration section of this manual and
take corrective action.

7. If the output is clear and undistorted, continue to the Adjusting
the Sound of the System section of this manual.

!DJUST

ING

THE

3OUNDOFTHE

3YS

TEM

Once

you have checked the system’s operation, adjust the sound of
the system. Adjusting the sound of the system is accomplished by set­ting the level controls and adjusting the internal crossovers.

1. Turn

the signal source volume control all the way down. Set any
tone controls to their flat or defeated positions. This includes the
loudness control.

2. Turn the level controls of the amplifier to their minimum posi­tions.

3. Choose music with high dynamic content that you like, with which
you are familiar, and will be used most often in the system.

4. Turn the source unit’s volume control 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. Listen for any audible distortion. If any distortion
is audible, reduce the volume of the source unit until you have
an undistorted output. Leave the volume control at this position
during your system tuning.

5. While listening to your chosen dynamic music, turn up the level
control corresponding to the midrange output until you hear

6.

7.

8.

9.

10.

11.

12.

slig

ht distortion and turn the level control back slightly for an
undistorted output. Depending on your system, the midrange and
tweeter output may be on the same output channels.

Turn up the level control corresponding to the tweeter output
until you hear slight distortion and turn back the level control
slightly for an undistorted output. Depending on your system
the midrange and tweeter output may be on the same output
channels.

Fine-tune the output level between midrange and tweeters.
Refer to the Internal Crossover Configuration section of this
manual for detailed instructions.

Repeat Steps 5-7 for the rear speakers. If you do not have rear
speakers continue to Step

10.

Set

levels between the front and rear midrange and tweeters for

optimum front/rear balance.
Turn up the level control corresponding to the woofer output

until you hear slight distortion and turn back the level control
slightly for an undistorted output.

Fine-tune the output level between satellite speakers and the
woofers. Refer to the Internal Crossover Configuration section of
this manual for detailed instructions.

Enjoy your awesome Orion sound system.

Power LED: This LED lights up green when the amplifier is turned on.
This represents normal operation if the Protection/ESP Status LED is on
solid, and the Thermal LED is off.

ESP/Pro

tection Status Indicator LED: This LED lights up blue when

the amplifier is turned on and periodically blinks as a normal default
state. When the amplifier goes into protection it will flash a specific
number of times (described below) indicating the source of the event.
It will also flash when the amplifier is powering up, approximately 4-5
flashes until the turn-on delay has expired (actual number of flashes
depends on the length of time selected via the bitwriter). Below is
a description of reasons the amplifier could engage the protection
circuit. While most protection modes are self-resetting when the
problem is resolved, short or overcurrent latches and power must be
cycled off/on to restore operation. The protection indications will self­reset once the condition has been fixed. Advanced troubleshooting
can be performed using the ESP/Protection Status indicator LED.

s Short

: Speaker wires pinched or shorted together or to ground

(frame of vehicle). ESP/Protection Status LED will also flash 2 short
flashes, followed by a long pause (approximately 8-10 seconds).

s Overcurrent: Check for possible speaker issue(s) or speaker wiring

pinched in a door or other metal. Make sure speaker(s) load is
not below minimum 2Ω load. The ESP/Protection Status LED will
also flash 2 short pulses, followed by a long pause.

s

DC

Offset:

This can happen if the installation inadvertently

!MPLIFIER6ISUAL

4ROU

BLESHOOTING

Your new Or

ion HCCA amplifier has three indicator lights (LED’s) on
the top cover of the amplifier as seen in the next figure. These lights
are very useful in trouble shooting possible amplifier problems and
issues.

connects the power wire to the speaker input(s). This can also
happen if the amplifier has an internal problem. The amplifier
will flash 4 short pulses, followed by a long pause, then repeat.

s Undervoltage: Vehicle charging system is not supplying enough

voltage to the amplifier. This can also occur if you use too small
a gauge wire or the terminals connecting the amplifier power

to t

he electrical system are dirty or corroded. The ESP/Protection

status LED also will give

1

short

flash followed by a long pause for

undervoltage. This cycle will repeat.

s Overvoltage: Vehicle charging system is supplying too much

voltage or over the amplifiers rated DC input. Usually this occurs
when there is a problem with the electrical system. Turn off the
headunit when jump-starting the car. The ESP/Protection Status
LED will also flash with

1

long

flash followed by a long pause

(approximately 8-10 seconds).

s Thermal: If the amplifier heat sink temperature is too high to

into account when installing any amplifier.

s The temperature inside the car where the amplifier is mounted is

extremely hot. This can occur in extreme climatic conditions. It
is not uncommon for temperatures inside a parked car to reach
in excess of 140°F (60°C). If airflow is restricted to the mounting
area, the main car cabin may cool down before the rest of the
car has dropped appreciably. Also, if the amplifier is near the
thermal protection temperature point, turning it on and off via
the remote line can result in it entering thermal protection.

continue safe operation, it will also enter protection mode. The
ESP/Protection status LED will give 3 short flashes followed by a
long pause. This cycle will then repeat.

Therm

al LED: This LED lights up red if the amplifier overheats. An

amplifier enters thermal protection due to conditions that might
otherwise result in damage to the amplifier. The thermal protection
mode is also indicated on the ESP/Protection Status indicator LED

Amplifier Top Cover (with LED locations)

Power

(gre

en)

Thermal

(red)

by a 3 s

hor

t fl

ash sequence that repeats every 8-10 seconds. Below
is a description of reasons the amplifier could engage the Thermal
Circuit.

s Speaker

loads lower than the amplifiers minimum 2Ω load will
cause the amplifier to draw more current and may result in
overheating. This can be avoided by using speakers or wiring
methods that result in a load greater than the amplifiers
minimum 2Ω load input. This may also result in the overcurrent
protection mode being engaged.

s The amplifier can also overheat if it is not receiving proper

ventilation, when mounting a amplifier make sure it has room for
air to circulate and keep it cool. Amplifiers will get hot because
they produce energy and care and consideration should be taken

ESP/Pr

otection Status

ind

icator

(bl

ue)

Figure 22
Figura

22

Abbil

dung

22

NOTE

: Please note that the top cover plate is designed to be reversible.

The LED colors will therefore appear to reverse their order relative to
the diagram labeling if the cover is reversed when reattached, for
example; the green LED (power) closest to the Orion logo in the
diagram will be the furthest from the logo with the cover reversed.

4ROU

BLESHOOTING4IPS

Sympt

om Probable Cause Action To Take

No output

Low or no remote turn-on Check remote turn-on voltage at voltage amplifier and repair as needed.
Fuse blown Check power wire's integrity and check for speaker shorts. Fix as needed

and replace fuse.
Power wires not connected Check power wire and ground connections and repair or replace as needed.
Audio input not connected. Check RCA connections and repair or replace as needed.
Speaker wires not connected Check speaker wires and repair or replace as needed.
Speaker are blown Check that ESP status indicator is not indicating an active event. Check sys-

tem with known working speaker and repair or replace speakers as needed.

Audio cycles on and off

Thermal protection engages when amplifier heat
sink temperature exceeds 75º C (167º F)

Make sure there is proper ventilation for amplifier and improve ventilation

as needed.

Loose or poor audio input Check RCA connections and repair or replace as needed.
Loose power connections Check power wires and ground connections and repair or replace as needed.

Distorted output

Amplifier level sensitivity set too high exceeding

maximum capability of amplifier , resulting in
distorted sound

Readjust gain. Refer to the Adjusting the Sound of the System section of this

manual for detailed instructions.

Impedance load to amplifier too low Check speaker impedance load, if below 2Ω, rewire the speakers to achieve

higher impedance.

Shorted speaker wires Check speaker wires and repair or replace as needed.

Sympt

om Probable Cause Action To Take

Speaker not connected to amplifier properly. Check speaker wires and repair or replace as needed. Refer to the Speaker

Connections section of this manual for detailed instructions

Internal crossover not set properly for speakers Readjust crossovers. Refer to the Internal Crossover Configuration section of

this manual for detailed instructions.

Speakers are blown Check system with known working speakers and fix or replace as needed.
RCA shield connection is intermittent or faulty Replace/Repair RCA cable.

Poor bass response

Speakers wired with wrong polarity causing can­cellation at low frequencies.

Check speaker polarity and fix as needed.

Crossover set incorrectly Reset crossovers. Refer to the Internal Crossover Configuration section of

this manual for detailed instructions.

Impedance load at amplifier is too low. Check speaker impedance load if below 2Ω, rewire speakers to achieve

higher impedance .

Battery fuse blowing

Short in power wire or incorrect wiring. Check power wires and ground connections and repair or replace as needed.
Fuse used is smaller than recommended. Replace with proper fuse size.

Actual current exceeds fuse rating. Check speaker impedance load if below 2Ω, rewire speakers to achieve

higher impedance .

Speaker is blown with shorted outputs Check system with known working speakers and fix or replace as needed.

ESP®-2

Status Indicator LED

Mode

Off

Amp

lifier Off

5 short f

lashes, pause, then repeats

Unit poweri

ng up

Soli

d Illumination

Norma

l Operation

1

long f

lash, pause, then repeats

Overvo

ltage

1

short

flash, pause, then repeats

Underv

oltage

2 short flash

es, pause, then repeats

Ove

rcurrent

3 short

flashes, pause, then repeats

The

rmal protection

4 short fla

shes, pause, then repeats

DC offset

APPENDIX—PROGRAMMABLE FEATURES

The f

ollowing listing are ESP

®

-2 featu

res that can be programmed or
accessed by your installer to customize or troubleshoot your system.
Factory default settings are shown in bold.

NOTE: The Bitwriter® must have software version 2.7 or above to
access the amplifier features menu.

NOTE: A setting marked “Reserved” is for future development. Some
settings are read-only, i.e. they cannot be changed, only viewed. If
changed, the bitwriter will fail verification of the parameters upon
write and indicate an error.

Turn

On Delay - 1.5, 2.0, 2.5, 3.0, 3.5, 4.0 seconds. Delays the amplifier

turn-on when the head or source unit is turned on. This eliminates any
annoying pops or noise during power up from the head or source unit
from feeding through to the amplifier.

Input Gain Range (Volts) - The position of the gain switch determines
the gain range available. If the gain switch is in the high mode, the
ranges are Default (0.2 - 4V), 0.2-1V,

1-1.5V

,1.5

- 3.5V

, 3.5-4V. If the
gain switch is in the low mode, the ranges are Default (0.4 - 8V), 0.4 ­2V, 2 -3V, 3V - 7V, 7-8V.

NOTE: If t

he Input Gain Adjustment is set to Lock (see below), the
Input Gain Range adjustment will not be altered until the Input Gain
Adjustment is set to Unlock.

Input

Gain Adjustment - Unlock, Lock. When set to “Lock”, the input

gain adjustment is disabled. This can be set to lock after the amplifier
has been installed and set up to prevent accidental or unwarranted
adjustment.

NOTE:

Use caution when adjusting or unlocking gain as restricting

the range or unlocking the range can result in sudden increases in
gain. We recommend turning down the source to avoid damage to
speakers and/or your hearing prior to exiting this mode.

Eve

nt 1 through 7 - Stores up to seven recent events that have

occurred to aid in diagnostic troubleshooting. The events that are
retained are: Undervoltage, Overvoltage, Reserved, No Fault, Thermal,
Overcurrent. These events are read-only, the amplifier will not allow
them to change, even if they are changed on the bitwriter, they can­not be written to the amplifier by the installer. Event

1

is the most

recent event, then Event 2, and so on. If event memory is full (Event

7

has a

stored diagnostic message), then if another event occurs the

7th

event

will be pushed out of memory.

NOTE: Wh

ile the Bitwriter

®

can be used

to read the amplifier during

an even

t, the priority of the amplifier is given to continually checking
its health. Attempts to Write to the amplifier during and immediately
following an event may result in communication errors.

Ex

cep

for overcurrent/short, the amplifier should clear any faults

t
when the condition that causes them clears. Substantial changes to
the amplifier parameters via the bitwriter may result in the audio
being interrupted momentarily. Also, the amplifier is designed to
fade up from protection events and when turned on.

NOTE: Th
battery terminals and keeping the remote line off for at least

onds.

sec

e amplifier can be reset by removing power to the main

30

The maj
referenced should it be necessary to contact MD Audio Engineering or
Orion.

or and minor revision levels of the ESP2 software should be

Orion Car Audio

Car Amplifiers