Orion Car Audio Speaker Orion HCCA Competition User Manual

©1999 Orion Industries, Incorporated  
9235 S. McKemy Street , Tempe, Arizona 85284  
Phone: 480.705.5600 Fax: 480.705.7339  
One of the ADST family of companies.  
Part # 319-0730 REV B, 11/99  
 
TABLE OF CONTENTS  
NOTES:  
Introduction..........................................................................................3  
About this manual..................................................................................3  
Features of your 3-series loudspeaker...............................................................4  
Warnings and tips.................................................................................5  
System planning....................................................................................5  
Amplifier requirements.................................................................6  
Mounting locations............................................................................6  
Controls and connections.........................................................................6  
Tweeter level control...............................................................6  
Midrange contour..................................................................7  
Connections to the amplifier........................................................7  
Speaker wiring................................................................................7  
Speaker wire selection............................................................7  
Polarity and phasing................................................................7  
Termination............................................................................8  
Speaker mounting............................................................................8  
Woofer installation.................................................................8  
Woofer mounting..................................................................8  
Tweeter installation..........................................................................10  
Surface mount....................................................................10  
Surface mount cup mounting......................................................10  
Flush mount.......................................................................10  
Blind installation...................................................................11  
Tweeter mounting................................................................11  
Crossover installation.....................................................................12  
Connecting the system............................................................12  
Connections to crossover network and radio or amplifier..........................13  
Bi-amplified connections to the crossover network.................................13  
Bi-wired connections to the crossover network....................................14  
Troubleshooting.................................................................................15  
Jack pinouts..................................................................................16  
Specifications....................................................................................16  
Warranty information.......................................................................17  
CE declaration of conformity................................................................19  
INTRODUCTION  
Thank you for purchasing the Orion HCCA component set. These components were designed to  
live up to the standard set by the legendary CONCEPT 98.1 separates: complete high fidelity  
with the Orion attitude. The tunable crossover uses only the highest quality components normally  
found in high end home audio equipment. Hand made in the USA, the HCCA separates represent  
the pinnacle of high performance car audio.  
ABOUT THIS MANUAL  
This manual is designed to instruct you on the use of your new HCCA components. It will enable  
you to get the most from your new speakers. But it cannot help you if you do not read it. Read  
it, learn it, and keep it handy for future reference. If you still need help, call the pros at your local  
authorized Orion dealer. Additionally, you can call Orion technical at (480) 705-5600.  
18  
3
 
FEATURES OF YOUR HCCA COMPONENTS  
WARRANTY INFORMATION  
There are two things you must do to ensure trouble free service in the event you need warranty repairs.  
1 - Keep your original sales receipt in a safe place. A copy of the receipt will be required to obtain warranty service.  
2 - Be sure your retail dealer has written the date, the model number, and the serial number (if applicable) of the Product on the  
receipt.  
Molded w oofer basket - The back bone of any good woofer is its basket. It provides the  
proper alignment and support structure for the magnet while the very thin braces guarantee a  
minimum of early reflections off the basket that would be ordinarily transmitted as sonic colorations  
through the cone.  
To give yourself an extra measure of protection, make a separate record of the information about your purchase and keep it in  
a safe place. In the event you misplace the sales receipt, your dealer may be able to give you a copy.  
Take a moment now to read the terms of your warranty. Check to be sure your sales receipt is dated and has the Product model  
number and serial number (if applicable) on it. Then put it away in a safe place.  
Tw eeter level control - A three position control adjusts the volume of the tweeter with respect  
to the midrange.  
Tw eeter contour control - A three position switch that adjusts the tweeters lower frequency  
Orion Limited Warranty  
Orion warrants to the original consumer purchaser of the Orion Products described in this manual, that the Product will be free  
from defects in materials and workmanship for a period of one (1) year after the date of purchase. If the product is installed by  
an authorized Orion retail dealer, the warranty is extended to three (3) years, Orion's sole obligation under this warranty shall be  
to provide, without charge, parts and labor necessary to remedy the defects, if any, that appear during the warranty period.  
response curve to compensate for off axis listening.  
Bass contour control - A three position switch that adjusts the woofers higher frequency  
response curve to compensate for off axis listening.  
This warranty is the sole and exclusive express warranty given with respect to the Product. All other express warranties are hereby  
excluded. Neither Orion nor the authorized dealer who sells the Product is responsible for indirect, incidental, or consequential  
damages. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or  
exclusion may not apply to you. This warranty gives you specific legal rights and you may also have other rights which vary from  
state to state.  
Multi-mount tw eeter - All of the tweeter mounting options (surface, flush, or angled flush)  
are supplied with the HCCA systems to mount the high quality ferrofluid cooled neodymium  
tweeter.  
IMPORTANT - Keep your original sales receipt. Be sure the retail dealer has written on it the date, model number, and serial  
number (if applicable) of the Product. This information is required for warranty service.  
Bi-amplifiable / Bi-w ireable - The passive crossover supplied with this system is bi-amplifiable  
or bi-wireable; typically only available in high quality audiophile home loudspeakers, and uses  
only the finest quality electronic components.  
This w arranty is limited to:  
Products purchased from authorized Orion retail dealers in the United States. Orion will supply a list of authorized dealers on  
request.  
Solid state tw eeter protection - Advanced protection circuitry provides protection for the  
tweeter against overpowering or amplifier clipping.  
In order to obtain w arranty service you must:  
Return the Product, freight prepaid, to the Orion dealer from which it was purchased. If necessary you may call Orions  
Customer Service Department for the names and addresses of authorized Orion dealers in your area.  
Provide proof of purchase in the form of a copy of your original sales receipt. The date, model number, and serial number (if  
applicable) of the Product must be written on the sales receipt.  
Optical tw eeter protection indicators - Indicates the tweeter protection circuit is enabled.  
This w arranty does not cover:  
Vented voice coil - Magnet structure cooling vent enhances power handling capabilities of the  
woofer.  
Damage that is the result of misuse, abuse, accident (including but not limited to damage by water), faulty hookup, defective  
or maladjusted associated equipment, or the use of the Product with equipment for which it was not intended.  
Cosmetic defects that appear more than thirty (30) days after the date of purchase. Cosmetic damage caused by improper  
handling is also excluded.  
Extended center pole - Woofer magnet geometry provides a symmetrical magnetic pattern to  
reduce THD.  
Products that are used for commercial purposes.  
The cost of removing or reinstalling the Product.  
Ultimate performance passive crossover - The passive crossover included with the HCCA  
separates is derived form the acclaimed CONCEPT 98.1 system. High quality audiophile  
components and tunable to meet the acoustical requirements of any vehicle.  
Damage that occurs while the Product is being shipped to whoever will service it. See the information above regarding  
shipping procedures.  
This w arranty is void if:  
The Product identification or serial number label is removed or defaced in any way.  
The Product is serviced or repaired by any one other than Orion or an authorized Orion dealer or service agency.  
4
17  
 
WARNINGS AND TIPS  
JACK PIN-OUTS  
Study your automobile thoroughly before you drill or cut any holes. Take extra care when  
working near gas tanks, gas lines, brake or hydraulic lines and electrical wiring.  
Wear eye and ear protection when using power tools.  
Keep the woofers and tweeters away from metal filings and shavings. Once foreign objects are  
stuck to the magnets or tweeter dome, it will be virtually impossible to remove them. Keep the  
tweeters in their protective bags until final mounting to prevent any possibility of metal dust or  
chips from passing through the grille and accumulating on the dome.  
Left Tweeter - Output  
Left Tweeter + Output  
Left Tweeter - Input  
Left Tweeter + Input  
Left Woofer + Input  
Left Woofer - Input  
Left Woofer - Output  
Left Woofer + Output  
Right Tweeter - Output  
Right Tweeter + Output  
Right Tweeter - Input  
Right Tweeter + Input  
Right Woofer + Input  
Right Woofer - Input  
Exercise caution when working with the HCCA’s with the grille removed. A slip of the hand with  
a screwdriver or other tool can result in irreparable damage to the cone or dome. Do not touch  
the cone or dome.  
Right Woofer - Output  
Right Woofer + Output  
Do not install the components where they will be subject to excessive heat, moisture or dust; or  
where they will be kicked or repeatedly bumped or brushed.  
HCCA 5s  
HCCA 6s  
Make absolutely sure that the woofer is connected to the lowpass output and the tweeter is  
connected to the highpass output of the crossover network. If these connections are reversed,  
low-frequency signals will be fed to the tweeter without fuse protection. In this case, the tweeter  
may be damaged. Such damage is not covered by the warranty.  
Frequency response +/-3dB:  
48Hz to 22kHz  
90dB  
40Hz to 22kHz  
91dB  
Sensitivity 2.83 volt RMS pink noise measured at 1 meter:  
Impedance, nominal:  
2 Ohms  
2 Ohms  
Recommended amplifier power watts RMS:  
15 to 100  
15 to 150  
When removing or installing the grille on the HCCA’s mids, be careful not to brush the woofers  
rubber surround or the tweeters dome with the edge of the grille. Cutting or tearing the surround  
or dome will destroy the unit.  
Dimensions – woofer/midrange transducer  
Mounting depth (woofer):  
2 3/8” / 60mm  
2 11/16” / 69mm  
6” / 152mm  
2 7/16” / 63mm  
2 15/16” / 79mm  
6 1/2” / 165mm  
5/8” / 16mm  
Never run wires outside or beneath the vehicle where they can be snagged by road hazards or  
the moving parts of the vehicle. Use existing wire channels, sills, panels and molding strips inside  
the automobile to hide the wiring for neat appearance and safety.  
Overall height:  
Overall maximum diameter:  
Maximum height above panel without grille:  
Maximum height above panel with grille:  
Maximum grille diameter:  
1/2” / 13mm  
3/4” / 20mm  
15/16” / 24mm  
7 1/8” / 181mm  
4 15/16” / 125mm  
6 1/2” / 166mm  
4 5/8” /118mm  
Make sure your radio/cassette/cd player and or other equipment is turned off while connecting  
the HCCA’s speaker terminals. Turn on the various components and slowly advance the volume  
control only after checking and double checking all connections  
Cutout size:  
Dimensions – tweeter transducer  
Standard mount height:  
1 1/4” / 32mm  
1 7/8” / 48mm  
1” / 26mm  
1 1/4” / 32mm  
1 7/8” / 48mm  
1” / 26mm  
Note: If sound is weak or distorted, immediately turn down the volume and see the section  
entitled Troubleshooting.  
Flush mount cutout diameter:  
Flush mount depth:  
SYSTEM PLANNING  
Dimensions – crossover network  
Length/width/height:  
5 3/16” x 3 1/2” x 1 5/8” 132mm x 89mm x 42mm  
Planning your system is the best way to get the most out of your high performance Orion gear.  
By planning your installation carefully you can avoid situations where the performance or reliability  
of your system is compromised. The pros at your authorized Orion dealer have been trained to  
maximize the potential of your Orion system.  
Thiele-Small specifications  
Free air resonance (F ):  
57.2Hz  
57.1Hz  
s
Electrical damping (Qes):  
Mechanical damping (Qms):  
Total damping (Qt):  
.34  
.47  
4.87  
.32  
6.00  
.44  
ORION is always looking for ways to improve its products. Therefore, the specifications are subject to change  
Orion tweeters are constructed in concert with the Ferrosound program and use Ferrofluid to provide increased power  
handling, decreased distortion, minimum electrical impedance change, higher linearity, and smoother frequency response.  
16  
5
 
AMPLIFIER REQUIREMENTS  
TROUBLESHOOTING  
Symptom Probable cause  
Remedy  
No output  
Source or amplifier not turned on  
Check source or amplifier and fix as  
needed  
A n o t e o n p o w e r h a n d lin g  
The HCCA component system requires a minimum of 20 Watts per channel to achieve reasonable  
listening volumes in a moving automobile without clipping the amplifier. Orion recommends  
150 Watts per channel as a maximum so as not to exceed the thermal or mechanical limitations  
of the speaker system. Any amplifier between 20 watts and 100 watts per channel may be  
used. If you choose to use an amplifier with more power than 100 Watts be very careful, you  
can damage the speaker system if played too loud.The HCCA components produce reasonable  
volume levels in the automotive environment using moderate amplifier power. However, the  
use of a low powered amplifier to try and attain very high volume levels can lead to overdriving  
the amplifier. This will generate high distortion levels which can easily damage loudspeakers,  
even when the amplifiers rated power is far below the maximum rated power of the loudspeaker.  
Underpowering a driver is every bit as damaging as overpowering it.  
Audio input not connected or no  
output from source  
Check RCA connections and signal  
integrity, fix or replace as needed  
Protection circuit activated  
Speaker wires not connected  
Speaker damaged  
turn down volume. Protection will self  
reset  
Check speaker wires and fix or replace as  
needed  
Audio cycles on and off  
Check system with known working  
speaker and fix or replace as needed  
Thermal protection engaged  
check that amplifier has adequate  
ventilation check speaker impedance  
load  
As a rule, do not turn the volume up above the point where you hear distortion on musical  
peaks from either an overdriven amplifier or mechanical noise from an overstressed speaker. For  
the best performance and reliability, select an amplifier with slightly more than the maximum  
power you are likely to need to generate the desired volume levels. This margin of reserve  
power will ensure that the amplifier will not attempt to deliver more than its design allows.  
Loose or poor audio input  
Check RCA, power and speaker  
connections and repair or replace as  
needed  
Distorted output  
Preamp volume set too high.  
exceeding maximum capability  
of amplifier.  
Check volume of preamp and adjust  
appropriately  
Warning: Practice safe sound! Excessive sound pressure level can permanently damage your  
hearing. The maximum volume levels attainable with high performance Orion speakers, combined  
with high-power amplification, may exceed safe levels for extended listening. When listening at  
high volume levels always use hearing protection or turn it down!  
Impedance load to amplifier too low  
Check speaker impedance load, if below  
1 ohm rewire the speakers to achieve a  
higher impedance  
Shorted speaker wires  
Check speaker wire connections and  
repair or replace as needed  
MOUNTING LOCATIONS  
Speaker not connected properly  
Check speaker wiring and repair or  
replace as needed. refer to the speaker  
wiring section of this manual for detailed  
instructions  
There are many possible choices of mounting locations. The automobile factory locations will  
usually dictate the woofer mounting position. Because of its small size and multiple mounting  
options, the tweeter can go virtually anywhere. Orion uses an unusually low crossover frequency  
for the tweeter which means you are not restricted to mounting the tweeter close to the midrange.  
The tweeter can be mounted as far as 24" from the midrange without causing adverse effects  
on the sound quality.  
Speaker damaged  
Check system with known working  
speaker and fix or replace as needed  
Poor bass response  
Speakers wired with wrong polarity  
causing cancellation at low frequencies  
Check speaker polarity and fix as needed  
Lack of stereo separation  
Speakers wired with wrong polarity.  
stereo / bridge switch set to bridge  
position  
Check speaker polarity and fix as needed  
set switch to stereo position  
Orion cannot recommend specific locations for the tweeter for each car, but we can give some  
general tips. Try to keep the tweeters as far to the sides of the car as practical, avoid placing  
them above ear level unless the woofers are also above ear level. Place the tweeters in similar  
locations on both sides. Try a few locations by just placing the tweeter or taping it in a location  
and listening to ensure the desired stereo image and high frequency dispersion are achieved  
before committing to a location by drilling holes in the automobile.  
Speaker connected across wrong  
output terminals  
Check that the speaker wires are not  
connected to the bridged terminals and  
fix as needed  
Source set to mono  
Check source and adjust controls as  
needed  
CONTROLS AND CONNECTIONS  
Tw eeter level control  
If you want to consult the factory, write or call our customer service department:  
Orion Industries  
The three position switch in the crossover box labeled TWEETER LEVEL” adjusts the relative  
volume of the tweeter with respect to the midrange. The 0dB position is referenced as equal  
output from the midrange and tweeter. The -3dB and -6dB positions offer -3dB and -6dB less  
output from the tweeter respectively. Tweeter level can be adjusted independently for right and  
left channels to compensate for different listening tastes and mounting locations.  
9235 S. McKemy Street  
Tempe. AZ 85284  
Phone:  
Fax:  
(480)705-5600  
(480)705-7339  
6
15  
 
Bi-w ire connections to the crossover netw ork  
Tw eeter contour  
When using a standard two channel amplifier, the HCCA components can be bi-wired. In this  
case there are two runs of wire from each of the positive and negative outputs of the  
amplifier for both the left and right channels. The left negative amplifier output is connected  
to the tweeter IN- and the woofer IN- of the left side of the crossover. The left positive  
amplifier output is connected to both the tweeter IN+ and the woofer IN- also on the left side  
of the crossover. This is repeated for the right side.  
The three position switch labeled TWEETER CONTOUR” adjusts the lower end of the tweeters  
frequency response. One position may sound better than the other, depending on where the  
tweeter is positioned with respect to close by objects and with respect to the midrange . After  
installing the system, experiment with both positions and listen carefully to the system.  
Bass contour  
The three position switch labeled BASS CONTOUR” adjusts the upper midrange frequency  
response. As with the tweeter contour, it is designed to compensate for off axis response and  
vehicle limitations. It can be adjusted based on your installation scenario and listening tastes.  
Your ears are the best tools for adjusting the HCCA crossover.  
Important note: You must cut the red and black wire jumpers on each side of the crossover  
that connect the low and high frequency sections of the crossover. Failure to do so could  
cause damage to the amplifiers or the crossover.  
Connections to the amplifier  
The HCCA crossover is supplied with two screw type connectors. Strip the wire from the amplifier  
about 1/4" from the end and insert into the connector input + and - positions and tighten the  
set screws. Strip the wire from the woofer and insert into the + and - positions for the crossover  
woofer output. Follow the same procedure for the connection to the tweeter. The HCCA passive  
crossover has two sets of input terminals, this allows the system to be bi-wired or bi-amplified.  
To bi-amplify the system you will need two stereo amplifiers (or 4 amplifier channels) one for the  
tweeters and one for the woofers.  
If you choose to bi-wire the system, connect the high-pass terminals to the amplifier and connect  
the low-pass terminals to the same amplifier with another set of speaker wires.  
Be sure to connect the positive crossover terminals to the positive speaker terminals and positive  
amplifier terminals. Also ensure that the negative crossover terminals connect to the negative  
amplifier and speaker terminals.  
Once all of the wires are attached to the connector and the crossover is mounted, the connector  
can be plugged into its mating receptacle on the crossover.  
SPEAKER WIRING  
Speaker w ire selection  
Use insulated two-conductor stranded wire to connect the HCCA crossover to the speakers and  
amplifier. The size of the wire can have an audible effect on the performance of the system.  
Standard 18 gauge “zip cord” will work, but can result in lower output or unpredictable frequency  
response. For wire runs of 50 feet or less, we recommend 16 gauge or larger wire. The crossover  
connector will accept up to 12 gauge wire.  
Polarity and phasing  
The polarity - the positive / negative orientation of the connections - for every speaker and  
amplifier connection must be consistent so all the speakers will be in phase. When the polarity  
of one connection is reversed, bass output is reduced and stereo imaging is degraded. All wire  
is marked so you can identify the two conductors. There may be ribs or a stripe on the insulation  
of one conductor. Identify the positive and negative conductors and be consistent with every  
speaker and amplifier connection.  
14  
7
 
Termination  
Bi-amplified connections to the crossover netw ork  
The woofer uses .187 spade lugs for electrical connections. Use standard .187 or .205 female  
quick disconnects to attach wires to the woofer.  
If you have two 2 channel amplifiers or a 4 channel amp, the HCCA components can be bi-  
amplified. Each driver will have its own discrete channel of amplification. Connect the channel  
selected for the tweeter to the positive (IN+) and negative (IN-) inputs next to the tweeter  
outputs (T+ and T-). The woofer channel will be connected to IN+ and IN- inputs next to the  
woofer outputs (W+ and W-).  
The tweeter is terminated with bare wire. Use insulated butt connectors, bullet connectors, or  
quick disconnects to extend the tweeter wires to the crossover location. Alternatively you may  
solder all connections and insulate them with high quality heatshrink tubing.  
Important note: You must cut the red and black wire jumpers on each side of the crossover  
that connect the low and high frequency sections of the crossover. Failure to do so could cause  
damage to the amplifiers or the crossover.  
SPEAKER MOUNTING  
Woofer installation  
The HCCA woofer will fit into standard factory mounting locations using the existing mounting  
holes in the automobile. The woofer uses .187 spade type terminals for electrical connections.  
To connect the woofer, use .187 or .205 female quick disconnects of a size appropriate for the  
wire gauge you chose. You may also solder wire directly to the terminals. If you choose to solder  
the wires, be careful not to use excessive heat so you do not melt the plastic around the terminal,  
which is not covered by the warranty  
Remove the trim panels and inspect the installation locations before you cut and drill the holes  
required to mount the woofer. Removing the panel will also make it much easier to route wiring  
inside the door. Look for original equipment speaker installation cutouts that can be used to  
install the HCCA woofers with little or no modifications. Use the template supplied to help you  
locate and mark the holes needed to install the speakers.  
If the planned installation location is in a door panel be sure the speaker will not interfere with  
the window lowering mechanism. Be sure that the speaker wires clear all moving parts inside  
the door.  
For each woofer you will need to cut one large hole and drill small holes around the circumference.  
If the mounting surface is covered by carpet or fabric, use a knife or razor to cut the material  
away from the holes and cutting path. This prevents material or fibers from becoming tangled in  
the drill bit or cutting blade.  
If you are using the sheet metal screws provided in the hardware kit, drill the four speaker  
mounting screw holes with a 1/8" / 3mm drill.  
Clean the work areas of all filings and shavings with a vacuum cleaner before you proceed with  
woofer mounting.  
Woofer mounting  
Route the speaker wire from the woofer installation locations to the crossovers. Pull the wire  
through the installation hole and attach the terminals on the ends to terminals on the speakers.  
Connect the positive wire to the positive (+) terminal, which is indicated by a +” on the speaker  
magnet. See the information in the speaker wiring section of this manual and the wiring diagrams.  
Push the wire back into the area behind the installation location and be sure it will not interfere  
with the speaker.  
Adhere the supplied foam gasket strip to the mounting surface of the speaker. This will ensure  
an air tight seal, which is required to achieve the best bass performance.  
When installing the speakers drive the supplied sheet metal screws by gradually tightening them  
in turn. Drive the screws in until the speaker is well seated, but take care not to overtighten the  
screws.  
Each of the HCCA woofers is installed in a slightly different way. See the following illustrations.  
8
13  
 
CROSSOVER INSTALLATION  
Connecting the system  
Trim the speaker wire as needed. Strip no more than 1/4" (6mm) of the insulation from the  
ends. Twist the exposed strands thoroughly to prevent any loose strands from causing a short  
circuit. If possible tin” the wire with a soldering iron. Either the tweeter or woofer input of each  
connector can be used when not bi-wiring/bi-amping (when the bi-wire/bi-amp jumpers are not  
cut, the tweeter and woofer inputs are connected in parallel). Insert the wires in the removable  
connector and tighten screws.  
Carefully route the wires from the HCCA tweeter and woofer to the crossover mounting location.  
The crossover installation location should be reasonably accessible to allow easy connection of  
the wires, tweeter level adjustment and tweeter phase selection. If the crossover must be mounted  
in an inaccessible location make the speaker wire connections and adjustments before final  
installation.  
Bi-w iring / Bi-amping  
The HCCA competition system allows bi-wiring, or bi-amping using the supplied passive crossovers.  
While conventional wiring can provide excellent sound, bi-wiring or bi-amping will further enhance  
the performance in no-compromise systems.  
Bi-wiring uses a separate pair of speaker wires for the high frequency and low frequency signal  
between an amplifier channel and its associated crossover network. This gives you the option of  
choosing wire which may have slightly different sonic characteristics in order to optimize  
performance of each frequency range. Also, it reduces the overall wiring resistance between  
the crossover and amplifier, much like the use of larger gauge wire. This option provides the  
most benefit when the crossover network is mounted a long distance away from the amplifier.  
If the crossover is mounted close to the amplifier it is doubtful that there will be an appreciable  
difference between bi-wiring and conventional wiring.  
Bi-amping is similar to bi-wiring except that it uses a separate amplifier channel for the high-  
frequency and low-frequency sections, instead of the single amplifier channel used in conventional  
and bi-wired connections. Bi-amping provides the additional advantages of reducing amplifier  
distortion and allowing the amplifiers level controls to provide an additional level of fine-tuning  
not possible with the tweeter-level switch alone. In addition, at high power levels, a bi-amplified  
connection protects the tweeter from amplifier clipping, which is most likely to occur on channels  
driving the midrange, due to the higher energy levels of midrange signals. When bi-amping  
using the passive crossovers, the midrange low-pass filter and tweeter high-pass filter on the  
amplifier or external electronic crossover should be bypassed.  
Important note: When bi-amping or bi-wiring, you must cut the red and black wire jumpers on  
each side of the crossover that connect the low and high frequency sections of the crossover.  
Failure to do so could cause damage to the amplifiers or the crossover.  
12  
9
 
TWEETER INSTALLATION  
Blind installation  
The HCCA speaker system is supplied with three different tweeter mounting options. Surface,  
flush and angled flush mount. After you have decided which option is best suited to your  
installation, refer to the following sections for specific details on mounting the tweeter.  
In a blind installation, the rear of the mounting surface is  
inaccessible. Give some thought to the electrical connections.  
You may be able to fish the tweeter signal wire to the crossover  
network location after installation of the tweeter assembly.  
You may need to fish a signal wire from the crossover network  
location to, and then through, the mounting hole and the  
rear cup before the cup is inserted through the mounting  
hole. You can then connect the signal wire to the tweeter  
wire.  
Surface mount  
The preparation of the mounting surface for the tweeter involves drilling three holes. Two holes  
are for the mounting screws. Their centers must be spaced 15/16” / 24mm apart. Use a 1/8" /  
3mm drill bit for the supplied flat head #6 X 3/4” screws to mount the cup. The third 1/4” /  
7mm hole is required for the wire to pass through.  
Use the template provided to locate the hole centers. Cut carpeting or fabric away from the hole  
locations to prevent tangling of fibers in the drill bit.  
Once you have decided the signal wire connections, pass one  
supplied #6 x 1 1/2” long screw through the slotted hole in  
the front cup and turn a couple of threads into the rear cup.  
This will allow enough mobility of the two cups to allow the  
rear cup to be inserted through the mounting hole. The two  
cups can be screwed together using the long screw and a  
second #6 x 3/4" through the remaining hole to pinch the  
mounting surface between them.  
Note: The orientation of the three holes determines the installed position of the tweeter.  
The Orion logo on the surface mount cup will end up closest to the wiring hole as shown.  
Surface mount cup mounting  
Insert two #6 X 3/4" flat head sheet metal screws through  
the holes in the bottom of the surface mount cup. Screw the  
cup in place. Be sure the mounting screws are driven in straight,  
so the heads sit flush on the cup mounting surface. This ensures  
the tweeter will seat properly in the surface mount cup.  
Tw eeter mounting  
Route speaker wire from the crossover locations to the tweeter  
locations. Pull the wire through the wire hole and attach  
crossover wires to the wires from the tweeters. Connect the  
positive wire to the positive (+) terminal on the tweeter, which  
is marked with a red wire. See the information in the speaker  
wiring section of this manual and the wiring diagrams. Push  
the wire back into the area behind the installation location  
and be sure it will not interfere with the speaker or with  
anything behind the mounting panel.  
Flush mount  
Check the intended installation site to be sure that there is sufficient depth behind the mounting  
surface for the rear cup and mounting screws. The minimum depth required behind the back of  
the mounting surface is 1” / 25mm.  
The front cup mounts into the mounting surface through a 1 7/8” / 48mm diameter hole. Be  
careful that the hole does not exceed 2 1/8” / 55mm diameter at any point so that the rim of the  
cup will completely cover the edge of the hole.  
Use the template provided to locate the hole centers. Cut carpeting or fabric away from the  
cutting path to prevent tangling of fibers in the saw blade.  
To attach the tweeter to the surface or flush mount cup, align  
the tabs in the mounting cup with the relieved areas in the  
tweeter module. The wires should line up just to the right  
side of where the Orion/ nameplate is located on the surface  
mount cup.  
Note: Once the surface mount cup is attached to the mounting  
surface, there is only one position in which the tweeter can  
be properly seated into the surface mount cup.  
Note: Place enough washers over the protruding screws on the back of the front cup so that  
their combined thickness is somewhat less than the thickness of the mounting surface. This will  
ensure adequate “pinching” of the mounting cups without danger of breaking the rear cup.  
Flush mount and angled flush mount cup mounting  
Insert two #6 X 3/4" flat head sheet metal  
screws through the holes in the bottom  
of the flush mount cup. Hold the back of  
the cup in place behind the hole cut in  
the panel and screw the front cup into  
the back cup. Use care not to overtighten  
the screws. Be sure the mounting screws  
are driven in straight, so the heads sit  
flush on the cup mounting surface. This  
ensures the tweeter will seat properly in  
the flush mount cup.  
Gently push the tweeter into the mounting cup, take up the  
slack in the wire, and twist clockwise until it moves no further.  
Do not force the unit if it does not turn freely. If the tweeter is  
not lined up properly with the tabs or the wire is interfering,  
the tweeter will not fully seat into the cup.  
To remove the tweeter, simply turn it counterclockwise, and  
pull the tweeter away from the cup.  
10  
11  
 

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