Application Report
DLPA028 – December 2011
DLP® LightCommander™ Development Kit:
Extending the Connection
Between the Controller Board and the DMD Board
ABSTRACT
The DLP LightCommander development kit was introduced as a platform for exploring the possibilities of
DLP technology, and facilitating the development of customer DLP applications. The LightCommander is
modular in concept, allowing for a certain amount of flexibility in the arrangement of the components and
modifications to the default setup.
One of the configurations often requested involves the use of the DLP5500 Digital Micromirror Device
(DMD) in a user-defined optical arrangement, rather than in the LC default configuration. As shipped, the
LC comes with the DMD attached to an optical train consisting of an LED source, an illuminator optical
system, and a F-mount lens port for projection of the DMD image on to a screen, or other area. The DMD
is located in a socket on a PC board which plugs into a connector located at one end of the LC Controller
Board, and is held at a right angle to the Controller Board. The combined assembly is then mounted inside
the LC such that the DMD board (with DMD) is properly located with respect to the optical components of
the illuminator and projection lens.
1
The Problem
If a user wishes to use a custom illuminator and optical system with the LC DMD, or simply desires to
have direct access to the DMD device while it is operating, the DMD board must be removed from the
normal mounting position in the LC. Since the DMD board must remain connected to the LC Controller
board by being plugged into the right-angle edge connector, this also involves removing the Controller
board from its mounted position. This operation requires a fair amount of disassembly of the LC, and
results in a Controller board/DMD board assembly which may be difficult to position as desired.
2
A Solution
It is possible to extend the connection between the LC Controller board and the DMD board by interposing
a flexible cable arrangement with PCB connectors attached at each end. This allows for the more flexible
placement of the DMD for alternative user-defined experimentation and optical path development.
NOTE: DISCLAIMER
This method of extending the connection of the LightCommander Controller board and DMD
board is not officially supported or guaranteed by TI. The user assumes all risk involved with
this modification of the DLP LightCommander development kit. It may work for you – or it
may not. However, what is presented in this application note is given because this
modification has been observed to work in some situations, and may be helpful to the user.
The signals that are extended by the cable and connectors discussed in this application note
are very high speed signals, with stringent requirements for timing and waveform fidelity. The
addition of cable length, PCBs, connectors, and other variables, may degrade the signals so
that the normal operation of the DMD is prevented. Please be aware of this before
implementing the steps shown in this note.
DLPA028 – December 2011
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DLP® LightCommander™ Development Kit: — Extending the Connection —
Between the Controller Board and the DMD Board
Copyright © 2011, Texas Instruments Incorporated
1
A Solution
2.1
www.ti.com
The Details
CAUTION
This application note does not give step-by-step instructions on how to
accomplish the removal of the boards and management of the wiring
connections. Observe ESD precautions!
Please refer to the LightCommander videos which are available at
www.logicpd.com/dlp-lc-videos. See the video titled “Mounting the DLP
LightCommander Modules to an Optical Bench” for details on disassembling
the LightCommander.
Carefully remove the cover of the LightCommander development kit box. Continue by identifying the
Controller board and DMD board. Carefully remove these boards from their default positions in the LC
box. Remove the Controller board first, and pull up gently on it while holding it level to unplug the DMD
board which will be plugged into the socket at the lens end of the Controller board. Then proceed to
remove the DMD board. This process may be somewhat involved, so proceed with patience and care.
The power supply connection to the Controller board may need to be rerouted, or extended also, in order
to allow for the new positioning of the Controller board.
2.2
The Pieces
The required components of the flex cable extension consist of:
• Flex Cable with bolster plates
There are two lengths of flex cable which have been used and observed to work in some situations:
– Amphenol (InterCon Systems) part number 7840-001 (5.2” and bolster plates)
– Amphenol (InterCon Systems) part number 7840-002 (12.2” and bolster plates)
www.interconsystems.com/cstackflex.php
• Two PCB assemblies
Assembly drawings are available (PCB assembly drawings)
See Figure 1 through Figure 7 .
• Edge connector, which must be attached to one of the PCBs for the DMD board to plug into: Samtec
part number MEC8-170-02-L-D-EM2
NOTE: At this time, TI does not have these cable assemblies for sale. This information is given only
so that interested users can make their own flex cable assemblies for the purposes
discussed in this application note.
Figure 1 and Figure 2 show the flex cable assembly with the 5.2-inch flex cable.
2
DLP® LightCommander™ Development Kit: — Extending the Connection —
Between the Controller Board and the DMD Board
Copyright © 2011, Texas Instruments Incorporated
DLPA028 – December 2011
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A Solution
www.ti.com
Figure 1. Flex Cable Assembly (With 5.2” Flex Cable) - Figure 2. Flex Cable Assembly (With 5.2” Flex Cable) Top Side
Bottom Side
Figure 3. Two Lengths of Available Flex Cable – 5.2" and 12.2"
DLPA028 – December 2011
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DLP® LightCommander™ Development Kit: — Extending the Connection —
Between the Controller Board and the DMD Board
Copyright © 2011, Texas Instruments Incorporated
3
A Solution
www.ti.com
Figure 4. PCBs – Top Side
Figure 5. PCBs – Bottom Side
4
DLP® LightCommander™ Development Kit: — Extending the Connection —
Between the Controller Board and the DMD Board
Copyright © 2011, Texas Instruments Incorporated
DLPA028 – December 2011
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A Solution
www.ti.com
Figure 6. DLP LightCommander Controller Board, DMD Board, and Flex Cable Assembly
Figure 7. DLP LightCommander Controller Board, DMD Board,
and Flex Cable Assembly – Plugged In
DLPA028 – December 2011
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DLP® LightCommander™ Development Kit: — Extending the Connection —
Between the Controller Board and the DMD Board
Copyright © 2011, Texas Instruments Incorporated
5
Putting It Together
3
www.ti.com
Putting It Together
CAUTION
Observe ESD procedures while handling the DMD board, or DMD. See the
application reports Series 4xx DMD Glass Cleaning Procedure, TI literature
number DLPA025 and Series 4xx DMD Handling Specification, TI literature
number DLPA019.
The DMD board will only plug into the socket in one direction, as is also true for the PCB which substitutes
for the DMD board at the Controller board socket. The fit may be tight, so be careful not to stress or break
the connector or the DMD board. Also, be careful not to dislodge the DMD from its socket. Check to see
that the DMD remains fully inserted into its socket. The socket is ZIF, and can be opened or closed with
the flat-head screw next to the socket.
Once the DMD board is extended from the Controller board, secure the boards in the desired positions,
taking special care to perfectly match the connectors avoiding shorts. Also, be careful to put as little strain
as possible on the flex cable connections.
Proceed by operating the DLP LightCommander development kit as before the modification, using the
LightCommander software GUI. However, the operations involving the internal illumination will not be
effective. The internal LEDs should be turned off (disabled) from the GUI.
There is no TI guarantee or support for the modification to the DLP LightCommander development kit as
described in this application report. However, comments and questions should be posted to the TI DLP
and MEMS E2E forum.
6
DLP® LightCommander™ Development Kit: — Extending the Connection —
Between the Controller Board and the DMD Board
Copyright © 2011, Texas Instruments Incorporated
DLPA028 – December 2011
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