BrightSign Expander
Hardware Guide
PCBA: Rev C
Version: 0.1
Saratoga, CA, USA
1
Table of Contents
OVERVIEW ..................................................................................................................................... 3
EXPANDER BLOCK DIAGRAM..................................................................................................... 4
PORTS .......................................................................................................................................... 6
POWER CONNECTOR ..................................................................................................................... 6
OPTICAL SPDIF CONNECTOR......................................................................................................... 6
DB25 SWITCH/LED CONNECTOR ................................................................................................... 6
USB ............................................................................................................................................. 8
1/8” AUDIO CONNECTORS .............................................................................................................. 9
POWER USAGE ........................................................................................................................... 10
ENVIRONMENTAL ....................................................................................................................... 10
THEORY OF OPERATION ........................................................................................................... 11
POWER SUPPLY .......................................................................................................................... 11
CYPRESS CY8C24894 PSOC (UCONTROLLER) ........................................................................... 11
AUDIO OUTPUTS .......................................................................................................................... 11
SPDIF OUTPUT ........................................................................................................................... 11
ON BOARD LED .......................................................................................................................... 11
ON BOARD DIP SWITCH .............................................................................................................. 11
USB ........................................................................................................................................... 12
APPENDIX A................................................................................................................................. 13
FLOW CHART: (FOR REPAIR CENTER USE) ........................................................................... 13
(1) POWER START ....................................................................................................................... 13
(2) USB DEVICES DO NOT ENUMERATE ......................................................................................... 14
GENERAL TROUBLESHOOTING NOTES:................................................................................. 16
1)
IF THE POWER LED IS LIT AND USB HUB IS GETTING 3.3V, WINDOWS DEVICE
MANAGER CAN BE USED TO SEE IF ALL 5 USB DEVICES ARE OPERATIONAL ON THE
EXPANDER. CONNECT EXPANDER TO A WINDOWS MACHINE, GO TO DEVICE MANAGER
-> VIEW -> “DEVICES BY CONNECTION” .................................................................................. 16
THERE SHOULD BE 4 USB AUDIO DEVICES AND ONE USB HUMAN INTERFACE DEVICE:16
....................................................................................................................................................... 16
2
BrightSign Expander
Overview
This hardware reference manual specifies the hardware interfaces on the BrightSign Expander, as well as
providing a guide to troubleshoot the hardware of the Expander for in-field service.
The BrightSign Expander is a 7 port USB Hub with 5 USB devices connected to the Hub, while
remaining two USB ports are used for expansion. There are 4 USB to Audio devices (3x Analog Audio,
1x SPDIF). There is also USB enabled microcontroller, which acts as an interface between USB and
General Purpose 3.3V I/O.
BrightSign Expander is designed to function in tandem with BrightSign Compact (HD810, HD1010) to
expand the capabilities of Compact to that of HD2000 and much more.
This information applies to a product under development. Its characteristics and specifications are subject to change without notice. Roku assumes no
obligation regarding future manufacturing unless otherwise agreed to in writing. www.rokulabs.com © Roku 2007
BrightSign Expander
Expander Block Diagram
Dual USB
Connector
USB
Type B
3x Analog
Audio
Connectors
SPDIF
Analog
Switch
Line Driver
2 Vrms
Headphone
Amp
USB
HUB
USB2517
3x
USB Audio
DACs
PSoC
USB
Device
DB25
GPIO Port
DIP
switch
LED
Regulator
3.3V
DC 5V
Conn.
This information applies to a product under development. Its characteristics and specifications are subject to change without notice. Roku assumes no
obligation regarding future manufacturing unless otherwise agreed to in writing. www.rokulabs.com © Roku 2007
BrightSign Expander
Expander Mechanical
This information applies to a product under development. Its characteristics and specifications are subject to change without notice. Roku assumes no
obligation regarding future manufacturing unless otherwise agreed to in writing. www.rokulabs.com © Roku 2007
BrightSign Expander
Ports
On back of the unit:
• Power plug for 5V power input at 3.0A
• 3 stereo 1/8” mini plugs for audio output
• S/PDIF Optical Audio Output
• USB Type B upstream port
• Two high speed USB downstream ports.
On front of the unit:
• Power LED
• 8 position dip switch
• DB25 Female for LED output and Switch input, as well as supplying 100mA of 3.3V power.
Note: Unless otherwise specified, Roku recommends that all cable lengths be 10 Meters or less. The
customer may be able to use longer cables in specific cases, but the customer must test the cable to see if
it will work. Generally higher quality cables with lower capacitances can be run longer than cheaper
cables.
Power Connector
The power connector on our board is rated at 5V @ 3.0A. The plug to go into our connector is standard
5.5MM plug, center positive, with a 1.65MM center pin hole. The power is over voltage protected and
reverse polarity protected with two 5W 5.6V zener diodes.
Optical SPDIF Output connector
This connector accepts a standard SPDIF optical cable.
DB25 Switch/LED connector
The Switch/Led connector is a DB25 Female. This connector is used to allow the Expander to control
external LEDs or other devices requiring 15mA of current or less. Connect the LED outputs to the LED
ANODE and connect LED CATHODE to ground. If you want to connect up some other device then the
output is capable of sourcing or sinking up to 24mA at 3.3V, but we do have a series resistor of 100 Ohms
in each line. This connector also allows connecting up external contact closures to ground. In order to
connect a switch, connect one side of the switch to the switch input, and connect the other side of the
switch to one of the ground pins on the DB25 connector. Finally the connector can also supply 3.3V at up
to 100mA to an external device. The 3.3V output is polyfuse protected.
If Expander is driving the inputs on another Expander, Compact, HD2000 or HD600, then you can at
most drive 3 inputs from 1 output. Calculations follow showing why this is:
The GPIO outputs have 100 Ohm series resistors, the inputs have 1K pullup resistors to 3.3V, and the
input threshold on the 541 chips is 2V high, and .8V low. The high voltage is not a problem, but the low
voltage can be if there are too many inputs connected to 1 output.
Here are the calculations:
This information applies to a product under development. Its characteristics and specifications are subject to change without notice. Roku assumes no
obligation regarding future manufacturing unless otherwise agreed to in writing. www.rokulabs.com © Roku 2007
BrightSign Expander
1 out driving 1 in:
1 out driving 2 in:
1 out driving 3 in:
1 out driving 4 in:
MAX!)
V=3.3*100/(100+1000)=0.3
V=3.3*100/(100+500)=0.55
V=3.3*100/(100+333.3)=0.76
V=3.3*100/(100+250)=0.94 (Too high, so we can only let 1 output drive 3 inputs
The DB25 female has the following pinout:
pin
1
3
5
7
9
11
13
15
17
19
21
23
25
Description
LED/Button 7
LED/Button 4
LED/Button 1
Ground
LED/Button 13
Ground
+3.3V output @ 100mA
LED/Button 15
Ground
LED/Button 16
Ground
LED/Button 10
LED/Button 8
pin
2
4
6
8
10
12
14
16
18
20
22
24
Description
Ground
LED/Button 2
LED/Button 17
LED/Button 14
LED/Button 11
LED/Button 9
LED/Button 6
LED/Button 3
LED/Button 0
LED/Button 15
LED/Button 12
Ground
DB25 female as viewed from the back of Expander:
The following Diagram shows how to wire up a button and LED to each input/output (this is the
schematic of the Roku button/led board that we sell for development use). You of course can use as little
or as many of the inputs and outputs as you wish.
This information applies to a product under development. Its characteristics and specifications are subject to change without notice. Roku assumes no
obligation regarding future manufacturing unless otherwise agreed to in writing. www.rokulabs.com © Roku 2007
BrightSign Expander
USB
The Expander has two high speed (400 mbit) USB host ports. Maximum cable length is 5 Meters. The
ports have the following pinout:
pin Description
1
VBUS
3
D+
pin Description
2
D4
Ground
This information applies to a product under development. Its characteristics and specifications are subject to change without notice. Roku assumes no
obligation regarding future manufacturing unless otherwise agreed to in writing. www.rokulabs.com © Roku 2007
BrightSign Expander
1/8” Audio connectors
The Expander has three 1/8” female audio connectors. Each connector has a stereo audio signal. The full
scale voltage output of the audio is 3.06V PP, with no load. The minimum load resistance that should be
connected to the audio output is 5 Ohms. The connectors are capable of driving headphones directly.
? 4 connectors?
The connectors have the following pinout:
Tip: Left audio
Ring: Right audio
Base: Ground for audio signal
This information applies to a product under development. Its characteristics and specifications are subject to change without notice. Roku assumes no
obligation regarding future manufacturing unless otherwise agreed to in writing. www.rokulabs.com © Roku 2007
BrightSign Expander
Power usage
The power supply on the Expander is a 15W 5V @ 3A power supply. The Expander will use
approximately 500mA of power when playing analog audio, driving high impedance load such as TV or
A/V receiver. Power consumption will be higher when driving low impedance headphones (16 Ohm).
This implies that up to 2.5A is available for peripheral and accessories, keeping in mind that 1,000mA
should be reserved for two external USB ports when USB devices are used.
The user should not connect up any combination of peripherals that will exceed 2500mA draw. If more
than 2500mA is drawn, then the external power supply will shut down due to overcurrent conditions. The
unit will not be damaged, but it may cause the unit to reboot or to not operate properly until the overload
is removed.
This 2500mA can be shared any way you like on the following connectors.
USB1 – 500mA max
USB2 – 500mA max
DB25 3.3V – 100mA
Each of 6 LED outputs on DB25 – up to 24mA each
Audio 1, 2, 3 – 200mA max (i.e. if you connect up 5Ohm headphones, then each audio connector can
output up to 200mA RMS)
Environmental
The Expander is designed to be used between the temperatures of 0 to 40C with 90% maximum relative
humidity, non-condensing.
This information applies to a product under development. Its characteristics and specifications are subject to change without notice. Roku assumes no
obligation regarding future manufacturing unless otherwise agreed to in writing. www.rokulabs.com © Roku 2007
BrightSign Expander
Theory of operation
Power Supply
The Expander has two onboard voltages present. These are 5V and 3.3V.. 5V comes in from the power
connector and is used directly for USB, the video filter chip, the optical SPDIF chip, and the audio DACs.
3.3V is created from 5V by Semtech SC196 switching regulator.
Cypress CY8C24894 PSoC (uController)
The Expander uses Cypress PSoC to control GPIOs via USB. PSoC is a Full Speed USB device, which is
configured to be Human Interface Device (HID).
Audio outputs
The Expander has three high quality audio DAC devices, which are Wolfson WM8729. These devices
take in digital audio signals from the PNX8950 for I2S audio. The AUD_LRCIN signal is the framing
signal for the audio, running at the frame rate of the audio source. The frame rate is usually either
44.1KHz or 48KHz. AUD_BITCLK signal is typically 64 times higher than AUD_LRCIN. The
AUD_MCLK is usually 4 times faster than the AUD_BITCLK signal. The I2S audio is also routed to the
HDMI chip.
The audio output from the Wolfson DAC is sent to TPA0211 high quality high power audio amplifiers.
These amplifiers are capable of driving 5 Ohm headphones directly.
SPDIF output
The Expander uses C-Media CM102S+ USB Audio device. SPDIF output from the CM102S+ is
connected to optical connector.
On Board LED
There is one Green Power LED on the board; LED indicates if power is applied to the Expander.
On Board DIP Switch
The onboard DIP switch is connected to PSoC and Analog Switch. On board Pull Up resistors are used,
when switches are open (OFF), PSoC and Analog Switch are at voltage high, when switches are closed
(ON), PSoC and Analog Switch are at voltage low. There are three Analog Switches for analog audio 1 This information applies to a product under development. Its characteristics and specifications are subject to change without notice. Roku assumes no
obligation regarding future manufacturing unless otherwise agreed to in writing. www.rokulabs.com © Roku 2007
BrightSign Expander
3. Only switch 6, 7, 8 are connected to the Analog Switches. Switches 6, 7 and 8 are used to select
between 2Vrms line driver and headphone amp. ON (down) position selects headphone amp.
USB
USB is implemented by a PCI ISP1563 USB dual host controller chip. There is also a dual over-current
protected switch TPS2042BD device, which is used to turn on and off power to the USB device, and to
detect over-current situations.
This information applies to a product under development. Its characteristics and specifications are subject to change without notice. Roku assumes no
obligation regarding future manufacturing unless otherwise agreed to in writing. www.rokulabs.com © Roku 2007
BrightSign Expander
Appendix A
Flow Chart: (for Repair Center Use)
(1) Power Start
No LEDs
on
Is the Output power
adapter 5V DC?
No
Replace Power
Adapter
Is the Voltage of
No
Check D1 & D2 for
shorts
No
Check U5, L4,
C28
No
Check R19
L1 = 5V?
Yes
Is the Voltage of
L5 3.3V?
Yes
Is the Voltage across
D3 ~= 2V?
Yes
Replace D3
This information applies to a product under development. Its characteristics and specifications are subject to change without notice. Roku assumes no
obligation regarding future manufacturing unless otherwise agreed to in writing. www.rokulabs.com © Roku 2007
BrightSign Expander
(2) USB Devices do not enumerate
No USB
Is there 3.3V DC at
C18, C19?
No
Check U5, L4, C28
Is there 3.3V DC
at U34?
No
Check U5, L4, C28,
L5
Yes
Is there 12MHz at
U34 pin 1 & 28
No
Check Y2,
C157, C158
Yes
Check U34
bad solder
joints.
This information applies to a product under development. Its characteristics and specifications are subject to change without notice. Roku assumes no
obligation regarding future manufacturing unless otherwise agreed to in writing. www.rokulabs.com © Roku 2007
BrightSign Expander
This information applies to a product under development. Its characteristics and specifications are subject to change without notice. Roku assumes no
obligation regarding future manufacturing unless otherwise agreed to in writing. www.rokulabs.com © Roku 2007
BrightSign Expander
General troubleshooting notes:
1) If the Power LED is lit and USB Hub is getting 3.3V, Windows Device Manager can be
used to see if all 5 USB devices are operational on the Expander. Connect Expander to
a Windows machine, go to Device Manager -> View -> “Devices by Connection”
There should be 4 USB Audio devices and one USB Human Interface device:
This information applies to a product under development. Its characteristics and specifications are subject to change without notice. Roku assumes no
obligation regarding future manufacturing unless otherwise agreed to in writing. www.rokulabs.com © Roku 2007