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Set-top Box

Motorola DCT2524-1612 Set-Top Box Teardown

09 January 2005
The following is an overview of a teardown analysis conducted by IHS Technology Teardown Services.

Basics / Main Features

  • Entry-level cable box
  • DCT2524-1612 is a derivative of Motorola 2500 series - this one for Comcast subscribers
  • Per Motorola the 2500 series is 'the world's most widely deployed digital cable set-top box'
  • Broadcom core a/v processor defines the box

Motorola DCT2524-1612 Set-Top Box Main ImageMotorola DCT2524-1612 Set-Top Box Main Image
Marketing/Positioning

The Motorola DCT2524 is a basic entry-level cable subscriber box offered to Comcast cable customers. This particular box has no real frills but does offer a few low-end extras - such as RS-232 interface, multi-segment LED user interface, digital audio out, and an extra outlet for plugging in other devices - but otherwise is a basic, entry-level subscriber box. However, it is important to note that the 2500 series is very customizable and offers many optional features not offered on this particular iteration of the box, such as S-Video output, USB and others (see link to Motorola 2500 literature for details).

Cost Notes

This box falls in line with other entry-level satellite boxes - and is well inline with similar boxes analyzed in the same segment. At the highest level, the biggest chunks of change in cost are the Broadcom chip, memory, power supply, PCB and mechanical components.

Motorola DCT2524-1612 Set-Top Box Cost AnalysisMotorola DCT2524-1612 Set-Top Box Cost Analysis

Main Cost Drivers representing 64% of total box production costs - mat'ls and mfg

Broadcom A/V Processor

Power Supply

Memory

Enclosures / Plastics & Metals

Main PCB

* - This pricing comes from industry insiders close to this business and may be as much as a $1 lower - other manufacturer's using the same device may pay much more.

Manufacturing Notes

The box is labeled as made in Mexico - the metals inside the box (this is a first) is labeled with a manufacturer's stamp - EnLight Corp. (with some manufacturing in Mexico) - so it is assumed that the everything, except the Lite-On power supply (made in China, as printed on the device) is manufactured in Mexico.

Motorola DCT2524-1612 Set-Top Box - Main PCB BottomMotorola DCT2524-1612 Set-Top Box - Main PCB Bottom
Design

With the exception of the Broadcom chip and memory devices - most other chips have limited functionality and dollar value, and little information was available on them - specifically the Sanyo chips.

  • Audio/Video Processing - Broadcom BCM7115KPB - Used in several manufacturer's boxes - this chip defines the box and represents the bulk of functionality and dollar value.
  • Memory - SDRAM - DDR, 128M (8Mx16), 133MHz, Flash - 32M (2Mx16), and SRAM - 2M (128Kx16bit).
  • Front End - Modular - use of modular Tuner - Down Convertor/Tuner, as well as diplex splitter from Pulse Engineering. Otherwise two other smaller Sanyo chips (one CATV tuner - other unidentified)
  • Interface - Motorola Microcontroller and a Sanyo VIF/SIF Minimum Adjustment Signal Processor represent the main functionality here.


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