iRobot Roomba 510 Page 65 Service Manual Download

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Side Brush Module
Side brush with Screw
Cleaning Head Module
Bristle Brush
Flapper Brush

Brush end caps
Brush Bearings
Wire Bale

Vacuum Bin Module

Filter Frame
Filter
Removable Squeegee
Bin Grill Cover (Green, White, Black)

Battery

Replaceable rubber dust shield

Roomba Accessory Spare Parts

WCC Battery Door
Virtual Wall Battery Door
Light House battery door

Roomba Spare Parts Replacement (Battery, Side Brush, Cleaning Head
and Wheel Modules)

Turn the robot over and remove side
screw brush screw

Summary of Contents for Roomba 510

Page 1: ...Roomba 500 Series Service Manual Published 10th September 2007 Base Robot 3 0 Model 510 Base Robot 3 3 Model 530 Base Robot 3 4 Model 535 540 Base Robot 3 5 Model 550 560 565 570 580...

Page 2: ...Test Wireless Command Center if applicable 9 15 Replace Faulty Accessories 9 16 Pack Record the Serial Numbers 9 17 Monthly Data Report to iRobot 9 Roomba 500 Series Vacuuming Robot 10 Roomba Terminol...

Page 3: ...ection and cleaning 60 FRONT WHEEL Module inspection and cleaning 60 CLEANING HEAD Module inspection and cleaning 61 BUMPER Module inspection and cleaning 61 CLIFF SENSOR Module inspection and cleanin...

Page 4: ...4 Roomba 500 Series Service Process...

Page 5: ...Roomba i Clean the cliff sensors under the bumper with a cotton bud 1 ii Remove any hair or obstruction from the three wheels 2 iii Remove any hair or obstruction from the brushes and bearings 3 iv C...

Page 6: ...the bristle brush Does the flexible brush counter rotate Remove the brush guard and check that both yellow brush bearings are present Reinsert all Roomba components and try to recreate the customer c...

Page 7: ...important that this step only diagnose Roomba failures For this reason conduct the BiT with approved accessories the customer accessories can be tested separately Ensure the Roomba has a charged batte...

Page 8: ...home base present The Roomba will run until the battery runs low The runtime should be at least 60 minutes If not replace the battery Note Battery can be discharged at a constant 2 2A until the batter...

Page 9: ...ual Wall IR emitter o Check power light if blinking then batteries are low o Perform Virtual Wall mobility tests Appendix B 14 Test Wireless Command Center if applicable Test Wireless Command Center w...

Page 10: ...R3 impacts with 50 less force vs R2 Quieter cleaning R3 has a 50 lower sound pressure level and a 75 lower sound intensity level on hardwood floor vs R2 Replaceable squeegee Lower standby current dra...

Page 11: ...ved Front Caster Wheel Electrical Contacts not all models Drive Wheel 80 rpm when driving straight Brush Guard or Wire Bail Vacuum Bin with removable filter and squeegee Removable Front Caster Module...

Page 12: ...12 Top View front panel removed Top View top chassis user panel removed...

Page 13: ...ase robots 3 4 and 3 5 uses radio frequency channels for wireless connection The Roomba will scan the channels at the start of a cleaning cycle and choose a channel with the least interference If duri...

Page 14: ...l current sensors 1 battery temp sensor 1 battery voltage sensor 1 main brush current analog sensor 1 side brush current analog sensor 1 main brush pwm pulse width modulation truncation sensor 1 side...

Page 15: ...ammed Roomba enters scheduled cleaning mode At the specified time Roomba leaves its Home Base cleans and then returns to the Home Base to recharge when it s done Max Mode To recreate a Max mode run th...

Page 16: ...sensor detects a cliff o RCON avoid Roomba turns whenever the RCON sensor detects an infrared beam o Bump follow Roomba follows a wall with its bumper o Panic spin Roomba will spin in place when the f...

Page 17: ...ubleshooting steps are detailed but as a last resort a replacement part is suggested Description Spare Part 0 Roomba BiT 0 PANEL LEDS BUTTONS SPEAKER Roomba Spare Part Service or Core Robot Replacemen...

Page 18: ...R Troubleshooting Clean RCON with a cloth Roomba Spare Part Service or Core Robot Replacement 10 Roomba BiT 10 FRONT DIRECTIONAL IR RECEIVERS Base robot 3 4 and 3 5 only Troubleshooting Clean front bu...

Page 19: ...Troubleshooting Redo test with new brush and flapper Ensure motor and pulley string of module is functioning Roomba Spare Part Cleaning Head Brush Flapper Drive and Bearing Replacement 17 Roomba BiT...

Page 20: ...and clean side brush from hair and dirt Inspect side brush axle Roomba Spare Part Side Brush Module Replacement 20 26 Roomba BiT 20 to 26 CHARGING Troubleshooting Clean robot and Home Base contacts i...

Page 21: ...21 Charging Accessories Battery Power Supply Home Base...

Page 22: ...oltage is under 10 8 V Charging Battery reset A robot charging system can be reset by holding down the SPOT and DOCK buttons together for 10 seconds This will also erase all schedules It is easiest to...

Page 23: ...charge condition is true in one of the following modes a Normal 1250mA for initial battery voltage greater than 10 8V b Recovery 300mA for initial battery voltage less than 10 8V 4 Post charge cooling...

Page 24: ...the normal slow pulse or recovery fast pulse charging state Note that this does not necessarily mean that current is actually flowing into the battery If the robot s hardware is damaged such that no...

Page 25: ...battery The charging sequence takes about 3 hours in a normal charge and 16 hours in a recovery mode The power light on the Home Base indicates that it is plugged in and operating properly This light...

Page 26: ...Walls closer than 2 5 meters from the Home Base 4 Place Roomba about 1 5 meters in front of the Home Base and press DOCK Roomba should drive back to the Home Base and it may take a few attempts 5 Onc...

Page 27: ...27 Roomba Accessories Virtual Wall Light House Wireless Command Center...

Page 28: ...n off automatically after 2 hours The Virtual Wall beam is triangular shaped A small halo prevents Roomba from bumping into the Virtual Wall and a larger cone shaped section blocks off areas of your h...

Page 29: ...ery door When replacing batteries wait 5 seconds between removal and insertion for a full reset Also choosing a higher range in Virtual Wall than necessary will drain the battery faster If Roomba goes...

Page 30: ...up to 35 minutes before opening and allowing the Roomba to pass into the next room o Light House and Robot pairing Light Houses need to be paired up with its Roomba and this occurs every time batteri...

Page 31: ...each Light House can only be controlled by its specific Roomba Therefore when a new strange service robot comes into the picture it is necessary to flush the Light House memory so it can be paired an...

Page 32: ...allic it will be reduced Prior to using a new Wireless Command Center WCC with Roomba it needs to be paired to the Roomba Remove WCC batteries Reinstall WCC batteries while holding down the left drive...

Page 33: ...Roomba s wheel has dropped below body of robot See Appendix C Inspect and Clean Wheel modules 2 beeps Please remove and clean Roomba s Brushes main brush stall Main brushes cannot turn See Appendix C...

Page 34: ...airs Most common causes Roomba was started on an uneven surface Roomba encountered a step and its cliffs activated Robot got stuck on a dark obstacle or high pile carpet that has obstructed its cliff...

Page 35: ...one wheel Circling interspersed with wiggling or rocking behavior Forward and or backward circling Circling at slow normal or rapid speed Most common causes Dirt has infiltrated the wheel encoder or a...

Page 36: ...e cleaning head module has entered anti tassel behavior The main brushes alternate between forward and reverse direction in order to escape from carpet tassels or wires Troubleshooting If thumping is...

Page 37: ...by 2 beeps main brush stall error Main brushes do not spin Roomba is not picking anything up in vacuum bin Roomba s brushes thump approximately once per second on all floor types Most common causes So...

Page 38: ...oper Home Base and Light House placement as described in the owner s manual If problem is not resolved follow the steps outlined in the Charging issues section below Wireless Command Center Customer o...

Page 39: ...persists replace Battery 2 blinks Err2 Charging Error 2 Battery overcurrent This occurs when the current is over 1250 mA 1 Replace Robot Power Supply 3 blinks Err3 Charging Error 3 Charging FET Faile...

Page 40: ...setup to a cooler environment and make sure there is no object on top of robot 2 If problem persists replace Battery and Robot 7 blinks Err7 Charging Error 7 Battery not Cooling This occurs when the...

Page 41: ...ower Supply Plug Power Supply directly into Roomba o If green light on the Power Supply goes out or starts blinking replace Robot Home Base and Power Supply o If CLEAN POWER light on Robot does not st...

Page 42: ...SPOT 6 times Release buttons Auto advance Mobility Test Hold CLEAN and DOCK and pulse SPOT 9 times Release buttons Manual advance Mobility Test Hold CLEAN and DOCK and pulse SPOT 12 times Release but...

Page 43: ...base robot assembly 3 3 and 3 4 check that a SPOT and DOCK are toggling b CHECK ROBOT is on Note Even in AUTO ADVANCE mode you must advance to Test 1 by pressing the DOCK button In the BUILT IN TEST...

Page 44: ...ext test number MANUAL ADVANCE MODE This is designed to be used for debugging particular sensors or actuators In this mode the robot DOES NOT decide PASS FAIL for each test number The test does not au...

Page 45: ...0 0411 L SUMMARY BOOTLOADER ID 0000 01BB SUMMARY BOARD ASSEMBLY 3 4 SUMMARY BOARD REVISION 0 SUMMARY FACTORY TEST PASS SUMMARY flash version 2 SUMMARY flash info crc passed 1 SUMMARY user button day d...

Page 46: ...urrent ok PASS mA 281 min 250 max 350 mV 16253 degrees C 37 SUMMARY int charging current ok PASS mA 1206 min 1000 max 1400 mV 16560 degrees C 37 SUMMARY int charging trickle current ok PASS mA 58 min...

Page 47: ...r pressed 3 Outer Cliff Sensors Briefly lift robot s left side to simulate cliff left Briefly lift robot s right side to simulate cliff right Cliff left detected Cliff right detected 4 Inner Cliff Sen...

Page 48: ...ectional IR receiver Virtual wall signal at front left directional IR receiver Virtual wall signal at front right directional IR receiver 11 Battery Sensors No user action Battery voltage between 12 a...

Page 49: ...K is on and side brush is turning counterclockwise Then briefly stall the side brush motor until DOCK and SPOT are on and solid Side brush turns clockwise then turns counterclock wise Side brush stall...

Page 50: ...black box that is an onboard data logging processor This processor is not erased when the robot is reset This data may be valuable if one wants to know the total cleaning time in the robot s life mis...

Page 51: ...5 bb main brush motor current 363 bb side brush motor current 98 bb right motor current stalled 785 bb left motor current stalled 773 bb main brush motor current stalled 1306 bb side brush motor curre...

Page 52: ...6 max discharge temp avg 606 max charge temp avg 803 n no current errors 0 n app exceptions 0 charging bbox unused 5 0 charging bbox unused 6 0 charging bbox unused 7 0 charging bbox unused 8 0 chargi...

Page 53: ...ly conduct Test Floor 3 Test Floor Tests Performed Floor Fixture Test Floor 1 o light touch max distance Test Floor 2 o light touch min distance Test Floor 3 o wall follow encoder check o wall follow...

Page 54: ...lso you may skip forward only not backward at any point before or during the test by pressing the DOCK button You will hear beeps and see the Sun Thu lights in Scheduler models to indicate which test...

Page 55: ...55 MOBILITY TABLE 3 CONSTRUCTION SPECIFICATIONS IN MM Metal threshold on long carpet edge only Wrap carpet around the edges of the floor...

Page 56: ...ify that the SPOT light on the robot is lit 6 Slow turn the fixture and verify that the SPOT light is on all the time 7 Set the VW at lowest power 0 0 9m and put it 2 4 m away 8 Verify that the SPOT l...

Page 57: ...Place the Roomba in the below distances from the VW Distance is measured from VW RCON to Roomba RCON The settings of the VW should be set at 0 9 S M L depending settings shown on the left hand side 4...

Page 58: ...e for each new robot the battery should be removed and reinstalled 2 Start a robot near the Light House and verify that the LED light on top of the Light House will go green 3 Verify that the Light Ho...

Page 59: ...est robot by pressing CLEAN and having it face a wall 3 The robot will attempt to start a spiral strike the wall and then follow the wall right to left 4 Verify that robot will deflect and not touch a...

Page 60: ...ist on flat surfaces when there are no obstacles present replace wheel modules FRONT WHEEL Module inspection and cleaning Flip robot over and hold wheel and pull out the entire front wheel module Look...

Page 61: ...g or if error alert persists replace cleaning head module BUMPER Module inspection and cleaning Gently tap both sides of bumper several times to shake out any debris that might be causing the bumper t...

Page 62: ...hat is wrapped around the hex shaft If the side brush does not spin after cleaning replace side brush module BRUSH FLAPPER inspection and cleaning 1 Remove brush guard by pulling on both yellow tabs 2...

Page 63: ...cleaning Make sure filter is properly installed Replace if necessary Make sure rear squeegee is properly installed Check for wear and tear on both front and rear squeegees Wipe dust off vacuum bin co...

Page 64: ...ews US EU Sing Japan Korea Core Robot Chassis Base Robot 3 0 US EU Singapore Japan Korea Core Robot Chassis Base Robot 3 4 US EU Singapore Japan Korea Core Robot Chassis Base Robot 3 5 US EU Singapore...

Page 65: ...e Filter Frame Filter Removable Squeegee Bin Grill Cover Green White Black Battery Replaceable rubber dust shield Roomba Accessory Spare Parts WCC Battery Door Virtual Wall Battery Door Light House ba...

Page 66: ...r and set aside BATTERY MODULE Remove Battery by lifting the pull tabs Replace with new Battery using pull tabs Press pull tabs against the body of the Battery SIDE BRUSH MODULE Replace the 2 screws t...

Page 67: ...ule Replace the 3 screws that retain the wheel module CLEANING HEAD MODULE 1 Remove the 4 screws that retain Roomba s cleaning head module 2 Remove Roomba s vacuum bin 3 Remove Roomba s cleaning head...

Page 68: ...68 5 Replace Roomba s bottom cover and the 4 screws that retain the bottom cover 6 Replace spinning side brush and screw...

Page 69: ...ling up from the bin The faceplate is secured in several places Lift the handle to make removal easier 3 Install Roomba s faceplate by inserting the tabs into the appropriate slots and then pushing do...

Page 70: ...lacement 1 Remove Roomba s vacuum bin 2 Open Roomba s filter compartment 3 Remove Roomba s old filter by pushing it upward 4 Install Roomba s new filter 5 Close Roomba s filter compartment 6 Re insert...

Page 71: ...ftware OSMO is a portable device that can be sent or used by service centers to update Roomba code To determine what version of software is in the OSMO inspect the OSMO date code sticker for the versi...

Page 72: ...g is less than 14 5V 3 To measure the voltage across a 5 resistor follow step 1 set the multimeter to measure DC VOLTAGE and press the 5 Ohm resistor push button Caution Do not press button for more t...

Page 73: ...etween 1 0A and 1 45 A 3 Plug Power Supply into wall outlet or AC supply 120 240VAC Measure open circuit voltage idle current and power Failure if DC output voltage is not between 21 1 VDC and 24 VDC...

Page 74: ...acturer ID JE or KY or PR Status N for new R for remanufactured LLLLL Model number 00000 09999 YY Year since 2000 this robot was manufactured mm Month this robot was manufactured dd Day of the month t...

Page 75: ...DOCK Light No Light Green Dock mode not activated Flashes green when attempting to dock Flashes green in Voice Tutorial CHECK ROBOT Light No Light Red Robot functioning normally Blinks for Pause erro...

Page 76: ...se of visible light 0 75 and 1000 m IR does not pass through walls Light Emitting Diode LED o Semiconductor light source that emits visible light or invisible infrared radiation Mobility o Capable of...

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