iRobot Roomba Discovery Service Manual Download Page 5 | Manualshive

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5

Roomba Service Process

The Roomba Service Manual will guide a technician through the Roomba Service Procedure.
The steps that involve record keeping will enable iRobot to better track and support product
improvements. iRobot requires the data to be sent to them in a standardized manner but it is up
to every Service Center to decide how detailed they require their record keeping to be.

Record Keeping

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Summary of Contents for Roomba Discovery

Page 1: ...1 Roomba Discovery Series Service Manual Published August 31 2006 Roomba Scheduler Roomba Discovery SE Roomba Discovery Roomba Sage Roomba Red...

Page 2: ...___________________ 12 Roomba Vacuuming Robot ______________________________________________________ 13 Roomba Terminology_______________________________________________________________ 13 Roomba Chas...

Page 3: ...________________________________________________ 43 Virtual Wall Troubleshooting _______________________________________________________________ 43 Roomba Remote ______________________________________...

Page 4: ...val Procedure _____________________________________________ 79 Roomba Swivel Caster Removal Procedure_____________________________________________ 80 Roomba Swivel Optical Stasis Switch Removal Proced...

Page 5: ...Procedure The steps that involve record keeping will enable iRobot to better track and support product improvements iRobot requires the data to be sent to them in a standardized manner but it is up t...

Page 6: ...should a customer send the Roomba to a service center A Customer should clean Roomba i Clean the cliff sensors under the bumper with compressed air 1 ii Remove any hair or obstruction from the three w...

Page 7: ...laint Code Appendix C Remove the vacuum bin and turn the Roomba on its back on a flat surface Perform a general outer visual inspection of the Roomba condition Look at the wear on the chassis caster d...

Page 8: ...from hair and dirt Clean drive wheel bearings Clean the wheel axles from hair using tweezers o Front caster o Drive Wheels Remove and clean under the side brush of hair and dirt Clean the sensors with...

Page 9: ...issue that caused return Take special notice of the button speaker performance Appendix C 07 Capture Built in Test Data Use iRobot Factory Test Client Version 1 1 software to download the BiT output A...

Page 10: ...ix C 11 Test Power Supply Test returned Power Supply o Output current at 90 VAC and 240 VAC o Output current at 60 VAC o Solid green light under load Appendix K Troubleshoot Power Supply pg36 Note If...

Page 11: ...licable Test returned Remote with charged batteries o Clean Remote IR emitter o Check power light if blinking then batteries are low o Verify all command buttons function with a Roomba Troubleshoot Re...

Page 12: ...pped up file of monthly Built in Test output files The zip file should have a name format of YYYYMM_RoombaBiT_ csv where is the name of the service center Save the file as a CSV comma delimited 2 The...

Page 13: ...Bin Cliff Sensors Vacuum Inlet Battery Side brush Front Caster Contacts Main Brush Drive Wheel Flexible Brush Debris Sensor IR Receiver RCON Wall Sensor Serial Port Bumper Handle Chassis User Interfac...

Page 14: ...14 Roomba Chassis Disassembly Procedure o Remove Vacuum Bin o Unscrew bumper screws 1 o Unscrew chassis screws 2 3 4 5 o Unscrew side brush if necessary 6...

Page 15: ...sed air Go to Appendix M for details on how to remove the Cleaning Frame PCB Inner Bumper Diver Wheels and Front Caster Roomba Electrical Inter Relationships Roomba electrical design is proprietary Ho...

Page 16: ...to iRobot on a monthly basis However a service technician will repeat the BiT numerous times during the servicing of a Roomba A Roomba can only be returned to the customer after both the BiT and MT pa...

Page 17: ...under the failed top shell Are any pcb wires broken or disconnected BiT REPAIR STEPS If buttons are not working or intermittent and the Roomba is a Discovery SE or Scheduler open the user interface p...

Page 18: ...ensors in housing with alcohol Make sure the front caster is properly inserted and that the connectors are secure Inspect the bumper springs and ensure they spring back and that there are no wires or...

Page 19: ...pressed air Is the side brush blocking the outer sensor Rotate the side brush arms away from the cliff sensor opening Remove the outer bumper and inspect the cliff sensor wiring REPLACEMENT PART Inner...

Page 20: ...EPAIR STEPS Inspect the failed wheel switch and toggle it If the switch arm is worn or broken then replace the switch Clean the switch with a drop of alcohol and dry switch with compressed air If swit...

Page 21: ...ure BiT passes Failed BiT 4 Wall Sensor Roomba Symptom Roomba does not run parallel to the walls on its right side Clean the wall sensor with compressed air Perform a wall follow test see Figure 2 in...

Page 22: ...e bumper Plug in an approved outer bumper and retest with accessories to rule out pcb failures REPLACEME NT PART Outer Bumper Assembly QC o Ensure BiT passes Failed BiT 6 Battery Sensor Roomba Symptom...

Page 23: ...ests fail or sound bad Put the Roomba on its back and manually turn the wheel Is there an obstruction Is the axle and bearing centered Open wheel cover and clean under the cove with compressed air inc...

Page 24: ...24 REPLACEMENT PART Drive Belt Right Left Wheel Assembly QC o Ensure BiT passes o Verify wires are well routed and not pinched by the wheel cover o Verify the wheel supports are screwed in...

Page 25: ...that there is no hair in the axle and that it can spin fairly freely Replace caster module if cleaning did not help BiT REPAIR STEPS If the swivel caster stasis fails the optical switch may have faile...

Page 26: ...n approved cleaning assembly to pcb main brush connector and run test If test passes then the Roomba pcb is good and we need to inspect the returned cleaning assembly Inspect brush motor power wires f...

Page 27: ...Verify the string is attached to the chassis Failed BiT 12 Debris Sensor Roomba Symptom Roomba s blue light never comes on in a dirty environment BiT REPAIR STEPS Verify the debris sensor is not cove...

Page 28: ...clean or o Roomba ends with error uh oh and 3 beeps or o Vacuum Bin sounds loud TROUBLESHOOTING If the vacuum test fails or sounds loud Verify the vacuum is unobstructed Take out grill spin impeller...

Page 29: ...SHOOTING Verify the side brush has been cleaned Attach an approved side brush into the pcb and retest If test passes then the Roomba pcb is good and we need to inspect returned side brush If the motor...

Page 30: ...d Verify Power Supply is correctly plugged into the Roomba If step still fails replace pcb TROUBLESHOOTING If the external charging fails steps 18 20 Verify the Roomba is properly docked on the Home B...

Page 31: ...irt to from failing by allowing dirt not to compact in the bearing and stress the cleaning frame Side Brush A white bristle brush is transparent to IR and will not trigger false cliffs which could be...

Page 32: ...32 Charging Accessories Battery Power Supply Home Base Rapid Charger...

Page 33: ...33 Roomba Battery Batteries are made of 12 NiMH nickel metal hydride cells It has a thermistor to measure battery temperature and a ve and ve contact thermistor ve contact ve contact Skid pads...

Page 34: ...e carpet not in production 2600 mAH Battery Insertion Technique Hold the Battery with the Roomba logo facing up and place Battery over the battery well Lower the Battery slowly and then release it so...

Page 35: ...the Roomba unplugged Roomba sleep current when not running and left unplugged is about 7 mA which slowly drains the battery Batteries also naturally degrade over years They should never be stored in a...

Page 36: ...tion 2 implemented Jan 2005 implemented July 2006 Date code starts with 04 or 05 P branded in the plastic Date code starts with A Power Supply Troubleshooting Is the light solid green while charging I...

Page 37: ...tery The charging sequence takes about three hours with the fast APS power supply grey and six hours with the slow power supply black The power light on the Home Base tells you that it is plugged in a...

Page 38: ...emove any Virtual Walls closer than 8 ft 2 4 meters from the Home Base 3 Place Roomba about 3 ft 1 m in front of the Home Base and press Spot and Clean buttons simultaneously Roomba should drive back...

Page 39: ...ht on the Home Base must be on and solid green while charging If the dock light is not on try cleaning the contacts on the Home Base and under the Roomba if this is the case Inspect the integrity of t...

Page 40: ...ck Battery in 2 5 hrs Although the Rapid Charger can be used for the 3000 mAH yellow Battery iRobot recommend that all batteries be charged in a Roomba This is to make use of the Roomba charging seque...

Page 41: ...41 Roomba Accessories Virtual Wall Remote Filters Bristle Brush Flexible Brush Side Brush...

Page 42: ...ole shaped and can get up to 3 feet wide 1 meter To avoid IR interference do not place the Virtual Wall within 8 feet 2 4 meters from a Home Base When turned on the standard Virtual Wall Unit will tur...

Page 43: ...6 m Beam Angle 27 deg Diameter 0 6 m Virtual Wall Troubleshooting If you press power and the light does not go on or flashes check the batteries and the virtual battery door If the Roomba goes through...

Page 44: ...and distances from Roomba o Confirm that Roomba is not inside a Virtual Wall and do not try to drive the Roomba through the virtual wall beam and keep in mind that Virtual Wall beams can reflect off s...

Page 45: ...r maximum vacuum power the filter should be cleaned and inspected after every use If desired the filter can be hand washed with soap and water but needs to be thoroughly dried before use If punctured...

Page 46: ...bin For maximum Roomba life the brushes should be cleaned and inspected after every use Brush Troubleshooting Remove and clean the brushes and inspect for tears Inspect the brush bearings and verify t...

Page 47: ...47 Appendices...

Page 48: ...x A Charging Troubleshooting Flowchart WARNING The Power Supply Home Base and pcb need to be replaced if the lights are OFF or BLINKING If only partial replacement a compromised Roomba could fail by o...

Page 49: ...nufacture Robot Barcode Serial Number Format barcode sticker in battery well MM Manufacturer ID JE Jetta PR PRC U Status N new R remanufactured LLLLL Model number 00000 09999 YY Year since 2000 this r...

Page 50: ...Power Supply Serial Number Format ASCII number on sticker o YYMMDD or AYYMMDD o The P on the plastic indicates it has been reworked If P exists on the plastic then add this to the end of the serial n...

Page 51: ...ility Circle Dance RB08 BiT7 9 drive wheels encoders CC09 Mobility Robot RB09 BiT10 front caster CC10 Mobility Accessory RB10 BiT11 cleaning frame CC11 General Robot RB11 BiT12 debris sensor CC12 Gene...

Page 52: ...IR Beams crosses v w AA01 replace upper shell HB02 force field hits base VW02 force field hits v wall AA02 replace outer bumper HB03 LED power VW03 LED power AA03 replace inner bumper HB04 contacts ch...

Page 53: ...o remove the grill at the back of the debris bin Spin the vacuum impeller around shaking out any debris that may be stuck Replace the grill and the dust bin Uh oh 4 beeps Roomba s drive motor is stall...

Page 54: ...14 BiT improvements Single Button Roomba code 29 August 2006 Version 3 OSMO Roomba s have been manufactured with two different chips E128 and DG256 and so there are two software release to match the d...

Page 55: ...ftware version inspect the OSMO date code OSMO Date Code OSMO Date Code JEN1387Xyymmdd01xxxxxx JEN1387Xyymmdd02xxxxxx JEN1387Xyymmdd03xxxxxx OSMO Version Version 1 1707 Version 2 1308 Version 3 1814 O...

Page 56: ...d CLEAN buttons For MANUAL ADVANCE mode 6 Continue holding down the SPOT and CLEAN buttons for a total of 3 SECONDS until you hear a second series of DESCENDING BEEPS 7 Release the SPOT and CLEAN The...

Page 57: ...o each sensor or actuator is tested only once In AUTO ADVANCE mode Activate the sensors for each sub test IN ORDER as described in the chart below When all sub tests in a test number have PASSED the b...

Page 58: ...es how to use each built in test number To PASS the built in test in AUTO ADVANCE mode the user must perform the actions EXACTLY AS DESCRIBED Test Name Tester Action Robot Action Spot LED Left Clean L...

Page 59: ...tall Right motor current and encoder speed OK 9 Wheel Encoders Verify the wheels are in the air and unobstructed Drive wheels turn in backward direction Left wheel encoder signal Right wheel encoder s...

Page 60: ...available Trickle current OK 18 Home Base Wall Mount Charger Precharge Remove the plug in charger Place Robot in dock or wall mount charger Home Base Wall Mount charger available Pre charge current OK...

Page 61: ...a computer o Press Max or Clean or Spot to capture the data o Disconnect the Roomba o You can continue to the next robot and the text file will just get appended as more outputs are added Alternative...

Page 62: ...MMARY int charging current ok PASS mA 1283 min 397 max 1602 mV 15725 degrees C 20 SUMMARY int charging trickle current ok PASS mA 52 min 33 max 72 mV 15391 degrees C 20 SUMMARY ext charging recovery c...

Page 63: ...11 Brush Current 566 mA 208 mA 11 Brush Stall Current 1901 mA 1302 mA 13 Side Brush Current 247 mA 52 mA 13 Side Brush Stall Current 423 mA 98 mA 14 Vacuum Current 352 mA 176 mA 14 Vacuum Stall Curren...

Page 64: ...64 Appendix H Roomba Mobility Test Procedure Figure 1 Parts of the Test Table Figure 2 Spiral Wall Following and Cliff Test...

Page 65: ...CLEAN As soon as it starts press CLEAN again to pause it Line up the Roomba and press CLEAN again it will run in a straight line 2 Place a VWU set to M 48 behind the Roomba and turn it ON 3 Roomba sho...

Page 66: ...No more than 60 1 Start the Roomba by pressing CLEAN and SPOT at the same time 2 Roomba follows the docking beams and docks correctly the first time 3 Ammeter indicates full charging current of 1 00 t...

Page 67: ...at the same time 2 Roomba follows the docking beams and docks correctly the first time 3 Ammeter indicates full charging current of 1 00 to 1 45 A No more than 60 Figure 7 Docking on Smooth Floor Tes...

Page 68: ...t wheel switch Brush motor Left wheel Debris Top Panel Right Wheel Vacuum contacts Side brush Right wheel switch Charging Socket Serial Port Bumper RCON Right Cliff sensors Bumper wall sensor Caster d...

Page 69: ...barge Failure if reading is not between 15 5 18V 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...

Page 70: ...voltage for 60 VAC Reconnect power supply to AC supply Failure if output current isn t zero power supply should shut down For 600mA SLOW Power Supply Equipment AC Voltmeter DC voltmeter ammeter variab...

Page 71: ...71 Appendix L Built in Test Toolbox kits These stripped down versions make it easier to attach and perform Built in Tests while fixing Roombas Source Toolbox version Bumper connector UI Connector...

Page 72: ...ocedure o Remove Vacuum Bin o Unscrew bumper screws 1 o Unscrew chassis screws 2 3 4 5 o Unscrew side brush if necessary 6 1 Lift outer bumper slowly as it is attached by the connector 2 Angle the bum...

Page 73: ...a 4 Clean off the internal dirt with compressed air Roomba Cleaning Frame Disassembly Procedure 1 Unscrew string mount and keep the string attached to the holder Disconnect the string mount from the c...

Page 74: ...if you have problems releasing the wires 5 Remove the 4 screws below the drive wheels secures side holders for the cleaning frame pivot arms 6 Lift two side holders from the main body 7 Remove cleani...

Page 75: ...Removal Procedure 1 Unscrew the mounts 4 holding down the pcb on the edges 2 Detach all the connectors attached to the pcb 3 Swing the inner bumper arm towards the pcb and outwards to disengage it 4 S...

Page 76: ...76 5 Lift the pcb out of the chassis Slide the charging plug out and release the wire from the wire routing features 6 To remove the inner bumper lift the bumper vertically up...

Page 77: ...rt screws 3 For certain models remove the chassis bridge Twist wheel out of the chassis but do not detach wires and connectors for general wheel maintenance 4 Unscrew 4 wheel cover screws 5 Carefully...

Page 78: ...it is correctly aligned and snapped into place Guide wires through wire tabs and verify the sensor wires are NOT pinched 8 Inspect the wheel supports and replace if bent or deformed 9 Replacing the wh...

Page 79: ...nector green purple and guide the wires out of the wire tabs 2 Unscrew the spring cover and remove it Release and remove the springs 2 underneath 3 Remove triangular screws 4 and caster guides that ho...

Page 80: ...assembly out of the chassis 2 To remove the wheel place flat head screwdriver under wheel and twist up Roomba Swivel Optical Stasis Switch Removal Procedure 1 Disconnect the optical stasis switch conn...

Page 81: ...drop switch from the chassis 4 Unscrew the spring cover and remove it Release and remove the springs underneath 5 Disconnect the optical connector 6 Remove screw that holds down optical pcb 7 Lift boa...

Page 82: ...82 Appendix N User Interface User Interface POWER Light...

Page 83: ...83 User Interface STATUS Light User Interface DIRT Detect...

Page 84: ...ls area from external dirt Ziptie 2005 04 11 Secure anti tassel halves of main brush with a ziptie This stiffens main brush and reduces bouncing IR Blocker 2005 04 11 The plastic formulation of the bu...

Page 85: ...cle dance dirty wheel encoders with open loop mode When in this mode may arc and have a different velocity 2 Recondition batteries with deeply discharged battery charging If battery ever under 10 8 V...

Page 86: ...ivel caster Also eliminated weights and paint Slim Virtual Wall 2006 06 28 Results in smaller packaging Seal Gearbox 2006 07 13 Seals gearbox from dirt infiltration Main brush with End caps 2006 08 14...

Page 87: ...rce Field o An IR avoidance beam that ensures the Roomba does not bump into it Force field used in the Home Base and Virtual Wall Home Base o The Roomba self charging station Infra Red IR o A wave of...

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