Roomba 400 Series Service Manual
Roomba 400 Series Service Manual
Roomba 400 Series Service Manual
Service Manual
Published August 31 2006
Roomba Scheduler
Roomba Discovery SE
Roomba Discovery
Roomba Sage
Roomba Red
Table of Contents
Roomba Service Process _________________________________________________________ 5
01: Customer Call___________________________________________________________________ 6
02: Roomba Return Procedure ________________________________________________________ 7
03: Incoming Roomba Inspection ______________________________________________________ 7
04: Roomba Cleaning ________________________________________________________________ 8
05: Roomba Software & Charging Reset ________________________________________________ 8
06: Roomba Diagnostics: Built-in-Test (BiT) ____________________________________________ 9
07: Capture Built-in-Test Data ________________________________________________________ 9
08: Roomba Diagnostics: Mobility Test _________________________________________________ 9
09: Fix or Replace Roomba ___________________________________________________________ 9
10: Test Battery____________________________________________________________________ 10
11: Test Power Supply ______________________________________________________________ 10
12: Test Home Base (if applicable) ____________________________________________________ 10
13: Test Virtual Wall (if applicable) ___________________________________________________ 11
14: Test Remote (if applicable) _______________________________________________________ 11
15: Replace Faulty Accessories _______________________________________________________ 11
16: Pack & Record the Serial Numbers ________________________________________________ 11
17: Monthly Data Report to iRobot ___________________________________________________ 12
17
18
19
20
21
22
22
23
25
26
27
28
29
30
Charging Accessories___________________________________________________________ 32
Roomba Battery ___________________________________________________________________ 33
Battery Types ___________________________________________________________________________
Battery Insertion Technique ________________________________________________________________
General Battery Maintenance Tips ___________________________________________________________
Battery Troubleshooting ___________________________________________________________________
34
34
35
35
Roomba Accessories____________________________________________________________ 41
Roomba Virtual Wall _______________________________________________________________ 42
Virtual Wall Generations __________________________________________________________________ 43
Virtual Wall Troubleshooting _______________________________________________________________ 43
Record Keeping
5
B) Customer should reset Roombas charging system by removing the battery, pressing the
Roomba power button for at least 5 seconds and reinserting the battery into the Roomba
C) Customer should fully charge the battery overnight in the Roomba.
Appendix B
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 & drive wheels.
Inspect the brushes:
o Remove the brush guard
o Manually turn the bristle brush. The flexible brush should counter
rotate?
o Remove the brushes and check that both yellow brush bearings are
present. Consider replacing old bearings with the new holed
bearing style.1
o Inspect the square ends of both brushes. Inspect the output gears on
the side gearbox. to see if
o Record the Robot Condition Code. Is the brush new, lightly
soiled or dirty condition.
Inspect the drive wheels:
o Inspect the front wheel and drive wheels. Turn the wheels.
Holed bearings allow captured dirt and hair to escape the cleaning assembly..
Appendix D
Appendix E
Appendix F
Record the Robot BiT Code and Robot BiT Sub-Code. Refer to
main issue that caused return. Take special notice of the button &
speaker performance.
Appendix C
Appendix F
Appendix H
Appendix C
Appendix M
Service
Procedure
(pg 16)
Appendix I
Retest the BiT and MT and continue fixing until 100% pass.
Record Action Code.
Appendix C
Appendix J
Troubleshoot
Battery (pg
35)
Appendix C
Appendix K
Troubleshoot
Power Supply
(pg36)
Appendix C
Troubleshoot
Home Base
(pg 39)
Appendix H
10
Appendix C
Troubleshoot
Virtual Wall
(pg 43)
Appendix C
Troubleshoot
Remote (pg
44)
Appendix C
Appendix C
Appendix B
11
Appendix C
12
Chassis
Wall Sensor
User Interface (UI)
Vacuum Bin
Charging Socket
Serial Port
Front Caster
Contacts
Cliff Sensors
Battery
Cleaning Frame
Brush Guard
Side brush
Flexible Brush
Drive Wheel
Cleaning Assembly
Debris Sensor
Vacuum Inlet
Main Brush
Vacuum Bin
13
o
o
o
o
14
Go to Appendix M for details on how to remove the Cleaning Frame, PCB, Inner Bumper, Diver
Wheels and Front Caster.
15
16
QC
REPLACEMENT
PART
Top Cover/Shell
o Inspect the wiring into the user panel and add hot
glue if it is needed for strain relief.
o Ensure BiT passes.
17
QC
REPLACEMENT PART
Main PCB
18
QC
REPLACEMENT
PART
19
REPLACEMENT PART
20
QC
QC
21
QC
REPLACEME
NT PART
22
REPLACEMENT
PART
QC
Battery
23
REPLACEMENT
PART
Drive Belt
QC
24
Roomba Symptom:
o Roomba will take longer to get unstuck.
o Roomba will abruptly interrupt its cleaning
path with a quick panic spin (left or right spin)
If the fixed caster stasis fails, the mechanical switch
may have failed:
Manually spin the wheel and verify that there is no
hair in the axle and that it can spin fairly freely.
Replace caster module if cleaning did not help.
If the swivel caster stasis fails, the optical switch may
have failed:
Remove the black/white wheel and clean the
wheel with alcohol and remove hair from the axle.
REPLACEMENT PART
QC
25
REPLACEMENT
PART
26
Output Gears
QC
REPLACEMENT
PART
27
QC
QC
REPLACEMENT PART
TROUBLESHOOTING
28
QC
REPLACEMENT
PART
TROUBLESHOOTING
29
QC
REPLACEMENT
PART
TROUBLESHOOTING
Main PCB
30
Precautionary Replacements
Speaker
Replace if it failed to work.
Precautionary replacements
Brush Bearing
A holed bearing will protect the cleaning assembly
best as it allows dirt 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 a reason for
customer return.
Filter
If filter is punctured it could allow dirt to enter
vacuum assembly. Replace immediately.
31
Charging Accessories
Battery
Power Supply
Home Base
Rapid Charger
32
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.
Skid pads
thermistor
-ve contact
+ve contact
33
Battery Types
3000 mAH
~500 cycle life
110 min runtime (hard floor)
55 min runtime (medium pile carpet)
Black Battery
not in production
2600 mAH
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 that it drops in to the battery well.
Press each Battery edge so that the latch engages and secures the Battery into the Roomba.
34
Battery Troubleshooting
Batteries will deeply discharge when left in 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 hot
environment.
Roomba can inaccurately calculate the battery charge capacity and not fully charge the
battery. Charging systems can be reset by taking the battery out, pressing the Roomba
power button for at least five seconds and reinserting the battery.
Verify that the Battery tested was charged in a Roomba. This is because a Rapid Charger
does not have the sophisticated software of a Roomba which dictates a proper charging
cycle based on the battery voltage.
The Battery latch may not be engaging well in the Roomba. Latches have been improved
and can be distinguished below.
Old latch Design
No notch
Notched
35
Generation 1A
Generation 2
Is the light solid green while charging? If not try another wall socket.
Generation 1 and 1A : If the power light is off or flashing, discard both the Home Base and
the Power Supply and replace the main pcb on the Roomba.2
Generation 2: If the power light is flashing or off, replace the Power Supply.
A flashing Power Supply and Home Base can destroy the Roomba pcb.
36
Power Light
Docked Light
IR Force Field
IR Docking Beams
Electrical Plug
Electrical Contacts
37
Manual Docking
To manually test the ability of the Roomba to dock successfully on the Home Base:
1. Verify that the Home Base is plugged in and that the power light is on.
1. Place the Home Base in a relatively open and flat area without any obstacles.
2. Remove 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 to the Home Base and it may take a few
attempts.
4. Once the Roomba is on the Home Base verify the two green lights on the Home Base are lit
and solid. If not, clean the electrical contacts under the Roomba and on the Home Base and
repeat these instructions.
38
The power light on the Home Base must be on and solid green while charging. If not, check
the connection and the charging brick. [Note: If flashing replace the Home Base, power
supply and Roomba pcb.3]
The dock light 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 the spring contacts
Wipe the IR lens from dust
Verify that the swivel caster Roomba is paired up with the new extended Home Base. The
new extended Home Base is compatible with fixed caster Roombas.
Perform the Mobility Test (see Figure 5-7 in Appendix H). This will test docking abilities
and Home base avoidance.
A flashing Power Supply and Home Base can destroy the Roomba pcb.
39
Rapid Charger
[Note: No longer in production]
Power LED
The Rapid Charger was designed to charge the 2600 mAH black 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 sequence that initially
measures the battery voltage and then proceeds with a proper charging mode.
40
Roomba Accessories
Virtual Wall
Remote
Filters
Bristle Brush
Flexible Brush
Side Brush
41
Strength Setting
IR Emitter/Force Field
42
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 the beam, wipe the Virtual Wall eye (RCON) on top
of the unit.
Use a Roomba and the Virtual Wall to perform the Mobility Test (see Figure 4 in Appendix H).
This will test Virtual Wall beam avoidance.
43
Roomba Remote
The Roomba Remote enables you to perform a variety of tasks with your Roomba without
touching the robot. It is compatible with all new Roomba models (except Roomba Original).
Remote Troubleshooting
The light above the buttons comes on when a button is depressed. If not, replace the batteries.
If the light is on but it does not communicate with the Roomba then :
o Wipe the Remote's IR emitter (located on the front edge of the Remote) and the Roomba's
IR receiver.
o Check that there is a direct line of sight from the remote to Roomba, and that the Remote is
pointed at Roomba. Try using the remote from several different heights 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
some surfaces.
o Roomba Remote also will not work if within 8 feet (~2.4 meters) of the Roomba Home
Base (if applicable). The Roomba Home Base creates Infrared (IR) frequency that
overrides the frequency of the Roomba Remote.
o It is possible that the remote is interfering with another IR device like a remote control for a
television.
o Confirm the front of the Roomba is not over a step or in front of an obstacle. The Roomba
should be emitting a low beep sound in this scenario.
o Try using the Roomba Remote in different lighting conditions. Certain halogen lights or
powerful florescent lights can interfere with the Roomba Remote's functioning.
44
Roomba Filter
Roombas filter is designed to keep Roombas vacuuming system clear of debris. For 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,
replace the filter.
Filter Troubleshooting
45
Brush Troubleshooting
46
Appendices
47
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 overheating.
48
LLLL
YY
mm
dd
c
ssss
Model number
Year (since 2000) this robot was manufactured
Month this robot was manufactured
Day of the month this robot was manufactured
CPU type: E or EA if E128 chip, empty if DG256 chip
Order that robot was made on date of manufacture
MM
U
LLLLL
YY
mm
dd
RR
sssss
49
o YYMMDD XXX
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 number.
Home Base Serial Number Format
(ASCII debossed in plastic)
YYMMDD
50
Code List
Customer Complaint Code
CC00-Complaint NONE
CC01-(Cleaning) Brush Assembly
CC02-(Cleaning) Vacuum Assembly
CC03-(Cleaning) Side Brush Assembly
CC04-(Charging) Robot & Battery
CC05-(Charging) Accessory
CC06-(Mobility) Drive Wheels
CC07-(Mobility) Caster Wheel
CC08-(Mobility) Circle Dance
CC09-(Mobility) Robot
CC10-(Mobility) Accessory
CC11-(General) Robot
CC12-(General) User Interface
CC13-(General) Accessory
CC14-(Error) ehh
CC15-(Error) dead battery song
CC16-(Error) uh-oh & no beeps
CC17-(Error) uh-oh & 1 beep
CC18-(Error) uh-oh & 2 beep
CC19-(Error) uh-oh & 3 beeps
CC20-(Error) uh-oh & 4 beeps
CC21-(Error) uh-oh & 5 beeps
CC22-(Error) uh-oh & 6 beeps
CC23-(Error) uh-oh & 9 beeps
CC24-(Error) uh-oh & 10 beeps
CC25-Complaint - OTHER
51
Roomba MT Code
RM00- MT PASS
RM01-fails initial spiral
RM02-fails to wall follow
RM03-fails cliff
RM04-fails to dock
RM05-fails rod transition
RM06-fails with home base
RM07-fails with virtual wall
RM08- MT-OTHER
Battery Code
B00- PASS
B01-voltage low
B02-voltage high
B03-voltage drop fail
B04-low run time
B05-thermistor
B06-contacts
B07-latch
B08-OTHER
52
What It Means
The battery is
low and needs
recharging
Connect Roomba to the Power Supply or Home Base and recharge the battery.
Ehh
No beeps
Uh-oh + 1 beep
Roomba's main
brushes are
stalled
Pick up the Roomba and turn it over and remove the wire guard.
Look for something blocking the brushes; you may need to remove and reinstall
the brushes to remove the obstruction.
Pick up your Roomba, put it in the middle of the room, power it OFF and then
ON again.
Select the cleaning cycle you prefer and let it go to work.
If Roomba travels for a long distance without bumping into anything (which
would be unusual), it might think its stuck and cant move; press Clean again
and it should resume cleaning.
53
Robot Production
Implementation
OSMO version
23 August 2005
Version 1
24 October 2005
Version 2
29 August 2006
Version 3
2005-10-04-1308
2006-08-14-1814
OSMO
Roombas have been manufactured with two different chips (E128 and DG256), and so there are
two software release to match the different chips. The OSMO Teal is used for E128 chips and the
OSMO Purple is used for DG256 chip. Determine the Roomba chip type from Roombas serial
number and then use the proper OSMO. Using the wrong OSMO does not harm the Roomba, it
just does not download software. Also, OSMO can only replace older software on the Roomba.
OSMO TEAL (E128)
- Roombas with barcodes.
54
OSMO Version #
JEN1387Xyymmdd01xxxxxx
JEN1387Xyymmdd02xxxxxx
JEN1387Xyymmdd03xxxxxx
Version 1 (-1707)
Version 2 (-1308)
Version 3 (-1814)
55
56
The SPOT and CLEAN LEDs indicate when the sensors are activated.
The STATUS LED indicates whether the current draw is within correct range where
appropriate.
Current measurements are taken in 0.5 second readings. During current readings, ALL
LEDS ARE OFF.
The DIRT ALERT LED will flash to indicate that the test is advancing to the next test
number.
The robot will BEEP when advancing to the next built-in-test number. Test numbers are
indicated by a pattern of long and short beeps, where one long beep is equal to five short
beeps. For example, test 11 is indicated by long-long-short.
AUTO-ADVANCE mode is designed to be used on the assembly line. In this mode, the robot
internally decides PASS/FAIL for each test number. The test advances automatically so 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 built-in-test will AUTOADVANCE to the next test number.
If a test does not pass, you can press the CLEAN button to MANUALLY ADVANCE to
the next test number to continue the built-in-test.
The test number checks may check multiple conditions other than those which turn on the
LEDs. Therefore the test number may FAIL even though the sensors that turn on the LEDs
seem to be working. In particular, the CURRENT DRAW of each actuator must be within
acceptable limits for the test to pass.
The POWER LED will be RED until all sub-tests in a test number are passed, then it will
turn GREEN for a moment before advancing to the next test number.
When you get to the last test number, either by AUTO- or MANUALLY advancing:
o If all tests PASSED:
The robot can be powered off using the power button and will operate
NORMALLY.
57
The robot CANNOT be powered off and will not respond to any buttons
until the BATTERY IS REMOVED.
Use the CLEAN button to MANUALLY ADVANCE to the next built-in-test number.
There is no pass or fail. If you advance past the last test number, the test number will wrap
around to the first test.
The following chart describes 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
Panel LEDs
Bumpers
Robot Action
Spot LED
(Left)
Clean LED
(Right)
Left bumper
pressed.
Right bumper
pressed.
Outer Cliff
Sensors
Cliff-left
detected.
Cliff-right
detected.
Inner Cliff
Sensors
Cliff-front-left
detected.
Cliff-frontright detected.
Wheel Drop /
Wall Sensor
Wheel drop
detected.
Wall
detected.
Status LED
58
Rcon IR
Receiver
Virtual-wall
signal at rcon
IR receiver.
Remote signal
at rcon IR
receiver
Battery
Sensors
No user action.
Battery
voltage
between 12
and 18 V.
Thermistor
present.
Left Wheel
Left wheel
turns in
forward
direction
Right Wheel
Right wheel
turns in
forward
direction.
Wheel
Encoders
Drive wheels
turn in
backward
direction.
10
Stasis
11
Main Brush
Main brush
turns on.
Brush over
current stall.
12
Debris
Main brush
turns on.
Debris
detected on
left side.
13
Vacuum
Vacuum turns
on.
Vacuum stall.
Vacuum
current OK.
14
Side Brush
Side brush
turns on.
Side brush
stall.
Side brush
current OK.
Left wheel
over current
stall.
Left wheel
encoder
signal.
Baseline
current OK.
Left motor
current and
encoder
speed OK.
Right wheel
over current
stall.
Right motor
current and
encoder
speed OK.
Right wheel
encoder
signal.
Motor
current and
encoder
speed OK.
Stasis signal
(caster
rotation
switch).
Brush current
OK.
Debris
detected on
right side.
59
15
Plug-in
Charger
Precharge
16
Plug-in
charger
available.
Pre-charge
current OK.
Plug-in
Charger On
Plug-in
charger
available.
Charge
current OK.
17
Plug-in
Charger
Trickle
Plug-in
charger
available.
Trickle
current OK.
18
Home Base /
Wall-Mount
Charger
Precharge
Home Base /
Wall-Mount
charger
available.
Pre-charge
current OK.
19
Home Base /
Wall-Mount
Charger On
Home Base /
Wall-Mount
charger
available.
Charge
current OK.
20
Home Base /
Wall-Mount
Charger
Trickle
Home Base /
Wall-Mount
charger
available.
Trickle
current OK.
21
Built-in-test
Complete
60
61
SUMMARY: START
SUMMARY: TIMESTAMP Fri Jun 30 07:09:35 2006
SUMMARY: DATE-TAG 2005-10-04-1308-L
SUMMARY: (baseline-current-ok?) PASS mA -91 min -202 max -13 mV 15279 degrees-C 20
SUMMARY: (left-drive-current-ok?) PASS mA -176 min -326 max -117 mV 15251 degrees-C 20
SUMMARY: (left-drive-stall-current-ok?) PASS mA -586 min -749 max -397 mV 15168 degrees-C 20
SUMMARY: (right-drive-current-ok?) PASS mA -176 min -326 max -117 mV 15251 degrees-C 20
SUMMARY: (right-drive-stall-current-ok?) PASS mA -553 min -749 max -397 mV 15140 degrees-C 20
SUMMARY: (brush-current-ok?) PASS mA -352 min -566 max -208 mV 15196 degrees-C 20
SUMMARY: (brush-stall-current-ok?) PASS mA -1387 min -1901 max -1302 mV 14917 degrees-C 21
SUMMARY: (side-brush-current-ok?) PASS mA -104 min -247 max -52 mV 15251 degrees-C 20
SUMMARY: (side-brush-stall-current-ok?) PASS mA -130 min -423 max -98 mV 15224 degrees-C 20
SUMMARY: (vacuum-current-ok?) PASS mA -254 min -352 max -176 mV 15196 degrees-C 20
SUMMARY: (vacuum-stall-current-ok?) PASS mA -384 min -423 max -299 mV 15140 degrees-C 20
SUMMARY: (int-charging-recovery-current-ok?) PASS mA 286 min 241 max 358 mV 15335 degrees-C 20
SUMMARY: (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-current-ok?)PASS mA 293 min 241 max 358 mV 15418 degrees-C 20
SUMMARY: (ext-charging-current-ok?) PASS mA 1152 min 397 max 1602 mV 15669 degrees-C 20
SUMMARY: (ext-charging-trickle-current-ok?) PASS mA 46 min 33 max 72 mV 15391 degrees-C 20
SUMMARY: (bump-left?) PASS
SUMMARY: (bump-right?) PASS
SUMMARY: (cliff-left?) PASS
SUMMARY: (cliff-right?) PASS
SUMMARY: (cliff-front-left?) PASS
SUMMARY: (cliff-front-right?) PASS
SUMMARY: (wheel-drop?) PASS
SUMMARY: (wall?) PASS
SUMMARY: (rcon?) PASS
SUMMARY: (any-remote-opcode?) PASS
SUMMARY: (battery-voltage-ok?) PASS
SUMMARY: (battery-temperature-ok?) PASS
SUMMARY: left-wheel-stall PASS
SUMMARY: (drive-speed-ok? left forward) PASS
SUMMARY: (drive-speed-ok? right stopped) PASS
SUMMARY: right-wheel-stall PASS
SUMMARY: (drive-speed-ok? right forward) PASS
SUMMARY: (drive-speed-ok? left stopped) PASS
SUMMARY: (drive-speed-ok? left reverse) PASS
SUMMARY: (drive-speed-ok? right reverse) PASS
SUMMARY: (stasis?) PASS
SUMMARY: brush-motor-stall PASS
SUMMARY: (debris-left?) PASS
Either PASS, FAIL or UNTESTED
SUMMARY: vacuum-motor-stall PASS
SUMMARY: side-brush-motor-stall PASS
SUMMARY: (int-charger-available?) PASS
SUMMARY: (ext-charger-available?) PASS
SUMMARY: (bootloader-ok?) PASS
SUMMARY: END
62
Description
MIN
MAX
Battery Voltage
Battery Temperature (C)
Baseline Current
Left Drive Current
Left Drive Stall Current
Right Drive Current
Right Drive Stall Current
Brush Current
Brush Stall Current
Side Brush Current
Side Brush Stall Current
Vacuum Current
Vacuum Stall Current
Internal Charging Prep Current
Internal Charging Recovery Current
Internal Charging Current
Internal Charging Trickle Current
External Charging Prep Current
External Charging Recovery Current
External Charging Current
External Charging Trickle Current
12V
5C
-202 mA
-326 mA
-749 mA
-326 mA
-749 mA
-566 mA
-1901 mA
-247 mA
-423 mA
-352 mA
-423 mA
32 mA
241 mA
397 mA
33 mA
32 mA
241 mA
397 mA
33 mA
18V
60C
-13 mA
-117 mA
-397 mA
-117 mA
-397 mA
-208 mA
-1302 mA
-52 mA
-98 mA
-176 mA
-299 mA
71 mA
358 mA
1602 mA
72 mA
71 mA
358 mA
1602 mA
72 mA
63
64
48"
65
3. Ammeter
indicates full
charging current
of 1.00 to 1.45 A
66
3. Ammeter
indicates full
charging current
of 1.00 to 1.45 A
67
Left wheel
Debris
Top Panel
Right Wheel
Side brush
Charging Socket
Serial Port
Side 2
Bumper - wall sensor
Battery
Bumper RCON
Left Cliff
sensors
Right Cliff
sensors
Electrical
Contacts
68
Ambient
Room
Temp
10 to 17 C
18 to 25 C
26 to 33 C
34 to 41 C
Thermistor
Min (K
Ohm)
12.0
8.5
6.0
4.3
Thermistor
Max (K
Ohm)
21.8
15.5
11.0
7.8
69
2.
Plug power supply into variable voltage AC supply with AC voltmeter connected across AC supply. Connect resistive load across output of power supply,
with DC ammeter connected in series to measure current supplied to load. Connect DC voltmeter across resistive load and ammeter, so ammeter voltage drop
is included in voltage reading.
Set AC supply voltage for 90 VAC. Failure if DC output voltage < 20 VDC or > 24 VDC; DC output current <1.0 A or > 1.45 A.
3.
Set AC supply voltage for 240 VAC. Failure if DC output voltage < 20 VDC or > 24 VDC; DC output current <1.0 A or > 1.45 A.
4.
Disconnect power supply from AC supply. Set AC supply voltage for 60 VAC. Reconnect power supply to AC supply.
Failure if output current isnt zero (power supply should shut down)
1.
Plug power supply into variable voltage AC supply with AC voltmeter connected across AC supply. Connect resistive load across output of power supply,
with DC ammeter connected in series to measure current supplied to load. Connect DC voltmeter across resistive load and ammeter, so ammeter voltage drop
is included in voltage reading.
2.
3.
Set AC supply voltage for 240 VAC. Failure if DC output voltage < 20 VDC or > 24 VDC; DC output current <1.0 A or > 1.45 A.
4.
Disconnect power supply from AC supply. Set AC supply voltage for 60 VAC. Reconnect power supply to AC supply.
Failure if output current isnt zero (power supply should shut down)
Failure if DC output voltage < 20 VDC or > 24 VDC; DC output current <1.0 A or > 1.45 A.
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Toolbox version
Bumper connector
UI Connector
71
o
o
o
o
72
73
74
75
Lift the pcb out of the chassis. Slide the charging plug
out and release the wire from the wire routing features.
76
77
78
Remove caster.
79
80
81
82
83
2004-11-07
Serial Port
Housing
2004-11-15
Bevel the metal housing to reduce shorting between the hot tab of
the charging jack and the ground casing of the serial port.
Side Brush
2004-12-03
Vacuum Impeller
2004-12-12
Flapper Rod
2005-01-17
Vacuum Bin
Contacts
2005-01-22
Wheel Encoder
Tab
2005-02-22
Add a tab to the hub behind the encoder that seals 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
Bearing hole
2005-04-28
Hair and dust builds up in the yellow bearing can lead to bearing
pushing out and melting and even cracking cleaning frame. Extend
axial bore through bushing for hair extrusion.
2005-05-07
Rewiring
2005-05-09
Brush Gearbox
2005-05-24
Wheel Housing
bowed
2005-05-29
Use less hot glue and improve wire routing on bumper, chassis and
cleaning frame
Reduce housing / output shaft clearance on main brush gear box by :
Deepen hole in output gear to accommodate shaft an extra
1.5 mm
Lengthen pin in gearbox tat holds output gear
Shorten Shaft
Bowed housings allow more clearance between the o-ring and
cover. This prevents the o-ring from chaffing against the cover and
allowing the o-ring dust to contaminate the wheel encoder.
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2005-06-08
Wheel Hole
2005-06-23
Caster Material
2005-06-24
Change front caster material from Acetal to Nylon 801 (also black).
This material is more abrasion resistant and withstands life tests.
Long term fix is to design a swivel caster (in progress).
Motor Power
Wire
2005-07-27
ESD protection
2005-08-05
ESD entering the robot via the charging port may damage these
FETS and cause the robot lose the ability to control the charging of
its battery. Protective components added to board.
Wire Bail
2005-08-19
Software 1707
2005-08-23
1. Solve circle 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 it will go into a 16 hour charge
String
2005-08-29
If string breaks the cleaning head cannot be regulated and more drag
is experienced on carpet. Immerse string in silicon oil to strengthen
string.
Change material of o-ring from compression molded CR to injection
molded CR-B9. CR-B9 has improved abrasion resistance and
injection molding has better repeatable consistency in the molded
product.
1. Single Debris Mode
2. SCI Mode
O-ring
2005-10-10
Software 1308
2005-10-24
Brush motor
outboard housing
2005-10-25
Wheel cover
2006-04-18
Seal wheel assembly by adding ribs along the cover to better seal
the wheel compartment. Also extend the bosses to avoid vertical
gaps where dirt can infiltrate.
Frog grease
2006-05-18
Debris Connector
2006-05-31
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Swivel Caster
2006-06-24
Home Base
2006-06-15
2006-06-28
Seal Gearbox
2006-07-13
2006-08-14
Software 1814
2006-08-29
Reduces amount of hair and dirt entering side gearbox and yellow
bearings.
1. BiT improvements
2. Single Button Roomba Code (for new product Dirt Dog)
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Appendix P: GLOSSARY
o a component that is considered functional and used to verify
faulty components during Built-in-Test
APS
o Advanced Power System
BiT
o Built-in-Test
Chassis
o The plastic frame of the Roomba
o The Roomba symptom where robot circles continuously. This
Circle Dance
can be caused by dirty encoders, broken drive belts, broken
wheel IR, clogged bumper IR as so forth.
o The cleaning assembly includes the pivoting self adjusting
Cleaning Frame Assembly
frame that supports the brushes, brush guard, brush motor and
gearbox.
Debris
o Dirt that is being picked up by the Roomba
o Roomba 2 Series that includes the Roomba Red, Sage,
Discovery Series
Discovery, Discovery SE and Scheduler
Encoder
o A sensor that relays information to the pcb
o An IR avoidance beam that ensures the Roomba does not bump
Force Field
into it. Force field used in the Home Base and Virtual Wall
Home Base
o The Roomba self charging station
o A wave of light with wavelengths greater than those of visible
Infra Red (IR)
light.
o Semiconductor light source that emits visible light or invisible
Light Emitting Diode (LED)
infrared radiation.
Mobility
o Capable of moving or being moved readily
o Roomba 1 Series that includes the Roomba Original, Pro and
Original Series
Pro Elite
Over-currents
o Exceeds the current limits for the motors.
PCB
o Printed circuit board
o The visible surface of a carpet consisting of yarn tufts in a
Pile
loop, cut or cut/uncut configuration.
o Room confinement (reference to the IR receiver eye on the top
RCON
of the outer bumper)
Stasis
o Refers to things that are not moving or changing
o The physical means and method of interaction between users
User Interface (UI)
and products
Virtual
o Not physical
*approved*
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