iRobot Roomba 500 Series Service Manual

Roomba 500 Series Service Manual Published 10 th 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

2 Roomba 500 Series Service Process ....................................................................................................... 4 01: Customer Call ............................................................................................................................................. 5 02: Roomba Return Procedure........................................................................................................................ 6 03: Incoming Roomba Inspection ................................................................................................................... 6 04: Roomba Cleaning ....................................................................................................................................... 6 05: Roomba Software & Charging Reset ....................................................................................................... 7 06: Roomba Diagnostics: Built-in-Test (BiT) ................................................................................................ 7 07: Capture Built-in-Test Data ........................................................................................................................ 7 08: Roomba Diagnostics: Mobility Test .......................................................................................................... 7 09: Fix or Replace Roomba.............................................................................................................................. 8 10: Test Battery................................................................................................................................................. 8 11: Test Power Supply...................................................................................................................................... 8 12: Test Home Base (if applicable) .................................................................................................................. 9 13: Test Virtual Wall & Light House (if applicable) ..................................................................................... 9 14: 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 Terminology ..................................................................................................................................... 10 Roomba Features and Compatibility ............................................................................................................ 13 Roomba Cleaning Behavior and Technology ............................................................................................... 15 Service Procedure (based on Built-in-Test Failures) ................................................................................... 17 Charging Accessories............................................................................................................................ 21 Roomba Battery .............................................................................................................................................. 22 Roomba Power Supply ................................................................................................................................... 23 Roomba Home Base........................................................................................................................................ 25 Roomba Accessories.............................................................................................................................. 27 Roomba Virtual Wall ..................................................................................................................................... 28 Roomba Virtual Wall Light House ............................................................................................................... 30 Roomba Wireless Command Center (Base robot 3.4 and 3.5 only) ........................................................... 32 Roomba 500 Series Errors .................................................................................................................... 33 Roomba 500 Series Pause Errors(‘uh-oh’ + beeps) ..................................................................................... 33

3 Roomba 500 Series Behavioral Issues ........................................................................................................... 34 Roomba 500 Series Charging Errors ............................................................................................................ 39 Appendix A : Roomba 500 Series Built-in-Test Procedure ................................................................. 42 AUTO-ADVANCE MODE ......................................................................................................................................... 44 MANUAL-ADVANCE MODE................................................................................................................................... 44 BUILT-IN-TEST RESULT ......................................................................................................................................... 44 DATA COLLECTION ................................................................................................................................................ 45 SUMMARY OF ELECTRICAL CONSTANTS ......................................................................................................... 46 BUILT-IN-TEST CHART ........................................................................................................................................... 47 ROOMBA BLACK BOX ............................................................................................................................................ 50 Appendix B : Roomba 500 Series Mobility Test Procedure ................................................................ 53 MOBILITY TEST PROCEDURE ............................................................................................................................... 54 MOBILITY TABLE 3 CONSTRUCTION SPECIFICATIONS (IN MM) ................................................................. 55 ROBOT RCON TEST ................................................................................................................................................. 56 VIRTUAL WALL TEST ............................................................................................................................................. 57 LIGHT HOUSE TEST ................................................................................................................................................. 57 LIGHT HOUSE TEST ................................................................................................................................................. 58 HOME BASE AND DOCKING TEST ....................................................................................................................... 59 Appendix C : Module Inspection and Cleaning .................................................................................. 60 DRIVE WHEEL Module inspection 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 cleaning ...................................................................................... 61 SIDE BRUSH Module inspection and cleaning ........................................................................................... 62 BRUSH & FLAPPER inspection and cleaning ............................................................................................ 62 VACUUM BIN Module inspection and cleaning ......................................................................................... 63 Appendix D: Roomba Spare Parts Replacement Instructions ............................................................ 64 Roomba Spare Parts Replacement (Battery, Side Brush, Cleaning Head and Wheel Modules) ............ 65 Roomba Faceplate Replacement ................................................................................................................... 69 Roomba Filter Replacement .......................................................................................................................... 70 Roomba Front Wheel Replacement .............................................................................................................. 71 Appendix E: Roomba Software & OSMO............................................................................................ 71 Appendix F: Battery Test Procedure .................................................................................................... 72 Appendix G: Power Supply Test Procedure ......................................................................................... 73 Appendix H: Home Base Test Procedure ............................................................................................ 73 Appendix I: Roomba Serial Number .................................................................................................... 74 Appendix J: User Interface .................................................................................................................. 75 Appendix K: Glossary ........................................................................................................................... 76

4 Roomba 500 Series Service Process

5 01: Customer Call Depending on the sophistication of the Customer Service Representation at the service centers, Roomba issues can be diagnosed over the phone by guiding a user through a troubleshooting process. At a minimum, iRobot recommends that the customer be asked to perform routine Roomba maintenance steps to resolve the Roomba issue. Only if these steps fail to resolve the issue should a customer send the Roomba to a service center. A) Customer should clean 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. Clean contacts on Roomba and Home Base with alcohol pad (not all models). 4 v. Clean out the vacuum bin and vacuum filter.5 B) If necessary, customer should reset Roomba’s charging system by pressing down the Roomba’s SPOT and DOCK simultaneously for 10 seconds (this will clear the schedules as well). This can be done when the robot is ON, OFF or CHARGING. When ON the CLEAN button will go dark when the reset is complete. C) Customer should fully charge the battery. 1 2 4 5 3

6 02: Roomba Return Procedure If the initial maintenance steps did not solve the issue, a customer should proceed to return the Roomba, battery and all accessories to a service center. IMPORTANT : Before packing and shipping a robot, clear all schedules by resetting the Roomba : Press down the SPOT and DOCK buttons simultaneously for 10 seconds. This can be done when the robot is ON, OFF or CHARGING. 03: Incoming Roomba Inspection Perform a visual inspection of the Roomba condition. Look for wear and dirt on the chassis, cliff sensors, all wheels, and brushes. Manually turn 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 complaint by running the robot for a few minutes. If the battery is low, charge the battery first. If during the run, it has an error, record this. See ‘Pause Errors’; ‘Behavioral Issues’ and ‘Charging Error’ chapters below 04: Roomba Cleaning Remove and empty the vacuum bin and vacuum filter. Clean the main brush, flexible brush and bearings from hair and dirt. Clean drive wheels and front caster. Remove and clean under the side brush of hair and dirt. Clean the cliff sensors with compressed air or cotton bud. Clean the electrical contacts on Roomba and home base with alcohol.

7 05: Roomba Software & Charging Reset Ensure the Roomba has a charged battery and download the latest software, if necessary. Appendix D Reset Roomba’s charging system by pressing down the SPOT and DOCK buttons simultaneously for 10 seconds. This can be done when the robot is ON, OFF or CHARGING. This can be done when the robot is ON, OFF or CHARGING. When ON the CLEAN button will go dark when the reset is complete. 06: Roomba Diagnostics: Built-in-Test (BiT) It is 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 battery in the Roomba. If brushes are in bad shape, insert new brushes with bearings. Use *approved* Power Supply, Home Base, Virtual Wall and Remote. Perform BiT steps. Take note of the button & speaker performance. Appendix A 07: Capture Built-in-Test Data Use “iRobot Factory Test Client Version 1.1” to capture the BiT output. Use “R3BlackBoxReader” program to capture data in the black box Appendix A 08: Roomba Diagnostics: Mobility Test Perform the Mobility Test. Appendix B

8 09: Fix or Replace Roomba Replace parts using Built-in-test Fix and module disassembly procedure. See “Service Procedure Chapter” Appendix D Re-test the BiT and MT and continue fixing until 100% pass. Appendix A/B 10: Test Battery Fully charge the returned Battery. Perform Battery test o Battery Voltage should be between 15.5 - 18V. o Battery Voltage drop should be less than 2V. Appendix F When battery PASSES, discharge battery with a Roomba run by pressing DOCK and not having a 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 battery is at 12V. Measure time to discharge.) 11: Test Power Supply Test returned Power Supply o Shake the unit and make sure there are no loose parts o Connect to wall and ensure DC output is between 21.1-24.0 VDC o Solid green light under load o Measure idle current with AC RMS ammeter to be <18mA o Measure standby power is <0.5W Appendix G [Note: If the power supply light is off or blinking while charging, replace it and make sure the Home Base and Roomba pass all charging tests.]

9 12: Test Home Base (if applicable) Test returned Home Base with an *approved* power supply and robot o Clean Home Base (electrical contacts and IR emitter) o Check if power and dock LEDs are solid green when charging o Visually inspect contact springs o Perform Home Base mobility/docking tests Appendix B Appendix H 13: Test Virtual Wall & Light House (if applicable) Test returned Virtual Wall with charged batteries o Clean Virtual 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 with charged batteries 15: Replace Faulty Accessories Replace faulty accessories 16: Pack & Record the Serial Numbers Pack the robot. If a core robot exchange was necessary, record the new serial number in the service process report 17: Monthly Data Report to iRobot The detailed International Service Process Report should be managed monthly and sent Tonia Giesecke at tgiesecke@irobot.com or Martijn Braam at mbraam@irobot.com ).

10 Roomba 500 Series Vacuuming Robot The iRobot Roomba 500 series includes the following improvements: • Better reliability, robustness and product life (R3 core robot has a 500% longer life vs. R2) • Enhanced mobility system improves room coverage • Light Houses guide Roomba to clean more rooms • Larger vacuum bin capacity ( R3 has 117% larger bin capacity vs. R2) • Better vacuum suction (R3 has 133% greater suction vs. R2) • Light touch bumper results in a gentler impact (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 drain (R3 takes about 25% longer to discharge its battery than R2) • Voice tutorial demonstrates Roomba’s features to new users • Anti-tangle technology enables Roomba to extract itself from tassels and cord tangles • Added binoculars (IR emitters) in Roomba’s bumper to improve docking • Wireless Command Center allows Roomba to be scheduled and directed Roomba Terminology Top View RCON Vacuum Bin Release Charging Socket Dirt Detect Handle User Panel “Check Robot”

iRobot Roomba 500 Series Service Manual

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