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iRobot Roomba 570 Service Manual

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iRobot Roomba 570 | Service Manual - 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
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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
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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
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Roomba 500 Series Service Process 4
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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 2 1 4 3 5 B) If necessary, customer should reset Roomba's charging system by
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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
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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
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: Fix or Replace Roomba Replace parts using Built-in-test Fix and module disassembly procedure. Re-test the BiT and MT and continue fixing until 100% pass. 10: Test Battery Fully charge the returned Battery. Perform Battery test o Battery Voltage should be between 15.5 - 18V. o Battery Voltage drop
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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
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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
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Vacuum Bin ( with removable filter and squeegee) * rpm is revolutions per minute. These values may vary as battery charge declines Bottom View (bottom chassis + battery + brushes + bin removed) Removable Front Caster Module Removable Side Brush Module Removable Drive Wheel Modules Removable Cleaning
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Top View (front panel removed) Top View (top chassis +user panel removed) 12
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Roomba Features and Compatibility Virtual Wall compatible? Base Robot 3.0 Base Robot 3.3 Base Robot 3.4 Model 510 Model 530 Model 535, 540 Base Robot 3.5 Model 550, 560, 565, 570, 580 Home Base compatible? Light House compatible? WCC compatible? (no contacts) (no RF) (no RF) (no RF) (no
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sensors ƒ 1 battery-current sensor ƒ 2 wheel-current sensors ƒ 1 battery-temp sensor ƒ 1 battery-voltage sensor ƒ 1 main-brush current analog sensor ƒ 1 side-brush current analog sensor ƒ 1 main-brush pwm (pulse width modulation) truncation sensor ƒ 1 side-brush pwm truncation sensor ƒ 1 vacuum pwm
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not have a Home Base present. The robot will clean until the battery depletes to 12V. {Note: When using Roomba with Light Houses, Roomba will clean for a maximum of 35 minutes per room.} c d e Roomba features a 3-stage cleaning system 1. Spinning Side brush - sweeps along edge of walls and into
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drives in an outward spiral pattern o Bounce - Bumper activation makes Roomba back up, turn in place, and drive straight o Wall follow - Roomba follows along a wall When first started, Roomba goes into spiral mode (if the 'clean' button is held twice after the robot is ON, it will drive straight and
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/BUTTONS/SPEAKER Roomba Spare Part : Service or Core Robot Replacement Roomba BiT 2 - BUMPERS 2 Trouble shooting : Toggle the bumper and retest Roomba Spare Part : Service or Core Robot Replacement Roomba BiT 3 to 4 - OUTER + INNER CLIFF SENSORS 3-4 Troubleshooting : Has the side brush stalled
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Troubleshooting : Clean front bumper windows Roomba Spare Part : Service or Core Robot Replacement Roomba BiT 11 - BATTERY SENSORS 11 Trouble shooting : Tighten bottom cover. Roomba Spare Part : Battery Replacement Roomba BiT 12 to 14 - LEFT & RIGHT WHEEL & ENCODERS 12-14 Trouble shooting : Clean
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BiT 15 - STASIS 15 Trouble shooting : Remove front caster module. Clean optical stasis window in chassis. Clean white/black wheel if dirty. Roomba Spare Part : Front Caster and Wheel Replacement Roomba BiT 16 - MAIN BRUSH 16 Troubleshooting: Redo test with new brush and flapper. Ensure motor
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: Remove side brush and clean side brush from hair and dirt. Inspect side brush axle. Roomba Spare Part : Side Brush Module Replacement Roomba BiT 20 to 26 - CHARGING 20-26 Troubleshooting: Clean robot and Home Base contacts is necessary Roomba Spare Part : Service or Core Robot Replacement 20
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Charging Accessories Battery Power Supply Home Base 21
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ƒ Recovery battery charge : A recovery charge is automatically detected by the robot (indicated by rapid flashing CLEAN button) and takes 16 hours and should not be disrupted. This is activated if the battery voltage is under 10.8 V. ƒ Charging/Battery reset : A robot charging system can be reset by
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Supply Roomba's are charged by either a Universal (100-240V) or Domestic (120V) Power Supply. The Power Supply steps the voltage down to 22.5VDC and 1.25A. A solid green LED light on the Power Supply is an indication that it is plugged in and operating properly. Roomba 500 Series Charging Algorithm
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the robot is doing postcharge cooling and trickle charging. Power Supply Troubleshooting ƒ Is the Power Supply LED solid green while charging? If not try another wall socket. ƒ If the power light is off or flashing, replace the Power Supply and test the Roomba and Home Base for charging errors. 24
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a sophisticated infrared tracking mechanism) can drive back to at the end of a clean cycle or when its battery is low. After docking itself, the Roomba will recharge its 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
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these instructions. Home Base Troubleshooting ƒ The power light and charging light on the Home Base must be on and solid green while charging. If not, check the connection and the Power Supply. Also ensure the electrical contacts are clean. [Note: If flashing replace the Home Base and test Power
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Roomba Accessories Virtual Wall Light House Wireless Command Center 27
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Walls can be set to block an area ranging from 0 to 2.4 meters long. Light Houses turn off automatically after 2 hours. Infrared Beam Emitter Force Field Emitter (Avoid collision) Battery LED Status Power Button Strength Settings The Virtual Wall beam is triangular shaped. A small halo prevents
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• If the Virtual Wall is turned on but the battery status light is off or flashing, the batteries are low. Check the batteries and the virtual battery door. When replacing batteries wait 5 seconds between removal and insertion for a full reset. Also, choosing a higher range in Virtual
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either mode, the Light House will automatically turn ON when the Roomba is on and within radiofrequency range (~15 meters). The Light House will turn OFF when Roomba is OFF or out of range. Light Houses indicate that their battery is low by flashing the power light repeatedly. Infrared Beam Emitter
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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 anew. o The user can confuse the Roomba by moving the lighthouse to another room during a clean cycle. Then issues come up
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Wireless Command Center allows a user to remotely turn the Roomba on or off, be directed and scheduled. To schedule a Roomba to clean, use the buttons on the Wireless Command Center as if they were on the robot user panel itself. Wireless Command Center Troubleshooting The WCC should work normally
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Please inspect and Clean Roomba's Left Wheel ƒ Please inspect and Clean Roomba's Right Wheel ƒ Please inspect and Clean Roomba's Wheels ƒ Please remove and clean Roomba's Brushes wheel-drop error Roomba's wheel has dropped below body of robot main-brush-stall Main brushes cannot turn See Appendix
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brush has stalled and is obstructing an outer cliff sensor • CLIFF SENSOR Module inspection and cleaning (Appendix C). • Replace core robot if all fixes fail. Bumper issues Customer observations Troubleshooting: ƒ Roomba backs up for no apparent reason. ƒ "Uh-Oh" + 9 beeps (bumper stuck error
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Uh-Oh" + 7 beeps (wheel drop rate error) ƒ Robot spins around in circles - circle dance ƒ Roomba wiggles or rocks from side to side Most common causes: ƒ Roomba was started on an uneven surface or got stuck on an obstacle during the cleaning cycle. Troubleshooting: • Pick Roomba up and set back on
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clogged and cannot spin. Troubleshooting: • FRONT WHEEL Module inspection and cleaning (Appendix C). • Replace front caster wheel module if fixes fail. Main Brushes are thumping Customer observations ƒ Roomba's brushes thump (approximately once per second) on all floor types. Most common causes
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beeps (main brush stall error) ƒ Main brushes do not spin ƒ Roomba is not picking anything up in vacuum bin ƒ Roomba's brushes thump (approximately once per second) on all floor types. Most common causes: ƒ Something is stuck in the main brushes. Troubleshooting: • CLEANING HEAD Module inspection
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in the owner's manual. • If problem is not resolved, follow the steps outlined in the "Charging issues" section below. Wireless Command Center Customer observations ƒ Wireless Command Center (WCC) has poor range. Most common causes: ƒ WCC is not paired with Roomba. Troubleshooting: • Follow WCC
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Roomba 500 Series Charging Errors CLEAN/POWER light flashes orange and blinks every 2 seconds for a number times indicated below. For charging errors that do not produce error codes, see Battery and Runtime issues. # of Robot Blinks Robot Display Not all models Robot Says What it means What
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second. Charging Error 7 Battery not Cooling. This occurs when the battery doesn't cool within 4 hours. Most likely the battery thermistor is shorted. 1. Move charging setup to a cooler environment and make sure there is no object on top of robot. 2. If problem persists, replace Battery and Robot
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and Runtime issues Customer observations ƒ Short battery runtime. ƒ Robot doesn't charge on Home Base. ƒ Robot does not turn on. ƒ Power supply light blinks or goes out. Most common causes: Troubleshooting: • If charging error blinks, consult charge error table. • Verify all four bottom cover
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Appendix A : Roomba 500 Series Built-in-Test Procedure Start with Roomba powered OFF by pressing the CLEAN button for a few seconds. To enter : Auto-advance Built-in-Test Manual-advance Built-in-Test Auto-advance Mobility Test Manual-advance Mobility Test Display + beep software date code Enter
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, hold down DOCK and SPOT for 10 seconds. o To advance a step press DOCK and to go back a step press SPOT. BUILT-IN-TEST 0 tests the user panel LEDs. o For base robot assembly 3.5 check that a. DIRT ALERT flashes at beginning b. SPOT and DOCK are toggling c. SCHEDULE and CLOCK are toggling d. CHECK
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to pass. The CLEAN 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. MANUAL-ADVANCE MODE This is designed to be used for debugging particular sensors or actuators. In this mode, the robot DOES NOT decide
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bump?))) PASS SUMMARY: (and (lt-bumper-center-right?) (not (bump?))) P SUMMARY: (wheel-drop-left?) PASS SUMMARY: (wheel-drop-right?) PASS SUMMARY: (rcon?) PASS SUMMARY: (valid-code-in-channel? dir-left) PASS SUMMARY: (valid-code-in-channel? dir-right) PASS SUMMARY: (battery-voltage-ok?) PASS SUMMARY
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charging trickle current Min -300 -150 -850 -500 -1400 -230 -120 -550 250 1000 40 Max -14 -75 -700 -200 -1250 -50 -30 -440 350 1400 70 Units mA mA mA mA mA mA mA mA mA mA mA Sensor battery wheel motor wheel motor main brush main brush battery side brush side brush battery battery battery
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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 Dock LED Check correct flashing 0 Panel LEDs of LEDs. Press CLEAN to advance to the first test. Buttons Press and release DAY, then
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. Briefly lift robot to 8 Wheel Drop cause a wheel drop on left wheel, then right wheel. Briefly simulate Battery Sensors No user action. Make sure wheels are 12 Left Wheel in the air and unobstructed. Wait until DOCK is on solid. Then briefly stall left wheel until SPOT Left wheel turns
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17 Debris Briefly place robot in debris pile on left side. Briefly place robot in debris pile on right side. Main brush turns on. Debris detected Debris detected 18 Vacuum No user action. Vacuum turns on. Vacuum current OK. Make sure side brush 19 Side Brush is unobstructed. Wait until
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BLACK BOX Every Roomba has a 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 (mission runtime) or how long it has been charging on the Home base
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output : run-time-hours run-time-minutes factory-test-passed? bit-summary-0-15 bit-summary-16-31 bit charge avg-time-on-doc avg-time-direct-charge n-charger-availables est-battery-capacity n-batt-overtemps n-bumper-clicks-low n-bumper-clicks-high n-clean-clicks n-spot-clicks n-home-clicks n-wheel
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mission-runtime-minutes mission-runtime-hours voice-demo-listen-count n-clean-cycles-in-open-loop calib-validation cliff-adjustments [Bumper-Clicks] [max-discharge-temp-avg-Degrees-C] [max-charge-temp-avg-Degrees-C] [est-battery-capacity-mAh] 13 2 3 11 3 2 1 3 2 1 0 10 1 1 6 1 6 1 6 1 6 1 6 606 803
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B : Roomba 500 Series Mobility Test Procedure The Mobility Test procedure for tests the robot's mobility and sensors across 5 different test floors, of which service centers need only conduct Test Floor 3. Test Floor # Tests Performed Floor/Fixture Test Floor 1 o light-touch-max-distance Test
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to a serial terminal after the test is finished and tap the bumper to receive a summary. MOBILITY TEST PROCEDURE Test Floor 3 - (TUE is lit on Scheduler display) ƒ Place the robot facing the long linoleum wall as shown above. ƒ Press CLEAN until it is in test 3 or 3 beeps or TUE is on the display
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MOBILITY TABLE 3 CONSTRUCTION SPECIFICATIONS (IN MM) Metal threshold on long carpet edge only Wrap carpet around the edges of the floor 55
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RCON lens as shown below 2. Put a Virtual Wall (VW) 1.5 m away from robot's RCON lens. 3. Put robot into Built-in-Test #9. 4. Turn on the VW and set it at medium power (1 - 2 m). 5. Verify that the SPOT light on the robot is lit. 6. Slow turn the fixture and verify that the SPOT light is on all the
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VIRTUAL WALL TEST The procedures for this test are 1. Put the robot in Built-in-Test # 9. 2. Turn Virtual Wall (VW) on (make sure the VW is not pulsing or off). If in doubt you can verify that the VW emitters are on using IR viewer or a digital camera. 3. Place the Roomba in the below distances from
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The procedures for this test are 1. Put batteries in the Light House. Make sure 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 House gate
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NAVIGATION BEAM TEST : 1. Place the Home Base on the floor, plugged in. 2. Place the robot in front of the Home Base about 1.5 m away, within the expected beams. 3. Turn robot on with CLEAN 4. Press DOCK on the robot. 5. Verify that the robot autonomously finds the Home Base and starts charges (red
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wheels turn freely. ƒ If there is uneven resistance between the wheels, hold down Roomba's SPOT and DOCK buttons for 10 seconds to reset the robot and try again. ƒ Check tires for wear and tear. ƒ If tire treads are no longer visible, or if large tears are present, replace wheel modules. ƒ If wheel
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bumper with compressed air, if available. ƒ If problem persists, replace robot. CLIFF SENSOR Module inspection and cleaning ƒ First determine that Roomba was not started on an uneven surface, or a dark surface that could have triggered a false cliff or a continuous false cliff. ƒ Turn the robot
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shaft. ƒ 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. Remove brush caps and use scissors to cut any hair wrapped around the brush. Use the Roomba cleaning tool to comb hair
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VACUUM BIN Module inspection and cleaning ƒ Make sure filter is properly installed. Replace if necessary. ƒ Make sure rear squeegee is properly installed. ƒ Check for wear and tear on both front and rear squeegees. ƒ Wipe dust off vacuum bin contacts with finger or pencil eraser. 63
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D: Roomba Spare Parts Replacement Instructions Roomba Spare Parts Bottom Cover with 4 screws - (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
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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) 1. Turn the robot over and remove side screw
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the pull tabs. ƒ Replace with new Battery using pull tabs. ƒ Press pull tabs against the body of the Battery. SIDE BRUSH MODULE ƒ Replace the 2 screws that retain the new side brush module. ƒ Remove Roomba's side brush module. ƒ Install Roomba's new side brush module. ƒ Replace the 2 screws that
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retain Roomba's wheel module. ƒ Remove Roomba's wheel module. ƒ Install Roomba's new wheel module. ƒ 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
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5. Replace Roomba's bottom cover and the 4 screws that retain the bottom cover. 6. Replace spinning side brush and screw 68
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Roomba Faceplate Replacement 1. Remove Roomba's vacuum bin. 2. Remove Roomba's faceplate by pulling 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
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Roomba Filter Replacement 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 Roomba's vacuum bin. 70
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Reinsert the wheel and module back into the chassis. Appendix E: Roomba Software & OSMO Roomba's software is continuously being updated and latest production will have the most recent software. OSMO is a portable device that can be sent or used by service centers to update Roomba code. To determine
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measure the voltage across a Roomba 500 series battery, to measure voltage across a 5-Ohm resistor, and to measure the thermistor resistance. Equipment : Battery Voltage Tester, Multimeter, and fully charged battery under test. Method 1. Fully charge battery with Roomba and latest software. Remove
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charging Method Plug power supply into variable voltage AC supply with AC voltmeter connected across AC supply. Connect resistive load (18 1. ohm 50 W) across output of power supply, with DC ammeter connected in series if it fails Home Base Mobility test (manual dock and Home Base avoidance) 73
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I: Roomba Serial Number Robot Barcode Serial Number Format (barcode sticker on inside chassis - seen when vacuum bin is removed) MM Status: LLLLL YY mm dd RR SSSSS Manufacturer ID: 'JE' or 'KY' or 'PR' 'N' for new, 'R' for remanufactured Model number (00000 - 09999) Year (since 2000) this robot
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Appendix J: User Interface CLEAN Light While charging : No Light -Battery depleted. While cleaning : No Light - SPOT Light Green -Solid green when finished charging. Yellow -Pulsing slow when charging in normal mode. -Pulsing fast when charging in recovery mode. Red -Flashes red if battery has
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Stasis User interface (UI) Virtual o Built in test o Robot data recorder that tracks information during the robot's life. o The plastic structure/frame of the Roomba o The cleaning assembly includes the pivoting self adjusting frame that supports the brushes, brush guard, brush motor and gearbox