iRobot Roomba Scheduler, Roomba Discovery SE, Roomba Discovery, Roomba Sage, Roomba Red Service Manual
Roomba Discovery Series
Service Manual
Published August 31 2006
Roomba Scheduler
Roomba Discovery SE
Roomba Discovery
Roomba Sage
Roomba Red
1
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
Roomba Vacuuming Robot ______________________________________________________13
Roomba Terminology_______________________________________________________________ 13
Roomba Chassis Disassembly Procedure _______________________________________________ 14
Roomba Electrical Inter-Relationships ________________________________________________ 15
Service Procedure (based on Built-in-Test Failures)______________________________________ 16
Failed BiT 0 - Panel LEDS _________________________________________________________________ 17
Failed BiT 1 – Bumpers ___________________________________________________________________ 18
Failed BiT 2 or 3 – Outer & Inner Cliff Sensors_________________________________________________ 19
Failed BiT 4 – Wheel Drop_________________________________________________________________ 20
Failed BiT 4 – Wall Sensor_________________________________________________________________ 21
Failed BiT 5 – RCON / IR Receiver __________________________________________________________ 22
Failed BiT 6 – Battery Sensor_______________________________________________________________ 22
Failed BiT 7, 8 or 9 – Drive Wheels & Encoders ________________________________________________ 23
Failed BiT 10 – Stasis (front wheel) __________________________________________________________ 25
Failed BiT 11 – Main Brush ________________________________________________________________ 26
Failed BiT 12 – Debris Sensor ______________________________________________________________ 27
Failed BiT 13 – Vacuum___________________________________________________________________ 28
Failed BiT 14 – Side Brush_________________________________________________________________ 29
Failed BiT 15-20 – Charging _______________________________________________________________ 30
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Precautionary Replacements ________________________________________________________________ 31
Precautionary replacements ________________________________________________________________ 31
Charging Accessories___________________________________________________________ 32
Roomba Battery ___________________________________________________________________ 33
Battery Types ___________________________________________________________________________ 34
Battery Insertion Technique ________________________________________________________________ 34
General Battery Maintenance Tips ___________________________________________________________ 35
Battery Troubleshooting ___________________________________________________________________ 35
Roomba Power Supply______________________________________________________________ 36
Power Supply Generations _________________________________________________________________ 36
Power Supply Troubleshooting______________________________________________________________ 36
Roomba Home Base ________________________________________________________________ 37
Manual Docking _________________________________________________________________________ 38
Home Base Generations ___________________________________________________________________ 39
Home Base Troubleshooting________________________________________________________________ 39
Rapid Charger ____________________________________________________________________ 40
Roomba Accessories____________________________________________________________ 41
Roomba Virtual Wall _______________________________________________________________ 42
Virtual Wall Generations __________________________________________________________________ 43
Virtual Wall Troubleshooting _______________________________________________________________ 43
Roomba Remote ___________________________________________________________________ 44
Remote Troubleshooting___________________________________________________________________ 44
Roomba Filter _____________________________________________________________________ 45
Filter Troubleshooting_____________________________________________________________________ 45
Bristle, Flexible and Side Brush ______________________________________________________ 46
Brush Troubleshooting ____________________________________________________________________ 46
Appendix A: Charging Troubleshooting Flowchart __________________________________ 48
Appendix B: Serial Number Format_______________________________________________ 49
Appendix C: Roomba Code List __________________________________________________51
Appendix D: Roomba Error Codes ________________________________________________ 53
Appendix E: Roomba Software & OSMO___________________________________________ 54
Appendix F: Roomba Built-in-Test Procedure_______________________________________ 56
iRobot Data Capture _______________________________________________________________ 61
Alternative Data Capture ___________________________________________________________ 61
Built-in-Test Output File (using iRobot Roomba Factory-Test-Client Version 1.1) ____________ 62
Appendix G: Roomba Built-in-Test Limits__________________________________________ 63
Appendix H: Roomba Mobility Test Procedure ______________________________________ 64
Appendix I: PCB Connector Designation___________________________________________ 68
Appendix J: Battery Test Procedure _______________________________________________ 69
Appendix K: Power Supply Test Procedure _________________________________________70
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Appendix L: Built-in-Test Toolbox kits_____________________________________________ 71
Appendix M: Disassembly Procedure ______________________________________________ 72
Roomba Chassis Disassembly Procedure _______________________________________________ 72
Roomba Cleaning Frame Disassembly Procedure _______________________________________ 73
Roomba Main PCB & Inner Bumper Removal Procedure ________________________________ 75
Roomba Wheel Disassembly Procedure ________________________________________________ 77
Roomba Fixed Caster Removal Procedure _____________________________________________ 79
Roomba Swivel Caster Removal Procedure_____________________________________________ 80
Roomba Swivel Optical Stasis & Switch Removal Procedure ______________________________ 80
Appendix N: User Interface______________________________________________________ 82
User Interface : POWER Light_______________________________________________________ 82
User Interface : STATUS Light ______________________________________________________ 83
User Interface : DIRT Detect_________________________________________________________ 83
Appendix O: Roomba Engineering Changes ________________________________________84
Appendix P: GLOSSARY________________________________________________________ 87
4
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
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. For example, Appendix A walks through the charging troubleshooting. 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 compressed air.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 electrical contacts on Roomba and Home Base with alcohol pad or eraser.4
v. Clean out the vacuum bin and vacuum filter. 5
2
1
4
3
5
B) Customer should reset Roomba’s 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.
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. The customer should add documentation
that provides the date, their name, address, a reference number and a description of the complaint.
In order to avoid receiving a depleted battery, ask the customer to remove battery from the
Roomba and place it separately in the box.
03: Incoming Roomba Inspection
Unpack the Roomba return.
Record serial number of the Roomba, Battery, Power Supply and
Home Base.
Record the date and ‘Customer Complaint 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 & 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.
Appendix B
1
Holed bearings allow captured dirt and hair to escape the cleaning assembly..
7
Reinsert all Roomba components (bearings, brushes, wire guard, side
brush and vacuum bin). Insert *approved* charged battery in the
Roomba and run the Roomba on ‘Clean’. Does the Roomba end
immediately with an error code? If not, continue.
04: Roomba Cleaning
Remove and empty the vacuum bin and vacuum filter.
Inspect the filter for punctures and replace if punctured.
Clean the main brush, flexible brush and bearings from hair and dirt.
Clean drive wheel bearings.
Clean the wheel axles from hair using tweezers.
o Front caster
o Drive Wheels
Appendix D
Remove and clean under the side brush of hair and dirt.
Clean the sensors with compressed air.
o Cliff sensors
o Wall sensor
o Bumper sensors
Clean the cleaning assembly with compressed air.
Clean the electrical contacts on Roomba with alcohol pad.
05: Roomba Software & Charging Reset
Insert an *approved* charged battery in the Roomba and download the
latest software (if outdated).
Reset Roomba’s charging system by removing the battery and pressing
the power button for at least 5 seconds.
Appendix E
8
06: Roomba Diagnostics: Built-in-Test (BiT)
Insert an *approved* charged battery in the Roomba.
Insert an *approved* main bristle brush and flexible brush.
Verify the vacuum bin is inserted in the Roomba.
Use *approved* Power Supply, Home Base, Virtual Wall and Remote.
Perform BiT steps. Take note of the button & speaker performance. 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
07: Capture Built-in-Test Data
Use “iRobot Factory Test Client Version 1.1” software to download
the BiT output.
Appendix F
08: Roomba Diagnostics: Mobility Test
Perform the Mobility Test. Appendix H
Record the “Robot MT Code’. Appendix C
09: Fix or Replace Roomba
Disassemble Roomba and clean Roomba with compressed air. Appendix M
Service
Repair parts using Built-in-test Fix.
Check pcb connections. Appendix I
Procedure
(pg 16)
Retest the BiT and MT and continue fixing until 100% pass.
Record ‘Action Code’. Appendix C
9
10: Test Battery
Fully charge the returned Battery in an *approved*Roomba.
Perform Battery test
o Battery Voltage
o Battery Voltage Drop with a 5 ohm load
o Thermistor value
[Note: If only battery voltage was low, attempt an uninterrupted 72
hour charge and repeat test. If the voltage drop failed, replace battery.]
When battery PASSES the test do a Roomba run time on a hard floor.
Run time should be over 60 minutes. If runtime is less than 60 minutes,
try a 72 hour charge again and see if run time improves. If no, replace
battery.
Record the ‘Battery Code’. Appendix 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 J
Troubleshoot
Battery (pg
35)
Appendix K
Troubleshoot
Power Supply
(pg36)
[Note: If the power supply light is off or blinking while charging,
replace the Power Supply, Home Base and the Roomba's main pcb.
The pcb in the Home Base and Roomba may have been damaged.]
Record the ‘Power Supply Code’. Appendix C
12: Test Home Base (if applicable)
Test returned Home Base with a power supply
o Clean Home Base (electrical contacts and IR emitter)
o Check if power and dock LEDs are ‘on’ when charging
o Visually inspect contact springs
Test Home Base Mobility
o Perform Home Base avoidance (Fig 5 in Appendix H)
o Perform the manual dock (Fig 7 in Appendix H)
Troubleshoot
Home Base
(pg 39)
Appendix H
10
Record the ‘Power Supply Code’ Appendix C
13: Test Virtual Wall (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 Check Virtual mobility (Fig 4 in Appendix H)
Record the ‘Virtual Wall Code’ Appendix C
14: Test Remote (if applicable)
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
Record the ‘Remote Code’ Appendix C
15: Replace Faulty Accessories
Troubleshoot
Virtual Wall
(pg 43)
Troubleshoot
Remote (pg
44)
Replace faulty accessories
Record the ‘Action Item Code’. Appendix C
16: Pack & Record the Serial Numbers
Wrap Battery so no electrical contact is made with the Roomba in
order to avoid creating a deeply discharged battery.
Record the serial number of all replacement parts. Appendix B
11
17: Monthly Data Report to iRobot
Send monthly report to iRobot (tgiesecke@irobot.com)
1. A zipped 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 detailed Record Sheet which captures all the service codes of
each serviced Roomba.
Appendix C
12
Roomba Vacuuming Robot
r
Roomba Terminology
IR Receiver / RCON
Bumper
Handle
Chassis
User Interface (UI)
Wall Sensor
Vacuum Bin
Cliff Sensors
Side brush
Drive Wheel
Vacuum Inlet
Front Caste
Contacts
Battery
Charging Socket
Serial Port
Cleaning Frame
Brush Guard
Flexible Brush
Debris Sensor
Main Brush
Cleaning Assembly
Vacuum Bin
13
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)
14
Lift outer bumper slowly (it is attached by a connector)
1
Angle the bumper outward and carefully disconnect
2
connector from outer bumper
Lift top shell slowly (it is attached by a connector).
3
Carefully disconnect the connector from Roomba.
Clean off the internal dirt with compressed air.
4
Go to Appendix M
Wheels and Front Caster.
for details on how to remove the Cleaning Frame, PCB, Inner Bumper, Diver
Roomba Electrical Inter-Relationships
Roomba electrical design is proprietary. However for servicing it is important to know that the
following sensors are in series:
1. Right front cliff sensor, Right outer cliff sensor, Right wall sensor
2. Left front cliff sensor, Left outer cliff sensor
3. Right bumper sensor, Right wheel sensor, Left bumper sensor, Left wheel sensor.
15
Service Procedure (based on Built-in-Test Failures)
Every Roomba return is required to undergo a Built-in-Test (BiT) and a Mobility Test (MT) which
will then dictate how to best service the Roomba. iRobot requires that only the initial BiT output
file be recorded and sent back 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 pass 100%.
The following Service Procedure is based on failed BiT steps or specific Roomba symptoms. We
provide basic steps on how to attempt to repair the component but as a last resort, a replacement
part is suggested.
BiT Repair Steps
Replacement Part (if needed)
Quality Check (QC)
16
Failed BiT 0 - Panel LEDS
Roomba Symptom: Roomba lights do not turn on.
Æ Connect an *approved* top shell to Roomba and
redo BiT step. If BiT step passes, Roomba is working
and we should now inspect the failed top shell.
Æ Inspect wiring and soldering under the failed top
shell. Are any pcb wires broken or disconnected?
BiT REPAIR STEPS
Æ If buttons are not working or intermittent and the
Roomba is a Discovery, SE or Scheduler, open the
user interface panel. Clean the pcb under the snap
dome with alcohol and reapply tape to seal switch
from dirt.
PART
Top Cover/Shell
REPLACEMENT
o Inspect the wiring into the user panel and add hot
glue if it is needed for strain relief.
QC
o Ensure BiT passes.
17
Failed BiT 1 – Bumpers
Roomba Symptom: Roomba may back up and circle
with no error code.
Æ Clean area where bumper arms meet the IR sensor
housing on pcb with compressed air. If test still fails
remove arms (see Appendix M) and wipe sensors in
housing with alcohol.
Æ Make sure the front caster is properly inserted and
that the connectors are secure.
Æ Inspect the bumper springs and ensure they spring
BiT REPAIR STEPS
back and that there are no wires or obstructions as
they compress.
Æ Check for broken bumper arms.
Main PCB
Inner Bumper Module
REPLACEMENT PART
o When reattaching the outer bumper verify that
wires are not being pinched and that the springs
QC
are free to compress.
o Ensure BiT passes.
18
Failed BiT 2 or 3 – Outer & Inner Cliff Sensors
Roomba Symptom: Roomba does not see cliffs or
o Does not run, says “ehh”
o Backs up in circular arcs
o Stops with “uh-oh and 5 beeps”
Æ Clean the sensors with compressed air.
Æ Is the side brush blocking the outer sensor? Rotate
the side brush arms away from the cliff sensor
opening.
BiT REPAIR STEPS
Æ Remove the outer bumper and inspect the cliff
sensor wiring.
Inner Bumper Module
PART
REPLACEMENT
o When attaching the inner and outer bumper verify
that the wires are well routed and not being
pinched.
QC
o Verify that the bumper can be compressed and
released freely on both sides
o Ensure BiT passes.
19
Failed BiT 4 – Wheel Drop
Roomba Symptom: Roomba has triangular wiggle
behavior at startup or stops with “uh-oh and 6 or 9
beeps”.
Æ Inspect the failed wheel switch and toggle it. If the
switch arm is worn or broken, then replace the switch.
Æ Clean the switch with a drop of alcohol and dry
switch with compressed air.
BiT REPAIR STEPS
Æ If switch is loose from its mounting support,
reattach it with hot glue.
REPLACEMENT PART
Fixed Front Caster Module
Speaker/Wheel Drop Switch
20
Wheel Drop Switch
Outer Bumper Assembly
o If replacing switch, verify the wires are well
routed and will not be pinched during reassembly.
o Ensure BiT passes.
QC
Failed BiT 4 – Wall Sensor
Roomba Symptom: Roomba does not run parallel to
the walls on its right side.
Æ Clean the wall sensor with compressed air
Æ Perform a wall follow test (see Figure 2 in
Appendix H
Æ Attach an *approved* outer bumper and retest to
rule out pcb failures.
BiT REPAIR STEPS
)
Outer Bumper Assembly
o Ensure BiT and MT passes.
QC
21
Failed BiT 5 – RCON / IR Receiver
Roomba Symptom: Crosses Virtual Wall beams, hits
accessories, and does not respond to the Remote.
Æ Wipe the RCON on top of bumper. Retest.
Æ Detach outer bumper and inspect wiring under the
bumper.
Æ Plug in an *approved* outer bumper and retest
BiT REPAIR STEPS
with accessories to rule out pcb failures.
Outer Bumper Assembly
NT PART
REPLACEME
o Ensure BiT passes.
QC
Failed BiT 6 – Battery Sensor
Roomba Symptom: Roomba does not charge
Æ Clean the electrical contacts on the Roomba (in the
battery well) with an alcohol pad.
Æ Remove the outer bumper and inspect for any
BiT REPAIR STEPS
broken wires leading from the electrical contacts to
the pcb.
22
PART
Battery
REPLACEMENT
o Ensure BiT passes.
QC
Failed BiT 7, 8 or 9 – Drive Wheels & Encoders
Roomba Symptom:
o Roomba spins both forward and backward in
circles and may end in “uh-oh and 4 beeps”.
o Wheels may not turn or sound loud.
If the wheel tests fail or sound bad:
Æ Put the Roomba on its back and manually turn the
wheel. Is there an obstruction? Is the axle and bearing
centered?
Æ Open wheel cover and clean under the cove with
compressed air, including wiping the encoder sensors
with alcohol. (A,B,C)
BiT REPAIR STEPS
Æ Inspect the drive belt and exchange it if it is very
worn or slipping.
Æ If the motor is dead, attach a new wheel assembly
into pcb and repeat test. If it works, the pcb is good
and the wheel needs to be replaced.
23
PART
Drive Belt
REPLACEMENT
Right/Left Wheel Assembly
o Ensure BiT passes.
o Verify wires are well routed and not pinched by
QC
the wheel cover.
o Verify the wheel supports are screwed in.
24
Failed BiT 10 – Stasis (front wheel)
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:
ÆManually spin the wheel and verify that there is no
hair in the axle and that it can spin fairly freely.
ÆReplace caster module if cleaning did not help.
If the swivel caster stasis fails, the optical switch may
have failed:
BiT REPAIR STEPS
Æ Remove the black/white wheel and clean the
wheel with alcohol and remove hair from the axle.
ÆWipe the optical stasis window in the chassis above
the wheel (see picture) using a lint free cloth. (see
picture)
REPLACEMENT PART
o Ensure BiT passes.
QC
Fixed Front Caster Module
Swivel optical stasis
25
Failed BiT 11 – Main Brush
Roomba Symptom:
o Roomba does not clean or
o Brushes do not spin or sound loud
o Roomba ends with error “uh-oh and 1 beep”.
If the main brush test fails or sounds loud:
Æ If the brush motor is not running, try connecting
an *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.
Æ Inspect brush motor power wires for breaks (see
picture 1)
Æ Inspect the output gear into brushes. Is the gear
worn out? (see picture 2)
BiT REPAIR STEPS
Æ If there is a ratcheting and grinding sound, inspect
the brush gear box and side gear box for missing
gear teeth. (see picture 3)
Main Brush Assembly
PART
REPLACEMENT
26
Output Gears
Brush Motor, Gearbox, Shaft
o Ensure BiT passes with returned or replaced
QC
brushes
o 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.
Æ Verify the debris sensor is not covered in dirt.
Æ If it test still fails replace main brush assembly.
BiT REPAIR STEPS
Main Brush Assembly
PART
REPLACEMENT
27
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