charging circuit problem

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charging circuit problem

Postby horizen96 » September 12th, 2010, 5:36 pm

I have a roomba 550 that worked just fine and then it would not even turn on light up or any thing

I know a lot about how roombas work so I quickly found the problem. There are 2 diodes in the charging circuit on the PCB.

I can remove it a solder on a new one but i need to know what kind. The label on the diode was the destroyed so i can't see what it was.

Is there any way i can get a circuit diagram or something like that.
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Re: charging circuit problem

Postby vic7767 » September 12th, 2010, 5:43 pm

Do you have a picture or physical location for this Diode ?
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Re: charging circuit problem

Postby horizen96 » September 12th, 2010, 8:19 pm

when the diodes exploded they made it hard to read the location. I think one of them says d47 but i can not tell the other. This is the 550 board with the transmitter for the light house. The diodes are placed right next to each other and one is bigger than another
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Re: charging circuit problem

Postby vic7767 » September 12th, 2010, 8:38 pm

I understand you can't tell what type they are but where are they on the PCB?
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Re: charging circuit problem

Postby sageman » September 12th, 2010, 8:56 pm

near left wheel/bumper etc i think vic7767 is trying to tell you :)
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Re: charging circuit problem

Postby mfortuna » September 12th, 2010, 8:59 pm

Hopefully replacing the two diodes will fix the issue. Very often when a transistor or diodes smokes there is another issue that caused the destruction.
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Re: charging circuit problem NOPE, its +5VREG PS

Postby Gordon » September 13th, 2010, 1:50 pm

horizen96 wrote:I have a roomba 550 that worked just fine and then it would not even turn on light up or any thing ... I quickly found the problem. There are 2 diodes in the charging circuit on the PCB.
Maybe not in the "charging circuit". Look at this photo:
+5V_PS-components.jpg

...and study the two diodes next to the toroidal inductor. You will see D47 and D55 next to each other. If those are the diodes that blew out on your board, I can tell you that neither one carries battery charging current.
... i need to know what kind. The label on the diode was the destroyed so i can't see what it was. Is there any way i can get a circuit diagram ,,, .
The circuit you need is that of the 5XX Buck Converter, (looking something like this circuit draft):
SMPS_SCHEMATIC.jpg
... which accepts either +21.5Vdc (approx) from a charging power supply, or battery_voltage, minus about one volt, to then create Roomba's +5Vdc regulated power form.

You can see where input diode D47 taps into those power sources by reviewing this post: viewtopic.php?p=81792#p81792

Of course, the attached +5VREG schematic shows you that D55, SR240 (found by TechGuy) is the converter's flyback diode.

I do show D47 as a "1N4001" in the schematic, partly because I read "1N4..." on its case, but I also think a 1N4001 could serve there.

D55 is a Schottky diode, whereas D47 need not be.

You have been forewarned by Mike, regarding probable damage to other components, so simply replacing a couple diodes can't be expected to make this board functional.

When power diodes behave as fuses, you really need to find out what caused the damage! Then see about tending to that area first.

Granted, it is feasible to think that D55 simply suffered a latent semiconductor fault which resulted in it turning into a low-resistance path. D47 would then have been faced with delivering as much battery-current as it could to a switched ON Q7 MOSFET and through the shorted D55. OR, if the 550 was in charging mode at the time D55 failed, then D47 would have been subjected to continuous 1.3Adc current that would eventually (hours) smoke it.

Normally, Q7 is not continuously ON, it is rapidly pulsed ON/OFF as directed by controller U3. U3 also monitors current being delivered to five-volt loads. If that current assessment has an upper limit, then U3 could have shut down ops before D47 got blown. You will have to read the U3 data sheet and app-note to see about its current limiting capability. If there is no current limiting I can see how U3 voltage regulator may cause U3's Q2 to be given maximum ON-time, to then pull Q7's gate low and keep it maximally conducting throughout the fault period.

If D47 blew due to a high battery current coursing through it, the battery's fuse would have been stressed, and the parasitic diode in FET Q18 would have been stressed. But, if it was the charging PSU that heated D47 to destruction, you might get away with simply replacing the two damaged diodes.

Seems to me that you have quite a bit of work to do! You might even have to buy another 5XX PCA, any model, just so you can dismount D47 to identify it. That board could also be used as a test device for verifying the normal power path (backwards) through Q18 & Q17 to D47A, as well as trouble-shooting the Buck Converter.

If you are not up to that kind of "fun", then buy a replacement 550 PCA.
Last edited by Gordon on February 2nd, 2015, 2:04 am, edited 2 times in total.
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Re: charging circuit problem

Postby TechGuy » November 13th, 2012, 2:23 am

Gordon, the D55 is a Schottky diode SR240.
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Re: charging circuit problem

Postby Gordon » November 13th, 2012, 12:06 pm

TechGuy wrote:Gordon, the D55 is a Schottky diode SR240.
Thank you for posting D55's part number. I have logged it.
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Re: charging circuit problem

Postby teoman » January 22nd, 2017, 2:10 pm

Hello, I know i am doing a major thread resurrection but this was the most relevant thread I found on the net. (And it is still relevant for the 700 series roombas).

My roomba is completely dead, no signs of life. I charged the battery externally using an IMAX B8 charger and still no joy. Checked the power plug and saw 22V.

Then i dismantled the robot and had a look around. Saw nothing burned or obviously wrong, then i started to check all the diodes and discovered that D47 was not functional and I will be replacing that. What else should i replace??

It is hard work opening up the robot so might as well replace all that i can while i have it open. If this doesnt work i will have to buy a new PCB.

BTW i have the roomba 780 and the basic configuration is the same.


Thanks in advance for your helf.
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Re: charging circuit problem

Postby a1robotrepair » January 22nd, 2017, 3:28 pm

D47 would surely make it not function at all. After changing the diode, reassemble the bot to just the circuit board level. Install the battery and hopefully you hear the wake up song. Press the start button to see if it lights up. Put it on the charger to see if it starts charging. If all is good, fully reassemble and check the BITs. The 5V SMPS is similar to the R3 but not identical.
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Re: charging circuit problem

Postby teoman » January 22nd, 2017, 4:05 pm

You lost me here "check the BITs".
The coil of the smps is different from the pictures in this thread.
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Re: charging circuit problem

Postby a1robotrepair » January 22nd, 2017, 5:43 pm

BITs = Built In Tests, coil and circuit and switching regulator chip are different but labeled nearly the same...U3, Q7, D47
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Re: charging circuit problem

Postby teoman » January 22nd, 2017, 6:09 pm

SO they are software activated? Or do i measure them with a DVM?
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Re: charging circuit problem

Postby a1robotrepair » January 22nd, 2017, 7:47 pm

Activated with user interface thru buttons. I assumed you knew more about Roomba troubleshooting and repair since you found the D47 diode.
No frets, put bot together to board level and see if it plays the tune and charges. If it does it's probably fixed, put it together completely.
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Re: charging circuit problem

Postby teoman » January 22nd, 2017, 8:10 pm

Thanks, I have a background in computer engineering and robotics. Although i have had the roomba for several years now, it never broke so i never needed to fix it, and i did not want to open it up for fun because it never goes back together quite the same way and the fact that they do not do those brass inserts in to plastic anymore, it is all screw directly to plastic.

To be honest, i found the D47 diode and then googled "D47 Roomba" and found this page :)
I also wanted to chime in and say that in the 700 series that resistor is named the same.

Thanks a lot for your help. I will tackle the problem on tuesday.
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