Botvac D85 fuel gauge failing and push switch down to on

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Botvac D85 fuel gauge failing and push switch down to on

Postby Tjeerdw » February 10th, 2019, 8:26 am

Hey all,

My D85 called Fred is a bit sick. I have read around the forum a bit and found people with similar problems, but not exactly the same. I am quite tech savvy and know my way around electronics, but i have not been able to determine the exact problem. Before repairing board level stuff I would like your opinion where i should search the problem.

The problem started out by Fred constantly yelling to push switch down to on and showing an empty battery on it's display. I have discharged(2A) and charged(also 2A) the battery with an external charger and it still shows close to full capacity (3550 mAh). I don't see the battery voltage dropping quickly under load. So i'm quite sure that the battery is fine.

This is the log when it is failing and bleeping. I see that the battery is quite full but the fuel gauge is showing 19%. this 19% is something that I saw in this topic also.
viewtopic.php?f=20&t=20227
Code: Select all
____   Discrete:   ____   
SNSR_DC_JACK_IS_IN   False
SNSR_DUSTBIN_IS_IN   False
SNSR_LEFT_WHEEL_EXTENDED   False
SNSR_RIGHT_WHEEL_EXTENDED   False
LSIDEBIT   False
LFRONTBIT   False
LLDSBIT   False
RSIDEBIT   False
RFRONTBIT   False
RLDSBIT   False
____   Analog:   ____   
BatteryVoltage   mV=13683
BatteryCurrent   mA=-87
BatteryTemperature   mC=20949
ExternalVoltage   mV=554
AccelerometerX   mG=6
AccelerometerY   mG=16
AccelerometerZ   mG=998
VacuumCurrent   mA=0
SideBrushCurrent   mA=0
MagSensorLeft   VAL=0
MagSensorRight   VAL=0
WallSensor   mm=70
DropSensorLeft   mm=0
DropSensorRight   mm=0
____   Buttons:   ____   
BTN_SOFT_KEY   False
BTN_SCROLL_UP   False
BTN_START   False
BTN_BACK   False
BTN_SCROLL_DOWN   False
BTN_SPOT   False
____   Charger:   ____   
FuelPercent   19
BatteryOverTemp   0
ChargingActive   0
ChargingEnabled   1
ConfidentOnFuel   0
OnReservedFuel   0
EmptyFuel   0
BatteryFailure   0
ExtPwrPresent   0
ThermistorPresent   1
BattTempCAvg   20
VBattV   13.68
VExtV   0.55
Charger_mAH   0
Discharge_mAH   90


Then I put it up against the charger, initially I see 18V external voltage
Code: Select all
____   Discrete:   ____=
SNSR_DC_JACK_IS_IN=False
SNSR_DUSTBIN_IS_IN=False
SNSR_LEFT_WHEEL_EXTENDED=False
SNSR_RIGHT_WHEEL_EXTENDED=False
LSIDEBIT=False
LFRONTBIT=False
LLDSBIT=False
RSIDEBIT=False
RFRONTBIT=False
RLDSBIT=False
____   Analog:   ____=
BatteryVoltage=mV=13652
BatteryCurrent=mA=-85
BatteryTemperature=mC=20738
ExternalVoltage=mV=17981
AccelerometerX=mG=0
AccelerometerY=mG=6
AccelerometerZ=mG=988
VacuumCurrent=mA=0
SideBrushCurrent=mA=0
MagSensorLeft=VAL=0
MagSensorRight=VAL=0
WallSensor=mm=70
DropSensorLeft=mm=0
DropSensorRight=mm=0
____   Buttons:   ____=
BTN_SOFT_KEY=False
BTN_SCROLL_UP=False
BTN_START=False
BTN_BACK=False
BTN_SCROLL_DOWN=False
BTN_SPOT=False
____   Charger:   ____=
FuelPercent=19
BatteryOverTemp=0
ChargingActive=0
ChargingEnabled=1
ConfidentOnFuel=0
OnReservedFuel=0
EmptyFuel=0
BatteryFailure=0
ExtPwrPresent=1
ThermistorPresent=1
BattTempCAvg=20
VBattV=13.65
VExtV=17.98
Charger_mAH=0
Discharge_mAH=85


then after half a minute the ext voltage drops and the unit is charging. It will continue charging till the Vbat reaches 16V, then it stops.
Code: Select all
____   Discrete:   ____=
SNSR_DC_JACK_IS_IN=False
SNSR_DUSTBIN_IS_IN=False
SNSR_LEFT_WHEEL_EXTENDED=False
SNSR_RIGHT_WHEEL_EXTENDED=False
LSIDEBIT=False
LFRONTBIT=False
LLDSBIT=False
RSIDEBIT=False
RFRONTBIT=False
RLDSBIT=False
____   Analog:   ____=
BatteryVoltage=mV=14689
BatteryCurrent=mA=1874
BatteryTemperature=mC=20742
ExternalVoltage=mV=14970
AccelerometerX=mG=6
AccelerometerY=mG=14
AccelerometerZ=mG=996
VacuumCurrent=mA=0
SideBrushCurrent=mA=0
MagSensorLeft=VAL=0
MagSensorRight=VAL=0
WallSensor=mm=70
DropSensorLeft=mm=0
DropSensorRight=mm=0
____   Buttons:   ____=
BTN_SOFT_KEY=False
BTN_SCROLL_UP=False
BTN_START=False
BTN_BACK=False
BTN_SCROLL_DOWN=False
BTN_SPOT=False
____   Charger:   ____=
FuelPercent=19
BatteryOverTemp=0
ChargingActive=1
ChargingEnabled=1
ConfidentOnFuel=0
OnReservedFuel=0
EmptyFuel=0
BatteryFailure=0
ExtPwrPresent=1
ThermistorPresent=1
BattTempCAvg=20
VBattV=14.68
VExtV=14.97
Charger_mAH=1871
Discharge_mAH=0
=Digital Sensor Name, Value


Then it still won't vacuum because it's fuel gauge is too low, after a reboot the fuel gauge dropped back to 19%.
Code: Select all
____   Discrete:   ____=
SNSR_DC_JACK_IS_IN=False
SNSR_DUSTBIN_IS_IN=False
SNSR_LEFT_WHEEL_EXTENDED=False
SNSR_RIGHT_WHEEL_EXTENDED=False
LSIDEBIT=False
LFRONTBIT=False
LLDSBIT=False
RSIDEBIT=False
RFRONTBIT=False
RLDSBIT=False
____   Analog:   ____=
BatteryVoltage=mV=14739
BatteryCurrent=mA=-82
BatteryTemperature=mC=26301
ExternalVoltage=mV=819
AccelerometerX=mG=-2
AccelerometerY=mG=20
AccelerometerZ=mG=996
VacuumCurrent=mA=0
SideBrushCurrent=mA=0
MagSensorLeft=VAL=0
MagSensorRight=VAL=0
WallSensor=mm=70
DropSensorLeft=mm=0
DropSensorRight=mm=0
____   Buttons:   ____=
BTN_SOFT_KEY=False
BTN_SCROLL_UP=False
BTN_START=False
BTN_BACK=False
BTN_SCROLL_DOWN=False
BTN_SPOT=False
____   Charger:   ____=
FuelPercent=19
BatteryOverTemp=0
ChargingActive=0
ChargingEnabled=1
ConfidentOnFuel=0
OnReservedFuel=0
EmptyFuel=0
BatteryFailure=0
ExtPwrPresent=0
ThermistorPresent=1
BattTempCAvg=26
VBattV=14.75
VExtV=0.81
Charger_mAH=0
Discharge_mAH=81
=Digital Sensor Name, Value


If set the fuel gauge to 100% in neatocontrol, the fuel gauge goes to 100% and in a couple of seconds it drops back down again. if I am quick enough the Neato will happily vacuum for over an hour.
I also made a log of when it is charging, this is attached.
Any ideas where I should search for the issue? Thanks a lot!
Attachments
log_charging.txt
(37.2 KiB) Downloaded 24 times
Tjeerdw
 
Posts: 4
Joined: February 9th, 2019, 5:30 am

Re: Botvac D85 fuel gauge failing and push switch down to on

Postby HiTec » February 10th, 2019, 12:36 pm

Measure the main power switch. They fail pretty often. Even slightest intermitting cut-offs and the robot starts acting strangely. If the power switch is not working correctly, you need to clean it with electro cleaner and flip it on off on off couple of times.
HiTec
Robot Groupie
 
Posts: 81
Joined: February 8th, 2015, 8:17 am

Re: Botvac D85 fuel gauge failing and push switch down to on

Postby Tjeerdw » February 10th, 2019, 3:32 pm

Thanks for the suggestion HiTec. I measured the switch and it seemed to work nice without any intermittent cut-offs. There was a bit suspicious looking solder joint, so i re-soldered all joints on the switch and battery connector. It's hard to say the fault is gone now because i have to charge it up again. I will post an update as soon as I know.
Tjeerdw
 
Posts: 4
Joined: February 9th, 2019, 5:30 am

Re: Botvac D85 fuel gauge failing and push switch down to on

Postby Tjeerdw » February 10th, 2019, 4:39 pm

Nope, still the same problem as before.
Tjeerdw
 
Posts: 4
Joined: February 9th, 2019, 5:30 am

Re: Botvac D85 fuel gauge failing and push switch down to on

Postby glnc222 » February 10th, 2019, 8:14 pm

The Maxim fuel gauge calculating IC has had to be replaced in other cases. This smart IC offloads this function from the cpu used on old XV models. Maxim IC at position U4 on the system board for calculating the Fuel Gauge, integrating current x time for charge measurement, part# MAX14047.
glnc222
Robot Master
 
Posts: 4849
Joined: January 23rd, 2012, 9:19 pm
Location: North Carolina, U.S.

Re: Botvac D85 fuel gauge failing and push switch down to on

Postby Tjeerdw » February 11th, 2019, 3:55 am

Thanks glnc222, I had already ordered the fuel gauge IC, but since it is a piece of unobtainium i will have to wait a couple of weeks for it to arrive. Any other suggestions are still welcome.
Tjeerdw
 
Posts: 4
Joined: February 9th, 2019, 5:30 am

Re: Botvac D85 fuel gauge failing and push switch down to on

Postby HiTec » February 11th, 2019, 10:07 am

I suspected fuel gauge chip on my D85 that i bought faulty from ebay, but in that case it was just the easier switch failure. But yea, because it didnt help with your case, then it's propably the U4.
HiTec
Robot Groupie
 
Posts: 81
Joined: February 8th, 2015, 8:17 am


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