Roomba 560 charging error 3

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Roomba 560 charging error 3

Postby dragon » December 28th, 2010, 2:31 pm

Hi everybody,

I am an owner of a roomba 560 (US 110v) living in an 220V country.
I bought a 220V - 110V convertor.
When I plug my Roomba, I have a charging error 3 with red blinking led.
I have changed the battery, I have removed the battery and did the 30s reset function on the power button.
I still have the "error 3"

Can anybody help please ?

Regards
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Re: Roomba 560 charging error 3

Postby TechGuy » December 28th, 2010, 3:02 pm

According to the service manual p39, charging Err3:
Charging FET Failed.
This occurs when the FET
test fails at the beginning
of the charge cycle.


1. Measure the no load voltage of the charger using the step-down transformer.
2. What is the wattage of your step-down transformer? The charger is using 33W. To allow transformer loss, 50W (just my guess) is on the safe side. At the beginning of charging stage, Roomba is doing a self test. If your transformer is under-rated and the charger will not supply enough current to charge the battery. This will pull down the charger output voltage to a level that Roomba will fail the test. I don't know the exact cut-off voltage level that Roomba is looking for. The battery is 14.4V. We know that we cannot charge the Roomba battery with less than 14.4V.

If you have the SCI cable, plug it in while charging. Post the result similar to the following output.

do-charging-checking-fets @ minutes 0
bat: min 0 sec 32 mV 15836 mA 0 tenths-deg-C 224 mAH 2695
Charging FET test passed.
do-charging-wait-initial @ minutes 0
do-charging-on @ minutes 0
bat: min 0 sec 33 mV 16059 mA 609 tenths-deg-C 222 mAH 2696
bat: min 0 sec 34 mV 16198 mA 1063 tenths-deg-C 221 mAH 2696
bat: min 0 sec 35 mV 16253 mA 1219 tenths-deg-C 221 mAH 2696
Last edited by TechGuy on December 28th, 2010, 3:11 pm, edited 1 time in total.
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Re: Roomba 560 charging error 3

Postby dragon » December 28th, 2010, 3:09 pm

Thanks for this quick reply, I will come back later with these results.
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Re: Roomba 560 charging error 3

Postby CleanMe » December 28th, 2010, 3:14 pm

Dragon -
If your voltage converter cannot be made to work and you're comfortable with a soldering iron, there are some threads on this site that show how to modify a Roomba power supply to work with 220v. Just use the search term '220v'.
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Re: Roomba 560 charging error 3

Postby TechGuy » December 28th, 2010, 3:57 pm

To determine whether you have the step down transformer issue, charge the battery directly and measure the charger output voltage and the charging current during direct charge as shown in the photo. Report the result.

Image
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Re: Roomba 560 charging error 3

Postby sonypc100 » December 28th, 2010, 4:47 pm

Dragon

We bought a US 560 and we used it for the first time with a converter in the UK on Christmas day, working fine.
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Re: Roomba 560 charging error 3

Postby dragon » December 29th, 2010, 12:24 am

TechGuy wrote:To determine whether you have the step down transformer issue, charge the battery directly and measure the charger output voltage and the charging current during direct charge as shown in the photo. Report the result.

Image

Hi Techguy,
The charger output voltage is 22.4V. I need to have croc jaws to measure the charging current during the direct charge. I'll come back later to report.
Thanks
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Re: Roomba 560 charging error 3

Postby TechGuy » December 29th, 2010, 12:40 am

dragon wrote:Hi Techguy,
The charger output voltage is 22.4V. I need to have croc jaws to measure the charging current during the direct charge. I'll come back later to report.
Thanks


The 22.4V is the no-load output. Am I correct?
The direct charge voltage should be between the 14.4V and 22.4V when the battery is charged directly. When you get 22.4V, check your connections because your are measuring the charger no-load output voltage and not the charging voltage with the connections properly connected.
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Re: Roomba 560 charging error 3

Postby dragon » December 29th, 2010, 1:12 am

TechGuy wrote:
dragon wrote:Hi Techguy,
The charger output voltage is 22.4V. I need to have croc jaws to measure the charging current during the direct charge. I'll come back later to report.
Thanks


The 22.4V is the no-load output. Am I correct?
The direct charge voltage should be between the 14.4V and 22.4V when the battery is charged directly. When you get 22.4V, check your connections because your are measuring the charger no-load output voltage and not the charging voltage with the connections properly connected.

Yes, the 22.4V is the no-load output. I will come back when i have the connections done for direct charging. Thanks
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Re: Roomba 560 charging error 3

Postby dragon » December 31st, 2010, 12:59 am

dragon wrote:
TechGuy wrote:
dragon wrote:Hi Techguy,
The charger output voltage is 22.4V. I need to have croc jaws to measure the charging current during the direct charge. I'll come back later to report.
Thanks


The 22.4V is the no-load output. Am I correct?
The direct charge voltage should be between the 14.4V and 22.4V when the battery is charged directly. When you get 22.4V, check your connections because your are measuring the charger no-load output voltage and not the charging voltage with the connections properly connected.

Yes, the 22.4V is the no-load output. I will come back when i have the connections done for direct charging. Thanks

Hi, the voltage taken on the battery charged directly is 15.4V (connection properly connected). Thanks for your help.
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Re: Roomba 560 charging error 3

Postby TechGuy » December 31st, 2010, 3:11 am

dragon wrote:Hi, the voltage taken on the battery charged directly is 15.4V (connection properly connected). Thanks for your help.

15.4V may be below the FET test pass/fail level used by Roomba because the step-down transformer is not big enough to handle load required by the Roomba charger. What is the wattage of your step-down transformer?

What is the charging current?

do-charging-checking-fets @ minutes 0
bat: min 0 sec 32 mV 15836 mA 0 tenths-deg-C 224 mAH 2695
Charging FET test passed.
do-charging-wait-initial @ minutes 0
do-charging-on @ minutes 0
bat: min 0 sec 33 mV 16059 mA 609 tenths-deg-C 222 mAH 2696
bat: min 0 sec 34 mV 16198 mA 1063 tenths-deg-C 221 mAH 2696
bat: min 0 sec 35 mV 16253 mA 1219 tenths-deg-C 221 mAH 2696
.
.
.
bat: min 0 sec 43 mV 16309 mA 1305 tenths-deg-C 221 mAH 2696
bat: min 0 sec 44 mV 16309 mA 1313 tenths-deg-C 221 mAH 2696
bat: min 0 sec 45 mV 16309 mA 1305 tenths-deg-C 221 mAH 2696
.
.
.


Do you have experience in soldering? If yes, you may consider doing the 200V hack. If no, get a step-down transformer with higher wattage.
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Re: Roomba 560 charging error 3

Postby dragon » December 31st, 2010, 3:17 am

TechGuy wrote:
dragon wrote:Hi, the voltage taken on the battery charged directly is 15.4V (connection properly connected). Thanks for your help.

15.4V may be below the FET test pass/fail level used by Roomba because the step-down transformer is not big enough to handle load required by the Roomba charger. What is the wattage of your step-down transformer?

What is the charging current?

do-charging-checking-fets @ minutes 0
bat: min 0 sec 32 mV 15836 mA 0 tenths-deg-C 224 mAH 2695
Charging FET test passed.
do-charging-wait-initial @ minutes 0
do-charging-on @ minutes 0
bat: min 0 sec 33 mV 16059 mA 609 tenths-deg-C 222 mAH 2696
bat: min 0 sec 34 mV 16198 mA 1063 tenths-deg-C 221 mAH 2696
bat: min 0 sec 35 mV 16253 mA 1219 tenths-deg-C 221 mAH 2696
.
.
.
bat: min 0 sec 43 mV 16309 mA 1305 tenths-deg-C 221 mAH 2696
bat: min 0 sec 44 mV 16309 mA 1313 tenths-deg-C 221 mAH 2696
bat: min 0 sec 45 mV 16309 mA 1305 tenths-deg-C 221 mAH 2696
.
.
.


Do you have experience in soldering? If yes, you may consider doing the 200V hack. If no, get a step-down transformer with higher wattage.

Hi, my step-down transformer is 100W. I didn't measure the charging current. How about testing the roomba with a true 220V charger ? Happy New Year
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Re: Roomba 560 charging error 3

Postby simplesimon » August 19th, 2011, 11:43 am

Hi Folks,

I was getting charging error 3 on my roomba 560. Checked the power supply it seemed ok. Checked the voltage on the battery it was very low around 2.5 volts. (Roomba had not been used for a few months)
I charged the battery directly from the charger (with alligator clips) as discussed here and reinserted it in the roomba. Tried to charge the roomba again and it has worked.
Guess the reason was the charge on the battery was too low and somehow it was activating charging error 3. Is my assumption correct or can I expect some other problem soon?

Thanks in advance for your reply.
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Re: Roomba 560 charging error 3

Postby vic7767 » August 19th, 2011, 12:46 pm

If you don't use the Roomba and it is not connected to the power supply then the internal circuits that are always active (like the IR receiver) will drain the battery. This may damage the battery and eventually cause charging system component failure when attempting to charge the battery. It is best to remove the battery if the power supply will not be connected for more than a day.
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Re: Roomba 560 charging error 3

Postby simplesimon » August 20th, 2011, 1:51 am

vic7767

Thanks for the info- much appreciated.
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Re: Roomba 560 charging error 3

Postby fatdiverpt » November 22nd, 2011, 11:26 am

Hello, all,

I own a Roomba 560 and have this same problem. It's probably due to the fact that often my wife leaves the roomba off the dock, so the battery will eventually discharge completely.... :( . From the info in this post and others I have already checked the battery, PSU and dock, all ok. If i charge the battery as described above and then put it on the roomba it will work normally. However, if I put it to charge it will give me the same error...My guess goes to some wrecked component in the motherboard. Any suggestions? I have the possibility to replace the faulty component(s), but for that I would need to know which :). Any help wolud be greatly appreciated!
Thanks in advance

Pedro
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Re: Roomba 560 charging error 3

Postby vic7767 » November 22nd, 2011, 1:04 pm

Pedro, have you considered replacing the battery ?
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Re: Roomba 560 charging error 3

Postby Gordon » November 22nd, 2011, 1:21 pm

fatdiverpt wrote:...I own a Roomba 560 and have this same problem. ...My guess goes to some wrecked component in the motherboard. Any suggestions? I have the possibility to replace the faulty component(s), but for that I would need to know which ...
Pedro, err3 points to a faulty "Charging FET", but before rushing to R&R both FETs (Q17 & Q18) you might like to know that a new MOSFET will overcome the error. If you wish, you may test both FETs by using information in some old posts to guide your testing.

This link will tell you where the FETs are located, and how Roomba uses them as safety devices for preventing run away charging: viewtopic.php?p=91612#p91612

A 2nd link explains how one may check charging FETs in the older 4XXX-Roomba (but the concept can be applied to the 500 series Roomba, as well): viewtopic.php?p=80761#p80761

A 3rd link will show you a quasi schematic of the 5XX's charging-FETs (see the Charging Mode diagram, which would be used in conjunction with link-2 to execute live testing):
viewtopic.php?p=81792#p81792

I think sufficient information has been given to guide verification as to whether either Q17 or Q18 has failed, and which it is. Of course, IF one has failed, it might be wise to replace both FETs.

Naturally, IF neither FET is faulty, the err3 problem has another source!
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Re: Roomba 560 charging error 3

Postby fatdiverpt » November 23rd, 2011, 5:46 am

vic7767 wrote:Pedro, have you considered replacing the battery ?


Yes, battery was replaced by a new one, still the same problem. Thanks for the hint. :)
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Re: Roomba 560 charging error 3

Postby fatdiverpt » November 23rd, 2011, 5:49 am

Gordon wrote:
fatdiverpt wrote:...I own a Roomba 560 and have this same problem. ...My guess goes to some wrecked component in the motherboard. Any suggestions? I have the possibility to replace the faulty component(s), but for that I would need to know which ...
Pedro, err3 points to a faulty "Charging FET", but before rushing to R&R both FETs (Q17 & Q18) you might like to know that a new MOSFET will overcome the error. If you wish, you may test both FETs by using information in some old posts to guide your testing.

This link will tell you where the FETs are located, and how Roomba uses them as safety devices for preventing run away charging: viewtopic.php?p=91612#p91612

A 2nd link explains how one may check charging FETs in the older 4XXX-Roomba (but the concept can be applied to the 500 series Roomba, as well): viewtopic.php?p=80761#p80761

A 3rd link will show you a quasi schematic of the 5XX's charging-FETs (see the Charging Mode diagram, which would be used in conjunction with link-2 to execute live testing):
viewtopic.php?p=81792#p81792

I think sufficient information has been given to guide verification as to whether either Q17 or Q18 has failed, and which it is. Of course, IF one has failed, it might be wise to replace both FETs.

Naturally, IF neither FET is faulty, the err3 problem has another source!


Thanks for the infos, that will keep me occupied for some time :)
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