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Chapter 5 - Diagnostics and Toolkit
5. Diagnostics The Diagnostics section of the Service Guide help to perform diagnostics in case of problems affecting the operation and to pinpoint about the source of the problem. The diagnostics can be done directly through the ‘Service’ menu in the Robomow or through the Toolkit software that gives more detailed information in one screen. The Toolkit and the ‘Service’ menu in Robomow have a series of self-diagnostic tests that allow it to pinpoint problems or test systems affecting the operation. By entering the specific system or component test, it will display either a ‘Pass’ or ‘Fail’ message or display a fault code, which is referenced in Section 5.6 to determine the nature of the problem. This section closely cross-references with Section 3, Troubleshooting. In Section 3, many of the troubleshooting flow charts request a specific diagnostic test to be performed. The results of each of these diagnostic tests are then used to determine the system or component of failure. This section outlines the procedure for performing these tests as well as an interpretation of the results, found in the Fault Code Tables, Section 5.6. Contents Subject 5.1 General test……………………………………………………………. 5.2 Service Key Procedure………………………………………………... 5.3 Toolkit Setup and Main Menu……………………………………….. 5.4 Toolkit Options………………………………………………………... 5.4.1 System View………………………………………………………….. 5.4.2 Tests…………….…………………………………………………….. 5.4.3 Calibrations…………………………………………………………… 5.4.4 Settings………………………………………………………………... 5.4.5 Information……………………………………………………………. 5.4.5 Downloads……………………………………………………………. 5.5 Service menu options………………………………………………….. 5.5.1 Settings procedures……………………………………………….…. 5.5.2 Calibration procedures……………………………………………… 5.5.3 Testing procedures…………………………………………………... 5.6 Diagnostics fault codes……………………………………….….…….. 5.7 Operation Stop Cause Table…………………………………….…..... 5.8 Battery Voltage Measurement………………………………………... 5.9 Charging Current Measurement……………………………………... 5-1 Page 5-2 5-3 5-6 5-10 5-10 5-16 5-17 5-18 5-19 5-20 5-24 5-24 5-29 5-31 5-35 5-37 5-40 5-42 5.1 General Test The General Test is a basic test that should be performed whenever a technician initiates a service repair on a Robomow. The test is designed so that most common problems found in normal operation will be readily apparent. The General Test should be performed regardless of whether any work was actually performed out on a unit. This ensures a “Duty of Care” to the customer, and will also serve to insure that all safety systems are working properly prior to a customer using the unit. The General Test should also be performed after any service routine was performed. This will insure that the maintenance was performed correctly and that no additional problems were introduced to the unit during the service routine. The General Test and certain of the other diagnostics tests need to be performed in a simulated lawn with the layout as shown below: Mi n3 m (10 ft) ft) m Figure 5.1 Simulated Lawn for General Test n2 Mi 5 (6. A. Remove batteries fuse from the Robomow and perform a mechanical inspection: 1. Check the operation of the cutting height adjustment. 2. Confirm the front cover chassis, operating panel and gear cover are closed well in its place. 3. Check that the blade is sharp and securely attached. 4. Check the operation of the front wheel by insuring it is free to rotate in all directions. B. Clean the unit using compressed air; particularly the mowing decks. A damp cloth and a wooden stick can also be used to remove stubborn dirt and debris. Do not wash with a hose. C. Insert the batteries fuse and perform the following tests: 1. Check that the operating LED illuminates when the fuse is inserted. 2. Check that the operating panel display and buttons are working properly. 3. Slightly lift the front of the unit and insure that the unit announces the Front Wheel lifted. Repeat the same test by holding the Front Wheel pressed so it will not activate and lift Robomow to more than 60 degrees to verify the tilt sensor is activated. 4. Confirm that the bumpers are functioning correctly by pressing them and hear the beeps. 5. Check charging using a Power Supply or through the Base Station. SAFETY FIRST! Before completing the following tests, insure that the test area is clear of persons and obstacles. Remove all floor debris to prevent it from being thrown by the rotating blade. Keep feet and hands away from the blades and the drive wheels when testing. 5-2 D. Using the Remote Control, drive the Robomow manually forwards, backwards, left and right and perform the ‘Drive motor test’ under the ‘Service’ menu. E. Manually activate the mowing motors and perform the ‘Mowing test’ under the ‘Service’ menu. F. Operate the Robomow automatically in the simulated lawn. Verify it follow the perimeter wire in edge mode and move in a straight lines when it moves inside the area in Scan mode. 5.2 Service Key The Service Key is a function in the Robomow software that allows a service technician to access diagnostics and service functions. These menu functions are not available to the end user. There are two ways to unlock the service password protection: § Formula that calculates the required password code based on a counter that is changed every 2 days and called Service Counter. § Master code: ‘01210’ When you are asked to enter the password code the Service Counter is displayed at the right side of the display inside the brackets. In case of instructing the customer to enter the ‘Service’ menu, it is recommended to use the Service Counter and not the Master code in order to prevent the user to reenter the ‘Service’ Menu in the future. The table in the next pages shows the code required for every Service Counter: 5-3 Service Counter and password: 5-4 Service Counter Service Password Service Counter Service Password Service Counter Service Password 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 00000 00001 00006 00015 00028 00045 00066 00091 00120 00153 00190 00231 00276 00325 00378 00435 00496 00561 00630 00703 00780 00861 00946 01035 01128 01225 01326 01431 01540 01653 01770 01891 02016 02145 02278 02415 02556 02701 02850 03003 03160 03321 03486 03655 03828 04005 04186 04371 04560 04753 04950 05151 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 05356 05565 05778 05995 06216 06441 06670 06903 07140 07381 07626 07875 08128 08385 08646 08911 09180 09453 09730 10011 10296 10585 10878 11175 11476 11781 12090 12403 12720 13041 13366 13695 14028 14365 14706 15051 15400 15753 16110 16471 16836 17205 17578 17955 18336 18721 19110 19503 19900 20301 20706 21115 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 21528 21945 22366 22791 23220 23653 24090 24531 24976 25425 25878 26335 26796 27261 27730 28203 28680 29161 29646 30135 30628 31125 31626 32131 32640 33153 33670 34191 34716 35245 35778 36315 36856 37401 37950 38503 39060 39621 40186 40755 41328 41905 42486 43071 43660 44253 44850 45451 46056 46665 47278 47895 Service Counter and password (con.): Service Counter 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 5-5 Service Password 48516 49141 49770 50403 51040 51681 52326 52975 53628 54285 54946 55611 56280 56953 57630 58311 58996 59685 60378 61075 61776 62481 63190 63903 64620 65341 66066 66795 67528 68265 69006 69751 70500 71253 72010 72771 73536 74305 75078 75855 76636 77421 78210 79003 79800 80601 81406 82215 83028 83845 84666 Service Counter 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246 247 248 249 250 251 252 253 254 255 Service Password 85491 86320 87153 87990 88831 89676 90525 91378 92235 93096 93961 94830 95703 96580 97461 98346 99235 00129 01026 01927 02832 03741 04654 05571 06492 07417 08346 09279 10216 11157 12102 13051 14004 14961 15922 16887 17856 18829 19806 20787 21772 22761 23754 24751 25752 26757 27766 28779 29796 5.3 Toolkit Setup and Main Menu 5.3.1 Tools required (Figure 5.2): § A computer at the test bench area § USB to RS-232 adaptor § RS-232 to RJ11 adaptor § Cable with 2 ends of phone jacks (RJ11 connectors) § Service Kit Package PC USB to RS-232 adaptor RS-232 to RJ11 adaptor RJ11 cable Figure 5.2 - Tools required 5.3.2 Copy the ‘Service Kit Package’ to your computer. It includes the following: Application for software download Service application Driver for the USB to RS-232 adaptor Figure 5.3 – Service Kit Package 5.3.3 Copy the ‘RM_Toolkit’ folder to the ‘C’ directory. The ‘RM_Toolkit’ folder MUST be copied to the ‘C’ directory to enable software downloads through the Toolkit application. 5.3.4 Double click to open the 5.3.5 Copy the to Desktop. 5.3.6 Install the driver for the USB to RS-232 adaptor following the instructions in Appendix A (The Driver for the USB installation is in the ‘USB to Serial’ folder’ – in the Service Kit Package). 5.3.7 Connect the USB to RS-232 adaptor to your PC, when the USB side is connected to the computer, as shown in Figure 5.4 below. 5.3.8 Connect the USB to RS-232 adaptor to the RS-232 to RJ11 adaptor, as shown in Figure 5.5 below. RS-232 to RJ11 Adaptor Figure 5.4 USB connection to PC 5-6 RS-232 Connector Figure 5.5 USB to RS-232 Adaptor connection to RS-232 to RJ11 Adaptor 5.3.9 Connect the RJ11 cable (phone jack) to the adaptor, as shown in Figure 5.6 and the other side of the cable to Robomow, as shown in Figure 5.7 (for your convenient, lift the bumper for easier access to the communication socket in the mower). Figure 5.6 RJ11 connection to Adaptor Figure 5.7 RJ11 (phone jack) connection to Robomow 5.3.10 The following Figure shows the connections from the computer to the Robomow: Robomow JR11 connector RS-232 connection USB to RS-232 Adaptor RS-232 to RJ11 Adaptor Computer USB connection Figure 5.8 Communication between Robomow and the computer 5-7 5.3.11 Double click on the Toolkit icon in the Desktop to open the Toolkit software. The first page of the Toolkit will be opened, where at the top left side of the display, the following options are available (Figure 5.9): Refer to Refer to 5.3.13 5.3.14 Figure 5.9 Toolkit Toolbar Refer to 5.3.12 Refer to Refer to 5.4.1 5.4.2 Refer to 5.4.3 Refer to 5.4.4 Refer to 5.4.5 Refer to 5.4.6 5.3.12 View – ‘Debug window’ uses for Friendly Robotics diagnostic only. 5.3.13 Settings – choosing the ‘Settings’ menu will open the following display (Figure 5.10): Figure 5.10 Settings menu Choose the ‘Communication settings…’ to set the COM in the PC that the Toolkit box is connected to (Figure 5.11). The ‘Baud Rate’ should be set always to ‘19200’ (default). Figure 5.11 Communication Settings 5.3.14 Help - choosing the ‘Help’ menu will open the following display (Figure 5.12): Figure 5.12 Help Menu 5-8 Press the ‘About RM Toolkit’ in the ‘Help’ menu to confirm that you are using the most updated Toolkit software version, as shown in Figure 5.13. (Ask your distributor or Friendly Robotics for the most updated Toolkit version). Figure 5.13 About RM Toolkit Press the ‘RM Toolkit Help’ to enter the online help. To have an access to the help pages in the website, it is required to enter ‘User name’ and ‘Password’ (Figure 5.14). Please contact your distributor or Friendly Robotics to receive the ‘User name’ and ‘Password’. Figure 5.14 About RM Toolkit 5-9 5.4 Toolkit Options 5.4.1 System View The System View (Figure 5.15) shows the following information in a real time: - Bumper state and analog readings (refer to paragraph 5.4.1.1) - Cover analog readings (refer to paragraph 5.4.1.2) - Rain sensor analog readings (refer to paragraph 5.4.1.3) - Front Wheel analog readings (refer to paragraph 5.4.1.4) - Tilt state (refer to paragraph 5.4.1.5) - Wire sensors information (refer to paragraph 5.4.1.6) - Remote Control (refer to paragraph 5.4.1.7) - Push buttons in the operating panel (refer to paragraph 5.4.1.8) - Battery and Charging (refer to paragraph 5.4.1.9) - Drive information (refer to paragraph 5.4.1.10) - Mow information (refer to paragraph 5.4.1.11) Figure 5.15 System View ‘Open’ / ‘Close’ saved files. When ‘Close’ is displayed there is no communication with the robot and the name of the opened file is displayed as shown below: 5 - 10 Save a file with the displayed values Click on the ‘Close’ to enable communication with the robot 5.4.1.1 Bumper The Bumper block shows the bumper state, where there are four options (Figure 5.16): ‘Clear’ if bumper is not detected. ‘Left’ if bumper is pressed from the left side of Robomow. ‘Right’ if bumper is pressed from the right side of Robomow. ‘Front’ if bumper is pressed from the front side of Robomow. When bumper is detected, the box color is changed to blue. Figure 5.16 Bumper block In addition it shows the analog reading of the bumper sensors for the left and right side. You should check that after the bumper is pressed and released, the analog readings are changed back to the original readings displayed in the ‘Clear’ state (+/-3). If the readings are not changed back to the original values, check for dirt or damage in the bumper, bumper shaft and confirm the screws of the bumper shafts are tighten well. Note: The analog readings of the right and left sensors should not be the same in the ‘Clear’ state, as the distance of the sensor from the magnet is changed between mowers and between the sides. 5.4.1.2 Cover The Cover block shows the cover sensor analog reading (Figure 5.17). When the cover is lifted the box color is changed to blue. When the cover is closed, the reading should be max 5 and when it is lifted it is expected to be higher than 130. Figure 5.17 Cover block 5 - 11 5.4.1.3 Rain Sensor The Rain sensor block shows the analog reading (Figure 5.18). When the reading goes down below 25, the mower detects rain. Normal reading during the season should be 27-29. Figure 5.18 Rain sensor block 5.4.1.4 Front Wheel The Front Wheel block shows the analog reading of the Drop-off sensor (Figure 5.19). When the Front Wheel is on the ground, the reading should be max 5 and when the Front Wheel is lifted it is expected to be higher than130 and the box color is changed to blue. Figure 5.19 Front Wheel block 5.4.1.5 Tilt The Tilt block shows the state of the tilt sensor (Figure 5.20). The tilt sensor is an optic sensor that detects the situation, which the mower is lifted from the front side in more than 60 degrees. When tilt is detected, the box color is changed to blue. Figure 5.20 Front Wheel block 5.4.1.6 Wire Note: While working through the Toolkit, the communication causes to noise in the signal, thus it is recommended to test the wire sensors and the signal through the ‘Special display> Sensors> Wire’ and not through the Toolkit. The Wire block shows the following information (Figure 5.21): - - 5 - 12 State - In / Out of the wire sensors referring to the perimeter wire loop. Amplitude - strength of the signal –will be higher as the detected signal is stronger. Count – digital reading of the sensor readings: 400 – inside the lawn 200 – out of the lawn 0 – no wire signal Gain – increasing the signal strength as needed (changed between 0 to 3, where ‘0’ is for very low increasing and ‘3’ is for the highest increasing). Figure 5.21 Out of the lawn Inside the lawn No wire signal 5.4.1.7 Remote Control The Remote Control block shows if it is activated and which button is pressed (Figure 5.22). The box color is changed to blue when there is transmission from the Remote Control to the mower and the check boxes show, which button is pressed. Manual drive Manual mow Figure 5.22 Remote Control block 5.4.1.8 Push Buttons The Push Buttons block shows if it is activated and which button is pressed (Figure 5.23). The box color is changed to blue when one of the buttons is pressed. Figure 5.23 Push Buttons block 5 - 13 5.4.1.9 Battery and Charging The Battery and Charging shows the following information (Figure 5.24): - Box color is blue when the battery is charged. - Charging Stage - The charging process is divided into three stages: Stage 1 (‘4’ is displayed): Adjust the Charging Power to maintain the max charging current until the battery voltage reaches 29.4V. Stage 2 (‘5’ is displayed): Adjust the Charging Power to maintain a battery voltage of 29.4V. Stage 3 - Floating (‘6’ is displayed): Adjust the Charging Power to maintain a battery voltage of 27.2V until charging process is terminated. - Charging Voltage – When using 0.9A Power Supply: Expected charging voltage in stage 1 – 30.0V (+/-10%) Expected charging voltage in stage 2 – ~30-37V Expected charging voltage in stage 3 – ~35-37V - Charging Current – This is the actual charging current. In stage 1 (4) – Max possible charging current. In stage 2 (5)– Changed to control constant voltage of 29.4V. In stage 3 (6)– 0-0.12A - Charging Power – The Charging Power (PWM) uses to control the parameters in the charging process: In stage one, Robomow changes the Charging Power (PWM) in order to control the max charging current. In stage two, Robomow changes the Charging Power (PWM) in order to control the batteries voltage to 29.4V. In stage three, Robomow changes the Charging Power (PWM) in order to control the batteries voltage to 27.2V. It is expected to be 0-1%. - Battery Voltage – Expected batteries voltage in stage 1 (4) – goes up until it reaches 29.4V. Expected batteries voltage in stage 2 (5) – 29.4V Expected batteries voltage in stage 3 (6) – 27.2V - Battery Temperature – battery temperature in Celsius. - Battery Type – Shows the battery type. Figure 5.24 Battery and Charging block 5 - 14 5.4.1.10 Drive The box shows the following information, where ‘L’ is for the left drive motor and ‘R’ is for the right one (Figure 5.25): - Box color is blue when the drive is activated. - Direction – shows the direction (0-359º), where it becomes zero in every ‘GO’ pressing. - Distance – accumulated distance (cm), where it becomes zero in every ‘GO’ pressing. - Power - Drive power (%) - Current - Actual drive motor current. No load (wheel in the air) – expected current 0.2-0.3A. Over current threshold (default) – 2.0A. - Temperature - The drive motor temperature. Drive over-heat threshold – 85Cº - Speed - The speed in percent from the max possible speed. - Ticks - The counter of the odometer ticks (turns of the drive motor). - Over-Current - shows indication for drive hardware over-current. Figure 5.25 Drive block 5.4.1.11 Mow The box shows the following information (Figure 5.26): - Box color is blue when the mow is activated. - Power – shows the mow power (%). - Current – shows the actual mowing current (should be around 1.0A in no load). - Temperature – shows the mow motor temperature. The mow over-heat threshold is 10 minutes above 90Cº or 1 sec 100Cº. - Over-Current – shows indication for mow hardware over-current. Figure 5.26 Mow block 5 - 15 5.4.2 Tests The ‘Tests’ page enables to perform test for the following systems/sensors, as shown in Figure 5.27 below: Figure 5.27 Test page All the tests above are available to be performed directly through the ‘Service> Tests’ menu in the Robomow LCD too. Press the key of the system you want to test. The results of the tests (Figure 5.28) will be a ‘Passed’ or ‘Fail’ with a fault code number. Refer to the fault code in Section 5.7 Diagnostics Fault Codes. Figure 5.28 Test results For more details of how to perform the tests procedures refer to section 5.5.3 Tests Procedures. 5 - 16 5.4.3 Calibrations The ‘Calibrations’ page enables to perform the calibrations the following systems/sensors, as shown in Figure 5.29 below: Figure 5.29 Calibration page All the calibrations above are available to be performed directly through the ‘Service> Calibrations’ menu in the Robomow LCD too. Press the key of the system you want to test and simply follow the instructions displayed in the Robomow LCD. The results of the tests will be a ‘Passed’ or ‘Fail’ with a fault code number. Refer to the fault code in Section 5.7 Diagnostics Fault Codes. For more details of how to perform the calibrations procedures, refer to section 5.5.2 Calibrations Procedures. 5.4.4 Settings The ‘Settings’ page enable to receive the settings from the robot, to change them in the computer (if required) and to send back the updated settings to the robot. This can be use in service mostly when it is required to replace Main Board – this option enable to keep the settings of the robot (such as Weekly program, entry points, work time and all the others) before the faulty Min Board is replaced, to replace Main Board to the new one and to send back the same settings to the Main Board. The ‘settings’ page is divided into three main sections, where the upper side of the screen shows the ‘Zones Setup’ settings (user’s level), the left bottom side shows the ‘User Settings’ (Robomow settings at the user’s level) and the right lower side shows the ‘Service Settings’ (Dealer’s level), as shown in Figure 5.30: 5 - 17 Figure 5.30 Settings page At the bottom of the screen there are four options: Receive Setting From Robot – Press ‘Receive Setting From Robot’ and wait until the display will be updated with the settings from the robot (it may take 40-50 sec). Send Settings To Robot – Press ‘Send Setting To Robot’ and wait until the progress line (the green line at the bottom of the display) is full (it may take few sec). Open / Close – Enables to open a saved file. The file can be opened only when using the Toolkit software. When a file is open the button is changed to ‘Close’ and there is no communication with Robomow. Press the ‘Close’ to enable communication. Save – Enable saving the ‘Settings’ screen as a file. This option is useful in the following: 1. In service when you want to keep the file of the settings so you can use it in the future. 2. When required help from Friendly Robotics in diagnostics of a problem, it is recommended to attached three files (System View, Settings and Information) as it will save questions and time in the diagnostics process. To change the setting, press the sign and choose the required setting. In case the setting is blocked for change, its window color will be gray – only the white boxes are available for updating. All the settings are explained in details in Chapter 2 – Menu Items. 5 - 18 5.4.5 Information The ‘Information’ page shows the ‘Information’ received from the robot (Figure 5.31). It displays the same information that is available in the ‘Information’ menu in the mower, but it is more convenient to see all the information in one page with no need to scroll between all the screens. When required help from Friendly Robotics in diagnostics of a problem, it is recommended to attached three files (System View, Settings and Information) as it will save questions and time in the diagnostics process. Figure 5.31 Information page The ‘Configuration’ is displayed in a different way (figure 5.32) from the way it is displayed in the ‘Information’ menu in the Robomow itself. Main Board: 1 – ESB5000E Software: 1 – RM200 5.2v 25/11/07 2 – RM400 5.4v 25/11/07 Base Station: Software version of the base Station Board 27 à 1.27v 5 - 19 Figure 5.32 Configuration 5.4.6 Downloads This option enables to download software version from the computer to the Robomow using the Toolkit application. There is another option to download software through the FTP application (please refer to Appendix A numbers 1 to 21). 5.4.6.1 Choose the ‘Download’ page and press the ‘Download Software Version’ button (Figure 5.33): Figure 5.33 Download Software Version 5.4.6.2 Perform reset in Robomow (Figure 5.34) before proceeding to the software download process by one of the following options: a. Press the On/ Off button continually for 4 seconds (there is no indication from Robomow after the reset is done). b. Remove the batteries fuse from Robomow for 2 seconds and reinsert. Press OK to proceed. Figure 5.34 Perform ‘Reset’ before software download 5 - 20 5.4.6.3 Choose the software to be downloaded and press the ‘Open’ button (Figure 5.35). Figure 5.35 Choose the software you want to download 5.4.6.4 The display in Figure 5.36 will be opened. Press the ‘Browse…’ button. Figure 5.36 Press ‘Browse’ to find the RM id file 5.4.6.5 Choose the and press the ‘Open’ button (Figure 5.37). Figure 5.37 Choose the RM.id file 5 - 21 5.4.6.6 The new screen with the ID will be displayed. Presses ‘OK’ to proceed in the software download process (Figure 5.38). Figure 5.38 Press ‘Browse’ to find the RM id file 5.4.6.7 Wait until the download process is completed. If the download is completed successfully, the following screen is displayed (Figure 5.39) with ‘Download Process: Succeed’ message at the bottom line. Figure 5.39 Download Process: Success 5 - 22 5.4.6.8 If the download process was completed successfully, you can choose between the following options: a. Continue downloading software to other mower; then you need to press again the , to perform reset and repeat the same process, but with no need to set again the RM ID. It is required to perform Reset in every Robomow after the software download is completed. b. Go out from the ‘Download’ page and change to the other Toolkit options; 5.4.6.9 If the software download process fails, check/ perform the following: - Perform reset to the Robomow before starting the download process; - Check connection to the Robomow; - Check connection to the PC; - Close and reopen the Toolkit application; - Confirm communication is enabled (using the ‘System view’ page of the Toolkit). 5 - 23 5.5 Service Menu Options The Service menu, while accessed under the User Options screen, is not a customer menu option. It is only to be used by a trained service technician and requires a specific 5-digit code to be entered in order to access the sub-menus. Various settings, calibrations and tests are found under the ‘Service’ menu that may be used by the technician. Each of these tests is selectable by simply scrolling through the menu. After completing work in a specific area, perform the test shown in the procedure and then perform the General Test outlined in Section 5.1. This will insure that the repair has been done properly and that the unit functions satisfactorily. The results of some tests will be a pass or fail while others will display a fault code number. Refer to the fault code in Section 5.6 Diagnostics Fault Codes. Please follow the instructions for each test carefully. At the end of each test press the ‘STOP’ button to exit. Continual pressing of the ‘STOP’ button will move you up through the menu levels, until you arrive at the Main Menu. Too busy, lack of time or do not understand the test fully: At least operate the Robomow on the test area in automatic mode, to make sure it is fully operational.. The Robomow has built in warning and indication system that will pop up on the display in Automatic mode in case you forgot to perform any of the needed calibrations after service. 5.5.1 Settings Procedures Only the Special Display is cover in this chapter as all the others settings are explained in Chapter 2 – Menu Items. The ‘Special Display’ is the most useful tool for diagnostics. 5.5.1.1 Special display Choosing the ‘Special display’ option enables to display the relevant parameters to tested process (such as temp, volt and sensor readings) and to perform detailed diagnostics. After a specific display is selected use the ‘STOP’ button to toggle between normal and special display, and the ‘ON/OFF’ button to terminate the special display. Special displays Press GO Sensors Press GO Wire sensors Press GO Charging Confirm Bumper Press GO Temperatures Confirm Front wheel Press GO Behavior Confirm Cover Press GO Drive motors Confirm Mowing motor Confirm Figure 5.33 Special display menu 5 - 24 Base Confirm Wire In this display the LCD will display the following information: ************************************************************************************** 1) Left amplitude 2) left in/out count 3) left gain 4) wire sensor state 5) Right amplitude 6) right in/out count 7) right gain 8) maximal wire gain ************************************************************************************** 1. Left amplitude (Strength of the signal). 2. Left in/out count (400 – in / 200 – out / 0 – no signal). 3. Left Gain (increasing the signal strength as needed). Wire gain (0-Very Low 1-Low 2-Mid 3-High). 4. Sensors state. 0-Both in 1-Right out 2-Left out 3-Both out 5. Right amplitude (Strength of the signal). 6. Right in/out count (400 – in / 200 – out / 0 – no signal). 7. Right gain (increasing the signal strength as needed). Wire gain (0-Very Low 1-Low 2-Mid 3-High). 8. Maximal allowed wire gain (3 in Scan / 1 in Edge). Bumper In this display the LCD will display the following information: ************************************************************************************* 1) Left reading 2) left idle threshold 3) left detection threshold 4) state 5) Right reading 6) right idle threshold 7) right detection threshold 8) sensitive bumper ************************************************************************************* 1. 2. 3. 4. 5. 6. 7. 8. Left reading (A/D). Left idle threshold (A/D reading / 10). Left detection threshold (A/D reading / 10). Sensor state 0=clear 1=left 2=right 3=front Right reading (A/D). Right idle threshold (A/D reading / 10). Right detection threshold (A/D reading / 10) Sensitive bumper detection 0=not detected 1=detected Front Wheel In this display the LCD will display the following information: ************************************************************************************* 1) Reading 2) idle threshold 3) detection threshold 4) state 5) 6) 7) 8) ************************************************************************************* 1. 2. 3. 4. Reading (A/D). Idle threshold (A/D reading / 10). Detection threshold (A/D reading / 10). Sensor state 0=on the ground 1=lifted 5 - 25 Cover In this display the LCD will display the following information: ************************************************************************************* 1) Reading 2) idle threshold 3) detection threshold 4) state 5) 6) 7) 8) ************************************************************************************* 1. 2. 3. 4. Reading (A/D). Idle threshold (A/D reading / 10). Detection threshold (A/D reading / 10). Sensor state 0=closed 1=lifted Charging In this display the LCD will display the following information: ************************************************************************************* 1) Charging voltage 2) charging current 3) Charging PWM 4) charging stage 5) Battery voltage 6) charger current supply 7) charger source 8) stage 1 time ************************************************************************************* 1. Charging voltage (10mV resolution) When using 0.9A Power Supply: Expected charging voltage in stage 1 – 30.0V (+/-10%) Expected charging voltage in stage 2 – greater than 30.0V Expected charging voltage in stage 3 – 34-38V 2. Charging current (10mA resolution) – This is the actual charging current. Stage 1 - Robomow changes the Charging Power (PWM) in order to control the charging current to the max. Stage 2 – charging current is changed between 0.2-07A Stage 3 – 0-0.12A 3. Charging Power (PWM) The Charging Power (PWM) uses to control the parameters in the charging process: In stage one, Robomow changes the Charging Power (PWM) in order to control the max charging current. In stage two, Robomow changes the Charging Power (PWM) in order to control the batteries voltage to 29.4V. In stage three, Robomow changes the Charging Power (PWM) in order to control the batteries voltage to 27.2V. It is expected to be 0-1%. 4. Charging stage: 4 – Stage 1 5 – Stage 2 6 – Stage 3 (Floating) 5. Battery voltage (10mV resolution) Expected batteries voltage in stage 1 – goes up until it reaches 29.4V Expected batteries voltage in stage 2 – 29.4V Expected batteries voltage in stage 3 – 27.2V 5 - 26 6. Charger current supply (in 10mA resolution) The Power Supply current set in the software version. The defaults set in the software are: RM400 Base Station – 0.9A RM400 Winter Charger – 0.3A RM200 Regular Power Supply – 0.9A 7. Charger source 0=unknown 1=Base station 2=Regular charger 8. First charging stage time (hours) Temperatures In this display the LCD will display the following information: ************************************************************************************* 1) Left drive temperature 2) right drive temperature 3) 4) 5) Row temperature 6) Main board temperature 7) 8) ************************************************************************************ 1. 2. 3. 4. 5. 6. Left drive temperature (ºC) Right drive temperature (ºC) Mow temperature (ºC) Main board temperature (ºC) Behavior In this display the LCD will display the following information: ************************************************************************************* 1) Edge distance 2) Last termination event 3) Edge quarters 4) Scan type 5 ) Last turn angle 6) Last leg distance 7) Corner legs number 8) Narrow passage legs number ************************************************************************************* 1. Edge distance (meters) 2. Last termination event (which terminated the head movement during scan) 0 = None 4 = Distance 5 = Time 6 = Wire 7 = Bumper 8 = Front wheel 9 = Drive overcurrent 3. Edge quarters 4. Scan type 1=random 2= parallel 5. Last turn angle during scan (Degrees) 6. Last leg distance during scan in (10cm resolution) 7. Number of corner legs detected 8. Number of narrow passage legs detected 5 - 27 Drive Motors In this display the LCD will display the following information: ****************************************************************************** 1) Left current 5) Right current 2) left temperature 6) right temperature 3) left over-current 7) right over-current 4) over-current count 8) total over-current events ****************************************************************************** 1. Left drive current (10mA resolution) 2. Left drive temperature (ºC) 3. Left hardware drive over-current 0-not detected 1-detected 4. Over-current counter 5. Right drive current (10mA resolution) 6. Right drive temperature (ºC) 7. Right hardware drive over-current 0-not detected 1-detected 8. Total over-current events in the current operation Mowing Motor In this display the LCD will display the following information: ************************************************************************************** 1) Current 2) temperature 3) over-current 4) over-current count 1 5) Motor on/off reason 6) 7) total over-current events 8) over-current count 2 ************************************************************************************** 1. Mow current (10mA resolution) 2. Mow temperature (ºC) 3. Hardware mow over-current (0-not detected 1-detected 4. Over-current counter 1 5. The reason mowing motor is on or off 1 – mow motor is disabled because the mow on/off menu option is set to off 2 – mow motor is halted 3- mow motor is disabled because bumper is detected 4 - mow motor is disabled because front wheel is detected 5 - mow motor is disabled because cover is detected 6 - mow motor is disabled because tilt is detected 7 - mow motor is disabled because robot is during charging 8 – mow motor is disabled because we are during exiting the base due to charging problem 9 – mow motor is disabled because wire sensors are outside the plot for a long time 10 – mow motor is on because we are during automatic operation and mow motor should be on 11 - mow motor is on because we are during manual mowing 12 - mow motor is on because we are during mowing motor stuck test 13 - mow motor is on because we are during mowing test 14 – mow motor is disabled because we are during demo version 15 - mow motor is disabled because we are during final test version 6. Total over-current events in the current operation 7. Over-current counter 2 5 - 28 Base In this display the LCD will display the following information: ************************************************************************************** 1) Primary wire 2) Secondary wire 3) 4) 5 ) Base version 6) Grass sensor reading 7) 8) ************************************************************************************* 1. Primary wire reading 0-1 = disconnected 2 = long cable or poor connection 3-7 = good signal 2. Secondary wire reading 0-1 = disconnected 2 = long cable or poor connection 3-7 = good signal 3. 4. 5. Base station board version 6. Grass sensor reading 0-6 = grass sensor reading 7-15 = grass sensor disconnected 5.5.2 Calibrations Procedures 5.5.2.1 Wire Sensors Wire sensors calibration is the process of teaching the wire sensors their position relative to the mower as well as to the signal of the perimeter wire. Wire sensors Calibrate Figure 5.34 Wire sensors Calibration menu Turn off signal then press GO Turn on signal then press GO Passed Press GO This menu is available just for backup, just in case that a problem was happened while writing to the EEPROM or in case which one of the wire sensor coils is wrapped in the opposite direction to the default. This process is done in Friendly Robotics and there is no need to perform it at any time. 5.5.2.2 Front Wheel Calibration ‘Front wheel’ calibration MUST be performed after Factory default (Main Board) is done Robomow will instruct you to complete the required steps, as shown below: Front wheel Calibrate Place on ground then press GO Lift mower then press GO Figures 2.28 Front wheel Calibration menu 5 - 29 Passed Press GO 5.5.2.3 Bumper Calibration ‘Bumper’ calibration MUST be performed after Factory default (Main Board) is done Robomow will instruct you step by step to complete the required calibrations, as shown below: Bumper Calibrate Close cover then press GO Lift cover then press GO Rotate bumper then press GO Press bumper then press GO Figure 5.35 Bumper Calibration menu A. Close cover Passed Press GO B. Lift cover C. Rotate bumper Rotate bumper for both directions as much you can although it is very difficult to rotate the joystick and the rotating strong is very short 5 - 30 D. Press bumper Press bumper for both directions, once to the right side then to the left (there is no need to press the joystick forwards or backwards). Figures 5.36 Bumper Calibration procedure 5.5.2.4 Voltage Calibration Option to calibrate the batteries voltage. There is no need to perform this calibration at any time, as it is done in the factory. The battery voltage read by the software should be +/-0.2V from the reading done through voltmeter – in case the different is higher then a voltage calibration should be done. 25.2 Voltage Calibrate 25.2V Confirm Figures 5.37 Voltage Calibration menu 5.5.3 Tests Procedures Settings Service Tests Figures 5.38 Tests menu 5 - 31 5.5.3.1 Sensors 5.5.3.2 Drive motors 5.5.3.3 Mowing motor 5.5.3.4 Edge termination Calibrations 5.5.3.1 Sensors The ‘Sensors’ tests menu includes the following tests procedures: Figures 5.39 Sensors tests menu 5.5.3.1 Sensors 5.5.3.2 Drive motors 5.5.3.3 Mowing motor 5.5.3.4 Edge termination 5.5.3.1.1 Wire sensors 5.5.3.1.2 Bumper 5.5.3.1.3 Front wheel 5.5.3.1.4 Cover 5.5.3.1.5 Tilt 5.5.3.1.6 Rain sensor 5.5.3.1.1 Wire Sensors Test The ‘Wire sensors’ tests the operation of the two wire sensors on the mower. This test contains 2 steps. The first step in with wire signal turned on and the second one is with wire signal turned off. Wire sensors Press GO Turn on signal then press GO Turn off signal then press GO Activate motors? Confirm Figures 5.40 Wire sensors test menu Passed Press GO Step1 This step should be performed when robot is inside the plot and wire signal is on. The following message will be displayed to the user ‘Turn on signal – then press GO’ In this test the following is tested: − Wire signal is detected − Robot is inside the plot − Wire readings are ok Step2 This step should be performed when wire signal is off. The following message will be displayed to the user ‘Turn off signal – then press GO’ In this test the following is tested: − Drive motors are turned on in order to see if wire readings abnormal noises are detected (this is done to make sure that the wiring of the wire system was done correctly). If test fails failure number will be displayed (Refer to the fault code in Section 5.6 Diagnostics Fault Codes) and if test passes then ‘Passed’ message will be displayed. 5 - 32 5.5.3.1.2 Bumper Test Press the bumper from different directions. If test fails failure number will be displayed (Refer to the fault code in Section 5.6 Diagnostics Fault Codes) and if test passes then the following will be displayed: Sensor state Bumper not detected Display - Sensitive bumper * Front bumper ^ Left bumper < Right bumper > 5.5.3.1.3 Front Wheel Test If test fails failure number will be displayed (Refer to the fault code in Section 5.6 Diagnostics Fault Codes) and if test passes then the following will be displayed: Sensor state Front Wheel on the ground Display - Front Wheel lifted ^ 5.5.3.1.4 Cover Test If test fails failure number will be displayed (Refer to the fault code in Section 5.6 Diagnostics Fault Codes) and if test passes then the following will be displayed: Sensor state Cover closed Display - Cover lifted ^ 5.5.3.1.5 Tilt Test If test fails failure number will be displayed (Refer to the fault code in Section 5.6 Diagnostics Fault Codes) and if test passes then the following will be displayed: Sensor state Display Tilt not detected - Tilt detected ^ 5.5.3.1.6 Rain Sensor Test If test fails failure number will be displayed (Refer to the fault code in Section 5.6 Diagnostics Fault Codes) and if test passes then ‘Passed’ message will be displayed. 5 - 33 5.5.3.2 Drive Motors This test should be performed when robot is in the air or on a floor and not on the grass where drive over current can occur. Figures 5.41 Drive test wheel in the air If test fails failure number will be displayed (Refer to the fault code in Section 5.6 Diagnostics Fault Codes) and if test passes then ‘Passed’ message will be displayed. 5.5.3.3 Mowing Motor Mowing motors is the process of testing the mowing motor system of the mower. It has one basic level of testing. This test should be performed when robot is not on the grass where mow over current can occur. If test fails failure number will be displayed (Refer to the fault code in Section 5.6 Diagnostics Fault Codes) and if test passes then ‘Passed’ message will be displayed. 5.5.3.4 Edge Termination Is used for testing the edge mode in case, which the mower does not complete the edge all around the perimeter or when the mower does not drive back to the Base Station at the end of the operation. After this test is selected, operate the mower in Edge mode. At the end of the edge, the mower will display a ‘Test result: X’, which is the reason for Edge termination in this performed test. Here are the optional Edge termination reasons: 1 – Minimal Edge quarters count 2 – Maximal Edge quarters count 3 - No change in edge quarters for a long time, which probably means the robot is get stuck 4 - Required edge distance reached 5 - Base station detected in a none Base zone 6 - Base station detected while looking for an entry point 7 - Required entry point reached 8 - Edge ended because of drive over current 9 - Edge ended because of drop-off 10 – Edge ended because robot is stuck in place 5 - 34 5.6 Diagnostics Fault Codes Table Failure Number Failure Reason Solution 1 Left Bumper pressed reading is equal or smaller than Left Bumper idle reading 2 Right Bumper pressed reading is equal or smaller than Right Perform calibration Bumper idle reading Refer to Flow chart 3.2.9.2 3 Difference between Left Bumper pressed reading and Left Bumper idle reading is too small. 4 Difference between Right Bumper pressed reading and Right Perform calibration Bumper idle reading is too small. Refer to Flow chart 3.2.9.2 7 Left bumper disconnected reading < 50 Check wiring Refer to Flow chart 3.2.9.2 8 Right bumper disconnected reading < 50 Check wiring Refer to Flow chart 3.2.9.2 12 Front wheel lifted reading is equal or smaller than Front wheel not lifted reading Perform calibration Refer to Flow chart 3.2.8.1 13 Difference between Front wheel lifted reading and Front wheel idle reading is too small. Perform calibration Refer to Flow chart 3.2.8.1 22 Cover lifted reading is equal or smaller than Cover not lifted reading Perform calibration Refer to Flow chart 3.2.9.3 23 Difference between cover lifted reading cover not lifted reading is too small. Perform calibration Refer to Flow chart 3.2.9.3 31 Bad battery voltage calibration Perform voltage calibration 32 41 42 43 44 Perform calibration Refer to Flow chart 3.2.9.2 If auto battery type detection does not work then constant battery type setting should be used Perform calibration Wire signal off reading is higher than wire signal on reading Refer to Flow chart 3.2.10.1 Difference between wire signal off reading and wire signal on Perform calibration reading is too small. Refer to Flow chart 3.2.10.1 Unknown battery type wire reading indicates calibration failed because we detect that in/out readings are bad Wire reading indicates calibration failed because we detect that robot is not inside the garden during the calibration with signal on 45 Wire test failed because wire signal is not detected 46 Wire test failed because robot is not inside the plot 47 Wire test failed because of invalid wire in /out count during the wire signal on test 48 Wire test failed because wire signal is detected 49 Wire test failed because of valid wire in /out count during the wire signal off test 5 - 35 Perform calibration Refer to Flow chart 3.2.9.2 Perform calibration Refer to Flow chart 3.2.10.1 Perform calibration Refer to Flow chart 3.2.10.1 Failure Number Failure Reason Solution Check wiring Refer to Flow chart 3.2.3.2 Check wiring Refer to Flow chart 3.2.3.2 51 Mow thermistor disconnected 52 Mow motor is disconnected 53 Mow test failed because of mow overcurrent detection Refer to Flow chart 3.2.3.2 54 Mow test failed because of mow motor is disconnected Check wiring Refer to Flow chart 3.2.3.2 55 Mow test failed because mow motor was disabled for some reason during the test 61 Left drive thermistor disconnected 62 Right drive thermistor disconnected 63 Left drive motor disconnected 64 Right drive motor disconnected 65 Left drive odometer problem 66 Right drive odometer problem 67 Drive test failed because of drive overcurrent detection Refer to Flow chart 3.2.7.1 Drive test failed because of left drive motor disconnection detection Drive test failed because of right drive motor disconnection detection Check wiring Refer to Flow chart 3.2.7.1 Check wiring Refer to Flow chart 3.2.7.1 Check wiring Refer to Flow chart 3.2.7.1 Check wiring Refer to Flow chart 3.2.7.1 68 69 Check wiring Refer to Flow chart 3.2.7.1 Check wiring Refer to Flow chart 3.2.7.1 Check wiring Refer to Flow chart 3.2.7.1 Check wiring Refer to Flow chart 3.2.7.1 Check wiring Refer to Flow chart 3.2.7.1 Check wiring Refer to Flow chart 3.2.7.1 70 Drive test failed because of left drive odometer problem 71 Drive test failed because of right drive odometer problem 72 Drive test failed because left drive motor current is too high 73 Drive test failed because right drive motor current is too high Refer to Flow chart 3.2.7.1 81 Rain sensor disconnected 5 - 36 Refer to Flow chart 3.2.7.1 Check wiring 5.7 Operation Stop Cause Table Stop cause number Message 1 No message 2 3 4 No message No message Close cover 5 Splice wire 6 Splice wire 7 Check wire 8 Check wire 9 Rain detected Start inside 10 Or Change wires in plot connector 11 No wire signal 12 15 16 No wire signal Replace blade after 200 hours Change wires in plot connector Failure: 32 Recharge battery 17 Low battery 18 No message 19 20 Time completed Start elsewhere 21 Start elsewhere 22 Check mow height 23 Check mow height 24 25 26 27 28 Rain detected Drive overheat Mow overheat Mow overheat Drive overheat 29 Check power 30 High temperature 13 14 5 - 37 Description User tries to initiate operation before the one time setup is completed STOP button is pressed during automatic operation Edge termination test is completed Cover lift is detected The base station indicates that primary wire loop is disconnected The base station indicates that secondary wire loop is disconnected The base station indicates that primary wire loop connection is poor The base station indicates that secondary wire loop connection is poor The base station indicates that the grass is wet Automatic operation was initiated by the user while robot is not inside the plot Wires in plot connector are inverted No wire signal is detected when automatic operation is initiated No wire signal is detected during automatic operation Mowing blade should be replace Wires in plot connector are inverted Battery type is unknown Low battery voltage is detected during automatic operation Very low battery voltage is detected during automatic operation Remote control communication is detected during automatic operation Timeout is detected during automatic operation Drive over-current is detected during automatic operation Drive over-current is detected during remote control operation Mow over-current is detected during automatic operation Mow over-current is detected during remote control operation Rain is detected during automatic operation Drive overheat is detected during automatic operation Mow overheat is detected during automatic operation Mow overheat is detected during remote control operation Drive overheat is detected during remote control operation Robot got off the base station because charging voltage is not detected Robot got off the base station because battery temperature is too high Stop cause number Message 31 Low temperature 32 Charging failure 34 35 36 Stuck in place (if robot is inside the plot) Cross outside (if robot is outside the plot) Start elsewhere Base problem Bumper pressed 37 Frnt wheel prob 38 Frnt wheel prob 39 No message 40 No message 33 44 Remove fuse then check blade No message 45 Stuck in place 46 Reposition Base 47 No message 48 Key pressed 49 Remove fuse before lifting 601 Bumper - calibrate 602 Bumper - calibrate 603 Bumper - calibrate 604 Bumper - calibrate 605 Bumper - calibrate 606 Bumper - calibrate 607 Failure: 7 608 Failure: 8 42 5 - 38 Description Robot got off the base station because battery temperature is too low Robot got off the base station because charging current is not detected Robot is stuck in place during automatic operation. Consecutive turn movements are received without any heading movements Wire escape is detected during automatic operation Robot failed to connect to the base station for several times Bumper detected when automatic operation is initiated Front wheel detected during when automatic operation is initiated Front wheel detected for a long time during automatic operation Power Supply overheats detected during the charging process. Delayed operation was stopped because operation was activated during the inactive hours Mow motor is stuck ON/OFF button is pressed during automatic operation Robot is stuck in place during automatic operation. Robot is performing forward legs without receiving any termination event such as wire or bumper, which means it, is stuck. Robot received a bumper event while searching for the Base station during the Base position one time setup operation Robot waited in place for too long during the wire position test waiting for the user to continue the test STOP / ONOFF button is constantly pressed and user is trying to start an automatic operation. Tilt is detected Represents Failure number 1 (look under system for more information) Represents Failure number 2 (look under system for more information) Represents Failure number 3 (look under system for more information) Represents Failure number 4 (look under system for more information) Represents Failure number 5 (look under system for more information) Represents Failure number 6 (look under system for more information) Represents Failure number 7 (look under system for more information) Represents Failure number 8 (look under system for more information) failures failures failures failures failures failures failures failures Stop cause number Message 611 Failure: 11 612 Front wheel - calibrate 613 Front wheel - calibrate 614 Front wheel - calibrate 621 Failure: 21 622 Bumper - calibrate 623 Bumper - calibrate 624 Bumper - calibrate 641 Wire - calibrate 642 Wire - calibrate 651 Failure: 51 652 Failure: 52 661 Failure: 61 662 Failure: 62 663 Failure: 63 664 Failure: 64 665 Failure: 65 666 Failure: 66 681 Rain sensor disconnected 801 No message 802 No message 803 No message 804 No message 805 No message 900-901 5 - 39 Error Description Represents Failure number 11 (look under system failures for more information) Represents Failure number 12 (look under system failures for more information) Represents Failure number 13 (look under system failures for more information) Represents Failure number 14 (look under system failures for more information) Represents Failure number 21 (look under system failures for more information) Represents Failure number 22 (look under system failures for more information) Represents Failure number 23 (look under system failures for more information) Represents Failure number 24 (look under system failures for more information) Represents Failure number 41 (look under system failures for more information) Represents Failure number 42 (look under system failures for more information) Represents Failure number 51 (look under system failures for more information) Represents Failure number 52 (look under system failures for more information) Represents Failure number 61 (look under system failures for more information) Represents Failure number 62 (look under system failures for more information) Represents Failure number 63 (look under system failures for more information) Represents Failure number 64 (look under system failures for more information) Represents Failure number 65 (look under system failures for more information) Represents Failure number 66 (look under system failures for more information) Represents Failure number 81 (look under system failures for more information) Unintended departure from base station occurred because no charging voltage was detected Unintended departure from base station occurred because no charging current was detected Unintended departure from base station occurred because battery temperature overheat was detected Unintended departure from base station occurred because battery temperature overcool was detected Manual departure from base station occurred because GO button was pressed System dead end. This should not happen; if it does a software fix is required. 5.8 Battery Voltage Measurement There are few options to measure the actual batteries voltage (not through the software version): 1. Using special tool (Figure 5.42) A. Building the tool. The following parts are required: ESB5004C Communication Board RL Manual Controller cable Power Supply cable + plug Figure 5.42 Special tool for batteries voltage measurement B. Exposed the wire ends of the Power Supply cable and solder them to the Communication Boards, as shown in Figure 5.43 below: 6 The ‘+’ (cable with the white line) is soldered to pin ‘1’ and the ‘-‘ to pin ‘6’ + 1 Figure 5. 43 Cable soldering to the board C. Connect the RL Manual Controller cable to the Communication Board (Figure 5.44) and the tool is ready for use. Figure 5.44 RM Voltage measurement tool 5 - 40 D. Lift the RM bumper and connect the cable to the communication board in the Robomow, as shown in Figure 5.45 below: Figure 5.45 Tool connection to the Robomow E. Measure the battery voltage of the RM, using voltmeter, as shown in Figure 5.46 below: Figure 5.46 Measuring the batteries voltage 2. Through the Charging Contacts (Figure 5.47) Lift the bumper and measure the voltage on the charging contacts as shown in Figure 5.8 below. Multiple the measured voltage by 2.73 to receive the batteries voltage. For example: The charging contacts voltage in the Figure below is 9.46V. Batteries voltage = 9.46 [V] x 2.73 = 25.83 [V] Figure 5.47 Charging contacts voltage 5 - 41 3. Directly on the Batteries contacts (Figure 48) If the Front Cover Chassis is removed during service, then it is possible to measure the batteries voltage directly from the batteries, as shown in Figure 5.8 below. Figure 5.48 Batteries voltage measurement 4. Through the software The ‘Battery voltage’ can be read in two places in the menu: 1. In the ‘Information’ menu: ‘Information > Battery > Battery voltage’ (Chapter 2 section 3.2). 2. In the ‘Service’ menu: ‘Service > Settings > Special display > Charging’ (Chapter 4.1.1). 5.9 Charging Current Measurement There are few options to measure the actual batteries voltage (not through the software version): 1. Using special tool (Figure 5.49) A. Tool Description: Connection to Charging Adaptor Connection to Multi-meter Power Supply plug Connection to Power Supply PCB0017B 5 - 42 Figure 5.49 Measuring the charging current B. Preparing the tool: - Take a Power Supply Plug from a faulty Power Supply and cut about 30cm wire length. - Remove the wire isolation from both wire ends. - Identified the positive (‘+’) cable comes from the Power Supply plug à the cable with the white lines marked along it (Figure 5.50) and solder it to the red cable in the 3 pin connector (available from Friendly Robotics). It is recommended to use a rubber shrink or other isolation on the soldering point. - Connect the two negative (‘-‘) wire ends, from the power supply plug and from the 3-pin connector, to banana plug using a screwdriver. - Connect the 3-pin cable to the DC socket (PCB0017 – available from Friendly). The wire with the white lines is the ‘+’ Banana plug Power Supply plug Red is the ‘+’ PCB0017B Red is the ‘+’ Figure 5.50 Tool Assembly C. Charging current measurement – - Connect the 3-pins connector to PCB0017B - Connect the DC plug of the tool to the Robomow charging contacts through the Charging Adaptor. - Connect the two banana plugs to the ampere-meter. - Read the charging current from the ampere-meter. 5 - 43
