Avi's page for iRobot Roomba 5xx / 6xx / 7xx / 8xx Battery pack rebuild

How did I mod (modify) and rebuild iRobot Roomba battery pack?

I my Roomba 560
(Well... I still do...)


This page is about rebuilding Roomba's battery pack.
After about 1.5-2 years of regular use and charge, Roomba will gradually start decreasing
its working time till a point it will stop working in a middle of its cleaning cycle.
This is the point where you should start considering replacing the battery pack.

You may purchase a new genuine iRobot 3000mAh battery pack for ~US$70 (July 2014),
a 3rd party pack for a little less, or you can rebuild your own pack for half the price and get better capacity.

Note:
This page describes Roomba 560 but it is the same for all 5xx 6xx 7xx 8xx series models that uses the shown type of battery pack

This fix / rebuild is ONLY for those with electronics and mechanical knowledge and skills.

Warning:
This fix / rebuild is NOT recommended by me
nor by iRobot and will void product warranty !
If you follow this guide, you do it on your own risk !


 

A. Preparing for the rebuild:

Suggested tools and materials:
  • Hand tools such as pliers, screwdrivers, x-acto knife etc.
  • Solder iron and related soldering tools and materials.
  • Hot-air gun.
  • A multimeter / multitester / VOM.

  • 12 Sub-C NiMH batteries with tabs. 3400mAh or higher
  • 70mm diameter heat shrinkable tube.
    You'll need 180mm (7") in length for 1x pack.
  • Some kind of thin adhesive tape.

How to rebuild Roomba's battery pack?

Roomba's battery pack is made of 12x Sub-C 1.2V batteries connected in-series to produce 14.4V.
Batteries are packed in a shrinkable sleeve and includes a special connection part
that incorporates a thermistor which protects from excessive heat.
Rebuild a new pack uses new batteries and the connection part taken from the fault pack.


1. Schematics of the battery pack showing front and rear battery raws.
Avi's CHM mod 1

2. Batteries soldering points
Avi's CHM mod 1

3. Top view of genuine battery pack and rebuild pack
(Image shows soldered batteries before packing and w/o connection part)
Avi's CHM mod 1

4. Bottom view of genuine battery pack and rebuild pack
(Image shows soldered batteries before packing and w/o connection part)
Avi's CHM mod 1

B. Disassembly of the battery and rebuilding the new battery pack
Note: It is advised to use hand screwdriver for fine torque control.

1. Place the Roomba top down on a solid work surface
Remove the screw from the rotating side brush and gently pull it out
Avi's CHM mod 1

2. Remove the four screws holding the bottom plate and remove the bottom plate
Avi's CHM mod 2

3. Take out the battery, lift it using the 2 tape tabs.
Avi's CHM mod 3

4. Arrange batteries according the above A1 schematics image.
Mark each battery with + and - signs on its side to avoid mistakes.

* This image shows 3400mAH NiMH batteries, any mAh may be used
based on how much you want to increase working time/battery cost.
Avi's CHM mod 4

5. Remove (-) tab from each battery.
(-) side has a larger area that makes it easy for the soldering.
Remove contact's sticker and scratch the metal surface a bit to help soldering.
Avi's CHM mod 5

6. Solder batteries in-series according to above A1 schematics.
When done, check voltage on center + and - contacts to verify ~14.4-15.5DCV
Avi's CHM mod 6

7. Remove the 2 green tape tabs from the fault pack and store it for later use.
Remove shrink sleeve of the fault battery.
* If cut horizontally in the middle, it can be served for the new pack.

Avi's CHM mod 7

8. To disassemble the connection part,
first remove the protective cover on both parts around center batteries
Avi's CHM mod 8

9. Bend the pack to reach connection part.
Avi's CHM mod 9

10. Carefully remove adhesive fill that holds the connection part to the batteries.
Avi's CHM mod 10

11. Take out the connection part
Measure its resistance. It should read ~8.5kOhm (taken from a 3000mAh NiMH battery pack)
Avi's CHM mod 11

12. Wrap adhesive tape around the batteries to hold its structure.
* Loosen it a bit in the gap of the center front batteries to make room for the connection part.
Avi's CHM mod 12

13. Place the connection part in the middle of the pack above the 2 unsoldered batteries.
Avi's CHM mod 13

14. Cut 180mm in length of the 70mm diameter shrinkable tube.

* In case you use the previously removed shrink from the fault pack,
place it over the new pack and wrap with a tape.
Avi's CHM mod 14

15. Insert new batteries pack inside the shrinkable tube. Position it symmetrically.
Use hot air gun to shrink the tube around the batteries pack.
When done shrinking, cut excessive tube from sides of pack.
Avi's CHM mod 15

16. Use sharp knife to cut around the top rib of the connection part.
* You may want to mark it prior of cutting to achieve clean line.
Avi's CHM mod 16

17. Place the 2x previously removed tape tabs on new pack sides.
You have now completed the rebuild of a Roomba battery pack.
Avi's CHM mod 17


C. Assembly - assemble the new battery pack in reverse order to what is listed above (B1-3)
Upon inserting the pack you should hear the restart melody.

D. Voila - you now have a working iRobot Roomba with a new battery pack

 

Have fun and enjoy your Roomba.


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Last update: July 28, 2014

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