This guide describes how to replace the side ultrasound sensor units on specific hardware versions of MiR100 and MiR200 robots in a way that resembles that of MiR100 and MiR200 HW 5.0.

In MiR100 and MiR200 HW 5.0, the side ultrasound sensor units are fastened more robustly than in previous versions of the robots and come in isolated casings, making them sturdier and more durable. Using this guide, you can update the ultrasound sensor units on MiR100 HW 3.0 to 4.0 and MiR200 HW 2.0 to 3.0 to have the same advantages.

The groups below are used throughout the guide to identify steps that are relevant for your robot. Identify which group your robot belongs to before beginning the guide so you know which steps to follow: 

• Group 1 (450232) - MiR100 HW 3.0

  • MiR100 robots with serial numbers 180100003001081 – 190100003001335

• Group 2 (450059) - MiR100 HW 4.0

  • MiR100 robots with serial numbers 190100004001336 – 190100004001526

• Group 3 (450232) - MiR200 HW 2.0

  • MiR200 robots with serial numbers 180200012000608 – 190200012000697

• Group 4 (450059) - MiR200 HW 3.0

  • MiR200 robots with serial numbers 190200013000906 - 190200013001103

Things you'll need

• 1 × three-claw drill

• 1 × T20 bit

• 1 × T10 bit

• 1 × standard 6.5 bit-holder

• 1 × Ø4.2 mm HSS drill bit

• 1 × 7 mm wrench

• 1 × pair of standard needle-nose pliers

• 1 × screwdriver (bits may vary)

Kit contents

All kits regardless of HW version contain the following:

• 2 × M4 self-locking nuts

• 3 × M4 X 10 Panhead T20

• 1 × ultrasound sensor bracket

• 2 × M3 X 10 Panhead T10

• 1 × ultrasound sensor unit

Before replacing the ultrasound sensor unit

Step 1: Turn off the robot, and remove the top cover. To turn off the robot, press the blue Power button.

Step 2: Disconnect the battery by pressing the Battery disconnect switch. When the switch clicks, the battery is disconnected. To reconnect the battery, turn the Battery disconnect switch clockwise.

Step 3: Turn off the power relays in the front-left corner of the robot. Make sure to turn them off starting with the inner-most relay.

Replacing the ultrasound sensor unit (Group 1 and 3)

Step 1: Mount the ultrasound sensor unit with the two supplied screws. The plastic can give a bit of resistance. Be aware that the socket pins must be positioned as shown below.

Step 2: Demount the front cover by removing the two screws (bits may vary).

Step 3: Push down on the cover so that the plate slit is released from the robot.

Step 4: Take off the front cover. Be aware of the wired connections attached to the front cover (the red arrows). Take note of the numbering on the wires and their respective connections. The notation is for later use when reassembling the cover and its wiring. When seen from above, the two front ultrasound scanners are connected with wire 127 and 128 respectively. When you reattach the wiring for the sensors (see Step 13), it is extremely important that the ground wires (the outer yellow wire of the four small wires) face left when seen from above on both wire 127 and 128, as shown with the red arrows in the image below.

Step 5: Put aside the front cover while it is still attached to the LED-wire. Turn the swivel wheel away to clear the working area.

Step 6: Disconnect the socket from the side ultrasound sensor.

Step 7: Remove the two existing rivets on the outside of the robot by drilling out the rivets with a Ø4.2 mm drill at the very center of the rivets.

Step 8: Remove the two existing rivets on the inside of the robot by drilling out the rivets with a Ø4.2 mm drill at the very center of the rivets.

Step 9: Drill the two indicated holes with a Ø4.2 mm drill. Be careful not to drill through any of the wiring.

Step 10: Remove all residual shreds and rivet residue from the robot.

Step 11: Mount the new side ultrasound sensor with the supplied screws.

Step 12: Place the supplied self-locking nuts (blue arrows), and reconnect the ultrasound sensor by replacing the existing socket on the new ultra sound sensor (red arrow).

Step 13: Reassemble the electrical sockets and screw configurations as noted in Step 4. When you reattach the wiring for the new side sensors, it is extremely important that the ground wires (the outer yellow wire of the four small wires) face up on wire 154 (the left connection when seen from straight ahead) and down on wire 150 (the right connection when seen from straight ahead), as shown with the red arrows in the image below.

Step 14: Remount the front cover. Make sure the recess in the cover is mounted on the plate slit firmly.

Step 15: Mount the two existing screws in the respective threaded holes and fasten firmly.

Replacing the ultrasound sensor unit (Group 2 and 4)

Step 1: Mount the ultrasound sensor with the two supplied screws. The plastic can give a bit of resistance. Be aware that the socket pins must be positioned as shown below.

Step 2: Turn the swivel wheel away from the working area.

Step 3: Remove the two existing screws that hold the bracket in place.

Step 4: Remove the socket from the existing ultrasound sensor by pulling it.

Step 5: Insert the existing socket in the new ultrasound sensor. Make sure the socket is inserted completely, and that the wiring turns the same way as it did before.

Step 6: Insert the supplied screws in the existing threaded holes in the battery box. Make sure both screws are fastened firmly.