CCFL Energy saver lamp repair instructions

CCFL energy saver lamp repair tutorial

How to open and disassemble a ccfl energy lamp

Here is my YouTube video supporting this document:

Here is my YouTube video supporting this document Hindi/ Urdu version :

Use of ccfl or cfl light bulbs

CCFL or CFL light bulbs are very commonly used everywhere. In the last three decades they were very popular and still are considered excellent as electrical lighting source. They are reliable and energy saving light sources. Their light quality is excellent as they have light close to daylight.

Having all good features, they have problems also. First they have definite tube light. Second they have electronic ballast circuit with is going sometimes defective. The good news is they are totally repairable now a days. Their parts like glass tube or glass element and other electronic parts are easily available. All they need are replacement parts which restores the lamp to new life. The parts price is also very low. Their repair is a cost effective solution as for the 1/5th of the price of the lamp one can restore the defective lamp to a new one.

CCFL light ballast circuit details

Here is the typical circuit for a CFL lamp electronic ballast:

Typical CFL lamp circuit showing all components

First of all you should verify that the lamp is not glowing by inserting it in 220V lamp holder.

Open the cover of the lamp ballast circuit using a small screw driver.

Carefully look at the circuit and look for any burning mark or any burnt or broken component.

Turn your multimeter selector switch or dial to ohm or continuity range.

Check the continuity of the two power prong of the lamp to the lamp circuit. There should be continuity from both prongs to circuit. otherwise check for blown line fuse i one of the wires.

If continuity is there, you should check for lamp heater filament continuity. There should be some 5 to 10 Ohm resistance in each filament. If there is no continuity of specified resistance or open circuit, the grass element filaments are fused and the glass needs replacement.

Put the lamp in a plastic bag and break the glass tube using some metal like a file or something. Break the glass inside the bag to protect you from glass chunks and from gas inside the tube.

Now look at the lamp and you will see the fused filament easily.

Now remove all four wires of the broken lamps from the pcb pins to remove the circuit pcb from the lamp.

Now break the remaining of the glass tube chunks and clean the lamp cover for new tube.

Now put four small piece of 1 mm glass fiber slew on wires to prevent them from shorting.

Now insert the new glass to the cover by passing the wires throw the plastic cover.

Now secure the glass tube temporarily by fixing it to the plastic cover using sticking tape pieces.

Now use some glue to fix the lamp glass with cover. I am using wood glow Vinamol Dura. You can use any glue of your choice.

Put some quantity of glue on glass and cover and spread it using a screw driver. Keep the lamp for some 24 hours to settle and dry the glue.

After the glue is settled, fix all the four wires on the ballast circuit board to make the connections complete.

Now fix the lamp covers and secure its locks.

Now verify your repair by powering up the lamp. The lamp should glow perfect with the new glass tube.

• Tweet
• Share
• Share
• Share
• Share