Magnaflux EV6000 User manual

© 2016 Magnaflux Page 1 Magnaflux-SRVC-TS032
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Rev. 1
EV-6000 LED UV Lamp Repair Technique Sheet

© 2016 Magnaflux Page 2 Magnaflux-SRVC-TS032
Issued: Mar 2016
Rev. 1
Repairs that are possible on the EV-6000 (Refer to Page 5 in the EV-6000
Manual for exact part location and part numbers)
A. Replacement of Rear Cover Gasket (Index #10)
B. Replacement of “On/Off” Power Switch (Index #12)
C. Testing and Replacing EV6000 Power Cable (Index #17)
D. Testing and Replacing EV6000 Power Supply (Not shown in manual)
E. Replacement of EV6000 LED Assembly (Index #7) — Note: Only complete replacement
of the EV6000 LED Assembly is authorized. No repairs are possible and the optic lens
are not field replaceable.
NOTE #1: Replacement of the UV filter, filter gasket and front cover gasket (Index #’s 3, 4
and 6)— Instructions are located on page 4 of the EV6000 manual.
NOTE #2: Anytime the rear cover is removed, the rear cover gasket should be inspected for
any signs of degradation, deformation, or tears. If anything unusual is observed, replace
the gasket.
Tools needed to perform work:
1. 2.5 mm Hex Key Wrench (Used for LED Array Assembly)
2. 3 mm Hex Key Wrench (Used for removal of front and rear covers
3. 22 mm wrench or crescent wrench (only needed if replacing “On/Off” Power Switch)
4. Needle nose pliers (only needed if replacing “On/Off” Power Switch)
5. AC/DC voltmeter — Capable of reading 115/230 volts AC and 24 volts DC
Additional items needed if replacing the EV6000 LED Assembly:
1. Static control mat with grounding protection
2. Techspray Silicone Free Heat Sink Compound 1978-DP (4 oz. tube). Please note that
other silicone free heat sink compounds have not been tested for compatibility with the
EV6000 LED Array Assembly and therefore are not authorized to be used.

© 2016 Magnaflux Page 3 Magnaflux-SRVC-TS032
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Replacement Procedures
Prior to starting any repairs — the EV6000 should be disconnected from
the power supply.
A. Replacement of Rear Cover Gasket
1. Using the 3 mm hex key wrench, loosen and remove the 4 shoulder bolts that hold on
rear cover shown in Figure 1.
2. Once the 4 shoulder bolts are removed, carefully lift the rear cover off of the EV-6000.
The rear cover gasket may or may not come off with the rear cover.
3. In order to replace the rear cover gasket, you will have to remove the electrical part of
the “On/Off” switch called the micro-switch This is easy to do — but it is also easy to
break the switch. Refer to Figure 2 on the following page and follow the instructions to re-
move the operational part of the “On/Off” switch.
Figure 1
Shoulder BoltsShoulder Bolts

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Rev. 1
Figure 2
Guide Pins that hold the opera-
tional part of the “On/Off” switch
in place. There is a set on each
side of the gray holder.
Rear cover gasket is
on the rear cover
Wires on switch are
on the bottom two
terminals
4. Grasp the micro-switch portion of the “On/Off Switch” with your forefinger & thumb and tilt
the switch in the gray holder until the two guide pins on the switch come out of the guide
pin holes of the gray holder. Then tilt the switch in the opposite direction so that the other
two guide pins on the switch comes out of the guide pin holes on the opposite side.
NOTE: You may have to rock the switch back and forth to free the switch.
5. Once switch is removed, you can now easily replace the rear cover gasket.
6. Once rear cover gasket is replaced, insert the micro-switch back into the gray switch hold-
er, ensuring that the two wires on the micro-switch are in the same configuration (closest
to the bottom of the EV6000). You will know when the micro-switch is in it’s proper posi-
tion as the guide pins on each side of the switch will lock into the guide pin holes on the
gray micro-switch holder.
7. Place rear cover onto EV6000 and insert the 4 shoulder bolts removed in step A.1 using
the 3 mm hex key wrench until they stop (little or no pressure required to do this. The
tighten the 4 shoulder bolts an additional 1/8—1/4 turn.

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B. Replacement of “On/Off” Power Switch
1. Perform steps A.1 through A.4 “Replacement of Rear Cover Gasket
2. Using 22 mm wrench or small crescent wrench, remove the nut that holds on the mechani-
cal portion of the “On/Off” Power Switch as shown in Figure 3. Note: Pink Post-It note is
shown in Figure 3 so that the nut can be seen.
3. Once nut is removed, the mechanical portion of the “On/Off Switch” will slide out easily.
4, Insert new mechanical portion into hole with the gray micro-switch holder aligned so that
the sides as shown in Figure 3. Screw on nut by hand until tight. Then tighten nut with
wrench an additional 1/8”.
5. Using needle nose pliers, remove the electrical leads from the micro-switch portion of the
“On/Off Switch” as shown in Figure 4. You will have to move the connector back and forth
in order to remove the lead from the terminal on the micro-switch.
Figure 3
Nut that holds on me-
chanical portion of
“On/Off” Switch.
Figure 4