Juwel vision 260 light unit repair

Well like most others my juwel light unit went bang, I didn't really take any notice of it because I had back up lights to use but they gave up on me as well so I decided to try repair the juwel unit

I found a thread online that helped me out a good bit, I then took over the kitchen table and started to open the unit up

As you will see I made my cuts along the sides instead of on top, this was to help me when it came time to put it all back together



I got it open and took note of all the wires and numbered them as I disconnected them






I then opened up the ballast itself to see the damage and I was a bit shocked to see and smell this



After I cleaned up all the rough edges from my cutter I gave it a good sanding all around the edges to help the sealer bond better later on, as I was in no hurry to finish I set it aside for a few weeks to dry out as it was soaked on the inside

I was lucky to pick up a brand new ballast in work for free from a contractor we had in redoing our emergency lighting, he also made up a wiring diagram for me as the juwel ballast had 8 wire sockets and the new one had only 6, I found it very easy to follow and here it is just in case anyone else come across this problem, on the top (new) part is the diagram that is on the new ballast and the bottom (old) is how the 8 wires are transferred to fit 6



And here thay are all in place for testing and 1st flick of the switch and we had light





With the test done I put a bit of solder on the twisted wires and a heat shrink cover with insulation tape over that as well



I let the unit run like this for an hour then I turned it off and let it cool then ran it again for another hour, when it was cool again I started to seal it up and make it water tight again, tec 7 is what I used I ran a good heavy beed all around the edges and sat the cover back into place, it looks a bit rough but I don't really care as it will not be seen





Once done I smooth out the sealer a bit and put the tubes back in to test it again and all is good, now it's just a waiting game as I have to leave it for 24 hours to cure fully





I really hope this helps someone as its a job I would recommend for you to try all in hour wise start to finish without testing there was just over an hour in it, il post up pics of it in the tank when its ready

Well done pal
Very good write up,could even get yourself
A few nixers

Cheers very easy to do hardest part I'd say is getting the right ballast

I still have your Ballast in the car lol sorry you can have it for a spare when u come down this way

very good description, danny. I have done this repair myself and the only difference was I cut the hole out at the flat part and left a small 1/4 inch lip and cut a new piece of flat acrylic and it can be finished very neatly. but as you say it is not really visible and is only important if the tank is eventually sold on. the new ballast cost me 17e and it is a great saving on the unreasonable cost of replacing these light units.

irish-zx10r wrote:

I still have your Ballast in the car lol sorry you can have it for a spare when u come down this way

Cheers man, my other job put me on night shifts for the next few months so when I'm not in there or sleeping I'm in the garage trying to make up lost time, but I might be "sick" soon and will be in Carlow again so il take the trip across to you

derek wrote:

very good description, danny. I have done this repair myself and the only difference was I cut the hole out at the flat part and left a small 1/4 inch lip and cut a new piece of flat acrylic and it can be finished very neatly. but as you say it is not really visible and is only important if the tank is eventually sold on. the new ballast cost me 17e and it is a great saving on the unreasonable cost of replacing these light units.

Thanks Derek, there is a few hints now I would do slightly different but it's working for now so if it gives up again i will finish it off better

Can't believe how much of a difference proper lighting makes, here's a short vid

not as irritating as it sounds how much space was there left between the cover and electronics

not much a couple of mm at best, just take your time with it is all you can do