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FORUMS General Gear Talk Flash and Studio Lighting 
Thread started 19 Jun 2008 (Thursday) 23:18
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How to: Replace broken 580ex flash tube

 
Rellik
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Jun 19, 2008 23:18 |  #1

Recently at a wedding, I was sitting down for dinner and had placed my camera on the chair next to me. The 580ex was attached to it along with the CP-E3. Of course, the CP-E3 was attached to me, so when I got up, the camera and flash took a short tumble. Took a quick look at it and found the hot shoe mount have cracked. Had a 430ex with me, so I just threw that on and worried about it later.

Got home and the next day, found the 580ex wouldn't fire. After some searching, I figured the flash tube has cracked during the fall. I came across this article on fixing the 550ex:

http://home.fuse.net/p​ets/EOS/550EX/550ex.ht​m (external link)

There were also cross section diagrams for the 550ex in PDFs, but none for the 580ex. The 580ex shouldn't be too different. So I called Canon US parts and had them look up the part for me. Apparently, they don't sell the flash tube separately anymore. Only with the reflector assembly and wiring. I checked with two reps to be sure. Here is the part number:

CY2-4135-000 - Holder Assembly, Main Lamp

Thankfully, the cost was only 30.78 + shipping. The 550ex tube was quoted on the above link for $12, so it wasn't too much. And also I don't have to do any soldering whatsoever. Anyways, here is the new unit.

IMAGE: http://www.generationphotography.ca/potn/580ex/580ex-01.jpg

Disassembly of the head is quite easy. Lift the rubber stickers and it will reveal 4 screws on each side. Remove those. There are also 2 more screws on the flash head. Take those off.

IMAGE: http://www.generationphotography.ca/potn/580ex/580ex-03.jpg

Now you will be slide one half of the housing off. The other half is attached with two screws that you will need to remove. Here is what it looks like with both sides off. There are still wires attached to one side for the wide panel diffuser sensor. I just left it on.

IMAGE: http://www.generationphotography.ca/potn/580ex/580ex-09.jpg

The lamp assembly is held on only by screw (1). Once remove, that black piece will come off as well. There is a spring and holder under (2), so make sure you don't lose that. The spring is used to push the holder down which has a nub on the end that goes into the rails that zooms the head. Also I found it necessary to remove screws (3) so that the lamp assembly could be released.

IMAGE: http://www.generationphotography.ca/potn/580ex/580ex-10.jpg

Take note of how the wires are placed in (1). There is an extra wire, that you find in (2). It is for some sensor, and you will need to detach that and place it on the new one.

IMAGE: http://www.generationphotography.ca/potn/580ex/580ex-12.jpg

Here is a close up. As you can see, (1) goes inside (2). But inside (2), there is also part (3) and (4). Not sure what they are, but (3) is on the bottom, then (4) goes on top, then (1) is inserted into (2).

IMAGE: http://www.generationphotography.ca/potn/580ex/580ex-13.jpg

You will need to loosen the PCB from the white housing by removing the two screws below. You need to do this to route the connector that you see in the first picture to the outside. Also, there are tape that holds the PCB down, so you will need to lift those to get it loose.

IMAGE: http://www.generationphotography.ca/potn/580ex/580ex-14.jpg

Now reattach everything and you should be set. I replaced my shoe mount as well and that was a piece of cake. In case you want the part number, it is: CY2-1227-000 @ $3.50 each.

Here you can see my old lamp assembly. Clearly, the middle has cracked along with some micro cracks around it. As you can see, the white rubber part is ripped. White taking it apart, I found the rubber there has melted to the flash tube. Making it impossible to remove without damaging that part. So, if you are able to just get the flash tube separately, you will need to get that rubber part as well. On the right is the broken shoe which I fixed with some super glue. It is actually quite stable after fixing, but it is only $3.50 for the part to replace, so why not.

IMAGE: http://www.generationphotography.ca/potn/580ex/580ex-16.jpg

Disclaimer: Just a word of warning. The capacitors in the flash can hold its charge for a LONG time. And you can get a HUGE shock from it. You should google how to discharge them. I left the flash empty for 2 weeks, and I still got 2 tiny discharge which I felt.

Canon US Part Order number: (732) 521-7230

Everything is in perfect working order now. Very happy with it, and took about an hour to fix. Well worth the savings since Canon wants 100+ to fix.

-Derek 40D, 5D, 5D MK II, 1D Mark III
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FlashZebra
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Jun 19, 2008 23:44 |  #2

What a well organized, generous and thoughtful post.

Thank you.

Enjoy! Lon


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René ­ Damkot
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Jun 20, 2008 07:25 |  #3

Nice post :)


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Alexajlex
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Jun 20, 2008 07:30 |  #4

Good info and a very detailed tutorial.


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Jim ­ G
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Jun 20, 2008 07:44 |  #5

Fantastic tutorial - I'll be referring to this should mine ever go.


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Titus213
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Jun 20, 2008 20:10 |  #6

Very nicely done. Great info to have. Thank you.


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SolidxSnake
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Jul 15, 2008 10:52 |  #7

Nice post. I love how Canon will sell OEM parts to pretty much all of their cameras and accessories with no questions asked, and for DIRT cheap.


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ben_r_
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Jul 15, 2008 19:25 |  #8

Excellent tutorial! Thank you for posting this!


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paten
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Jul 16, 2008 02:17 |  #9

nice,... thx for sharing this tutorial bookmarked :)


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Jul 16, 2008 08:44 |  #10

Many thanks for the post. I have a dead 430ex sitting on my desk... the tube is broken. DId you order through Canon or another outfit?

Thanks,
Hatch



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Rellik
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Jul 16, 2008 18:26 |  #11

Thanks guys. I ordered directly through Canon. They just take your orders no question asked and is quite helpful. Also, it is probably the cheapest since there is no middle man involved.


-Derek 40D, 5D, 5D MK II, 1D Mark III
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jlozano180
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Jul 17, 2008 20:18 |  #12

Great post, thanks for the info


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Chris&jess
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Sep 10, 2008 23:14 |  #13

Well, I just did finish repair of one of our 580's with the help of this thread. Mine broke when the wind blew over a light stand during an outdoor fashion shoot. Thankfully, It now works like a charm. I want to add though, that this is a fairly difficult repair.
You will need a very good and very small screwdriver set. I found my phillips wasn't quite small enough. Also, you will need to do this work is a very well lit area as the parts are TINY. The screws are so small you will need to set them in place during reassembly using a small set of needle nose pliers.
And, You will need a little bit of rubber cement that isn't mentioned. On photo #6, the little seeing eye item #1 goes into the socket #2. This has a little dab of flexible cement to keep it there as it doesn't really snap into place, but just sort of "fits" into it. You may need to do this repair again some day, so don't use crazy glue or such. Just dab a little dab in one side after you insert it.
Anyway, this repair is doable, but will be a test of your mettle. I'm an engineer, adept at this sort of thing, had an erector set when I was a kid, and I can walk and chew at the same time. I was really thrilled when I found the tiny thingy that flung out of there, and even more thrilled when I got done.
Oh, I almost forgot, plan on getting shocked a lot. I did my repair three weeks after I broke it, and I got zapped plenty.
Chris


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JMHPhotography
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Sep 11, 2008 14:10 |  #14

I have done the SAME thing. Fortunately, all I broke was the hot shoe itself, and that was also an easy fix. I've also forgotton to secure the flash to the light stand and watched it fall and hit the driveway pavement. The zoom head would just click and not work, but it still flashed, I took it apart and fixed it but got zapped just like you did... haha. Wow that smarts!

Nice tutorial... I'm sure I'll need it at some point.


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gjl711
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Dec 09, 2008 07:01 |  #15

What a great tutorial. I am bookmarking just in case somewhere down the line I need to replace a bulb.


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How to: Replace broken 580ex flash tube
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