Powerexpert has successfully cloned a control board that the original manufacturer no longer supports, had little documentation, and suffered from many obsolete components.

The scope of work included assessment of the components, re-engineering obsolete components/circuits, developing a modern bill of material, manufacturing, delivery, and integration into the customer’s system. Two board assemblies were successfully commissioned and are currently installed in the customer’s system. While the board passed all factory bench tests, the original board documentation did not include sufficient calibration settings, and it was found that the customer was calibrating their existing boards improperly. Powerexpert provided support by determining the proper calibration settings (over current trip, current regulation, power regulation, and various analog signal scaling) and providing a detailed calibration procedure. The customer is happy as they no longer are at risk of obsolescence; they can confidently purchase drop-in replacement board assemblies with updated copper and redesigned circuits due to obsolete components on their existing boards. Moreover, they now have a detailed and easy to follow calibration procedure to ensure repeatable performance and accuracy with their process.