High Voltage Power Board Design

@engrhasan01

Are you looking for a reliable PCB design engineer to recreate your two-sided through-hole board for high-voltage data communication on a 120V bus bar? I can accurately reverse engineer and redesign your existing PCB to ensure it is fully manufacturable, durable, and suitable for long-term industrial use. With over 5 years of experience in Electrical and PCB design, I specialize in high-voltage layouts, legacy board reproduction, and mixed through-hole assemblies involving RS232 interfaces, transformers, diodes, resistors, capacitors, and DIP ICs. I pay special attention to creepage and clearance requirements to ensure safe operation above 48V, especially in noisy industrial environments. I use Altium Designer and KiCad for PCB design, and Fusion 360/SolidWorks for any mechanical constraints or mounting alignment requirements. Deliverables: • Complete PCB layout project files • Manufacturing-ready Gerber files • Bill of Materials (BOM) • Optional schematic reconstruction from the existing board I can start immediately and ensure a clean, reliable redesign that replaces your aging 30+ year-old boards with production-ready files. Best regards, Hasan

@Ryan15222

Hi, This is a straightforward and practical reverse-engineering job, and I can help you recreate a clean, manufacturable PCB layout from your existing board. Since no circuit redesign is required, the focus will be on accurate replication + reliability improvements for long-term use. How I’ll approach it: • Board Capture & Reconstruction Recreate schematic from the existing board (trace mapping) Verify all connections, especially around transformer and RS232 interface Identify any worn/damaged areas and correct them • PCB Layout (2-layer, through-hole) Maintain original form factor and mounting points Improve trace routing for 120V bus safety and clearance Apply proper creepage/clearance distances for high voltage Optimize ground routing and signal integrity • Component Handling Through-hole components: resistors, capacitors, diodes, transformer DIP IC footprints (socket-ready if needed) RS232 connector footprint verified for mechanical fit • Reliability Improvements (without changing function) Thicker traces for power paths Better pad sizing for durability (rework-friendly) Optional silkscreen labeling for easier maintenance Deliverables: Native CAD files (KiCad / Eagle / Altium – your choice) Gerber + drill files (ready for fabrication) PDF layout + optional schematic (for documentation) Timeline: 3–5 days after receiving board photos/scans Best regards,

@jakubf41

Hi there, I can help recreate the existing two-sided through-hole PCB from the original board and deliver a clean CAD layout file ready for fabrication. Since no circuit redesign is required, my focus will be on accurate PCB replication, preserving the original footprint, component placement, through-hole geometry, and connector alignment so you can manufacture reliable replacement boards. I have strong experience in PCB layout, legacy board recreation, reverse engineering from existing hardware, and high-voltage board practices, including boards with transformers, DIP ICs, RS232 connectors, and through-hole passive components. For this project, I will provide: • Accurate PCB layout recreated from the existing board • Two-sided through-hole routing • Proper spacing for 120V bus-bar environment • Editable CAD source files (KiCad / Altium / preferred format) • Gerber and drill files if needed for fabrication • Verification of component footprints and pin spacing I can also review the existing board condition and flag any clearance, aging, or manufacturability concerns before finalizing the layout. Available to start immediately. Best regards

@yoshikos

Hi Mate , Good evening! I am professionalengineer with skills including PCB Layout and Circuit Design. I am checking your attachment, I'll update you shortly... Please contact me to discuss more regarding this project. Your Sincerely

@skylerj6

Hi, Jeffrey! I’m a PCB designer with extensive experience replicating legacy, through-hole boards and ensuring safe operation on high-voltage systems (>48 V). I can produce a faithful 1:1 redraw of your two-sided board for data communications over a 120 V bus bar—no schematic changes—focused on robust creepage/clearance, correct footprints, and clean fabrication outputs. Scope of work: - Accurately redraw the existing two-layer through-hole PCB from your reference board - Match all footprints: capacitors, resistors, diodes, transformer, 2 DIP ICs, RS232 connector - Maintain/verify creepage and clearance for 120 VAC (per IPC/UL guidance) - Provide native CAD file (Altium or KiCad), Gerbers, NC drill, fab/assembly drawings, and BOM To proceed, I’ll need: - Flatbed scans or high‑res, orthographic photos of both sides (with a measurement scale), plus edge views - Exact board outline, hole sizes/locations, thickness, copper weight, finish, mask/silk preferences - Part numbers or measurements for connector and transformer footprints - Any known fixes/errata and mounting/mechanical constraints - Preferred CAD platform I will ensure DRC/DFM compliance and a clean, production-ready package. Happy to sign an NDA. I am prepared to talk about your project and can begin right away. Best regards, Skyler

@alinar62

Hi there, This is exactly the kind of project I enjoy—bringing older, worn-out boards back to life. I can carefully reverse-engineer your existing PCB and recreate a clean, two-layer through-hole layout ready for manufacturing. I’ve worked with high-voltage boards before, so I’ll ensure proper clearances and safe routing for your 120V application. All listed components (including transformer, DIP ICs, and RS232) will be accurately placed and matched. You’ll receive complete CAD files and Gerbers so you can easily order new boards moving forward. Happy to review the board image and get started right away.