Custom Generator Repair Saves Boston Pharmaceutical Building from Extended Downtime

A prominent biopharmaceutical company located in Boston experienced a critical failure when the controller on their emergency generator became completely non-responsive. This failure rendered the building’s backup power system inoperable, exposing the facility to major liability and risking compliance with their stringent contingency plans—a serious concern for any pharmaceutical building where operational continuity is mission-critical.

What Did We Do?

Immediate On-Site Evaluation:

Understanding the urgency, Weld Power Generator immediately dispatched a technician to the site to evaluate the generator’s condition and assess the configuration of the existing controller. The unit, while mechanically sound, was effectively offline due to a failed controller. Complicating matters, a like-for-like replacement had a lead time of several weeks—an unacceptable delay for the customer.

Customized Retrofit Solution:

Weld Power collaborated directly with the customer to propose a faster and more cost-effective repair solution: installing a Deep Sea Electronics (DSE) universal controller in place of the OEM unit. While the customer initially expressed concern about integrating an aftermarket controller, our team addressed each question in detail. Once we provided a clear timeline and budget—both of which aligned better with the customer’s needs—they approved the retrofit plan.

Professional Installation and Integration:

Our technician carefully removed the failed controller, rerouted and labeled new wiring, and mounted the new controller in a custom-built enclosure. To complement the upgrade, we also installed a compatible remote annunciator system, enabling the customer to monitor the generator’s status remotely—an essential feature for a pharmaceutical building that relies on uninterrupted power for research, storage, and operations.

Thorough Testing and Fast Turnaround:

While the full installation took three days, Weld Power was able to bring the generator back online by the end of Day 1, ensuring that backup power was restored with minimal delay. The remaining time was spent organizing wiring, verifying configuration, and thoroughly cleaning the area to meet the customer’s standards.

Weld Power Generator’s rapid response, technical expertise, and flexibility in creating a custom generator repair solution prevented what could have been a prolonged outage. The customer appreciated our ability to think outside the box, deliver under pressure, and stay within budget—ultimately strengthening their trust in Weld Power as their emergency power partner.

This project highlights Weld Power’s capability to design and execute tailored generator repairs for our clients, especially when time and reliability are critical.