The overlay is a sticker essentially so the same board can be used on a white, black, or stainless range. The new board you get will be the board and housing only so the old overlay will need to be removed and put onto the new housing. Very easy to do. You can order a new overlay with the board if you like, but if the one you have is in good shape, why bother. As for how common, it does happen like most any other appliance failure. There is nothing particular about your range that would suggest anything other than an unfortunate occurrence. And as for return policy, generally electronic components cannot be returned once installed which is usually put into place to prevent damaged boards from entering the new parts stream. But based on your failure, the board is the entire unit so there isn't anything else I could suggest. I should be OK.