The Challenge
The customer faced a common but frustrating problem: their original, proprietary in-floor heating relay control board failed. Proprietary replacement parts were either prohibitively expensive or discontinued entirely, leaving the system inoperable.
They reached out to Kadrmas Controls seeking a **cost-efficient engineering solution** that could replace the faulty board, integrate seamlessly with their existing system, and guarantee long-term operation.
The Engineering Solution
We designed and manufactured a custom, drop-in relay control board from the ground up. Instead of copying the original design's flaws, we introduced critical improvements:
- Modular Architecture: Allows individual sections of the controller to be serviced or updated without replacing the entire unit.
- Scalable Controls: Designed to expand up to multiple heating zones if the customer decides to modify their layout.
- Industrial-Grade Robustness: Implemented wider trace paths, thicker copper layers, and transient voltage suppression (TVS) to prevent the electrical failures that destroyed the original board.
The Impact
The custom relay control board was installed into the main load control panel, functioning flawlessly. The customer received a much higher-quality, modular board for a fraction of the cost of the manufacturer's proprietary pricing. By choosing a custom design, they also secured local support and future-proofed their system.
