Jandy Zodiac Power Center Board w/CPU burning out relays?

[Mumbo Jumbo]

Hi there. I have a really strange situation and hoping you can check my sanity. I have had a Jandy Zodiac automation system for about 6 years. It's always worked pretty well until about a month ago. I was out of town for a week and returned to find the system equipment not functioning. Here were the symptoms:
1. The lights on the automation center looked like things were functioning, but nothing was actually coming on.
2. No breakers were flipped.
3. The relays make the clicking noise when you energize them with 24 vDC.
4. The relays test out OL (open loop) when energized.
5. Equipment runs fine when wired directly to the breaker and pulling the relay out of the circuit.
6. Steady and balanced amp load tested to pumps.
7. Automation board is measured to put out 24 vDC when I physically push the button to turn on a relay.
8. No physical evidence of arching or burning.

So, I somehow had 5 relays go bad all at one time. I bought some more relays, factory equipment. Zodiac R0658100 3-HP Relay with Harness Replacement Kit for Select Zodiac Jandy Pool and Spa Power Control System.
I put them in and it lasted about 3 days, and the new relays were bad. These suckers are $74 a pop!

I then replaced just the relay to the primary pump and turned off all other breakers. Now I only had the primary filter pump and the computer. And again, it burned out in 3-4 days.

Alight, so finally my question. Have you ever heard of an automation board burning out relays? This thing is quite expensive to replace, so I don't want to go down any unnecessary and expensive rabbit holes in trouble shooting this.

Thanks for any advice!

 

[1poolman1]

Generic Omron relays work just fine and cost less.
Is it the coil that is burning out? That they "click" would indicate no.
With the relay energized is there continuity 1/2, 3/4?

 

[Mumbo Jumbo]

Hey 1poolman1, thanks for the reply. I'm not sure what is burning out. I plan to open one up after I pull this set out. I threw the last away without cracking into them :| There is no continuity from 1/2 or 3/4, but they do click. They look and sound normal on the outside. One did "burn out" always on instead of always off.

 

[Mumbo Jumbo]

Thanks for the tip on the Omron relays! They are much more affordable.

 

[Mumbo Jumbo]

Here is an update and more information. Hopefully someone has some good advise. I ran the equipment just hard-wired to the breakers. I would flip the breakers to run the main pump and the cleaner booster. I ran it this way for a couple of weeks before I decided to buy a new computer (because it was so darn expensive!). I put in the new computer and a new relay and it worked for a week. I thought I had it solved and the issue was the computer....until the relay burned out yesterday. So this time, I took the relay apart.
1. There is no evidence of arcing or burning anywhere in the box.
2. I only had the filter pump and the new computer on.
3. The filter pump is also brand new.
4. Check out the contacts on the relay.


So this is reay #6. I have a new pump, new computer, new breakers and these are new relays. It is on a 2 pole 20 amp breaker and the input to the computer is on a GFI breaker. I have checked the amp draw and the voltage and everything looks normal when it is operating.

The only thing I can think of is that there are tiny little black ants that are in the box. Is it possible that they are getting into the relays?

 

[JamesW]

The only thing I can think of is that there are tiny little black ants that are in the box. Is it possible that they are getting into the relays?

That can happen.

The ants get squished in the contacts, which do not allow the contacts to make full contact and you get arcing which burns the contacts.

 

[1poolman1]

Here is an update and more information. Hopefully someone has some good advise. I ran the equipment just hard-wired to the breakers. I would flip the breakers to run the main pump and the cleaner booster. I ran it this way for a couple of weeks before I decided to buy a new computer (because it was so darn expensive!). I put in the new computer and a new relay and it worked for a week. I thought I had it solved and the issue was the computer....until the relay burned out yesterday. So this time, I took the relay apart.
1. There is no evidence of arcing or burning anywhere in the box.
2. I only had the filter pump and the new computer on.
3. The filter pump is also brand new.
4. Check out the contacts on the relay.
View attachment 457446

So this is reay #6. I have a new pump, new computer, new breakers and these are new relays. It is on a 2 pole 20 amp breaker and the input to the computer is on a GFI breaker. I have checked the amp draw and the voltage and everything looks normal when it is operating.

The only thing I can think of is that there are tiny little black ants that are in the box. Is it possible that they are getting into the relays?

Yup. Would happen to an Intermatic time clock and AOSmith motor with a centrifugal switch as well. On those motors, an invasion of ants can cause it to run backwards as well.

 

[Mumbo Jumbo]

So, it looks like the issue was the ants. Here is another relay I opened up.