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Retrofit nightmare made me dump the old relay panel approach
I used to wire every expansion zone through the existing relay board on retrofits, figured it was faster since the panel was already there. Then last month I did a bank in Des Moines where those old relays kept dropping the zone loop every time the HVAC kicked on. Spent three days chasing voltage drops and false trips before I ripped the relay board out and ran straight to a new expander. Now I always pull the old panel first and build fresh, even if it adds an hour to the job. Customer thought I was nuts for the extra labor but the system has been rock solid for 30 days straight. Has anyone else hit a similar wall with legacy relay gear on commercial retrofits, or is it just me?
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the_zara1mo ago
Just ripped a relay board out of an old grocery store last week for the same reason. Those things are time bombs. Every compressor cycle sent the zone into fault. Straight to the expander and zero issues since. Old parts are only worth keeping if they actually work.
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