QUOTE(ConeDodger @ Dec 30 2011, 11:25 AM)
Note to you business minded guys: We need someone to remanufacture these boards. They are going to get worse...
The photo shows
"normal average condition" relay board (underside).
The major cause of problem appears after sheet metal screws holding the
voltage regulator bite and crack the hardened original podding compound.
Click to view attachmentI would suggest the following:
Recondition your relay board yourself.Pick out the broken podding and expose all the metal traces.
Physically remove all the corrosion from each trace.
Chemically clean them as well with a good contact cleaner. Electricity flows near
or at surface, not in the core of the material.
Ensure that no traces cross or touch each other. "Ring-out" all electrical runs with an ohm meter.If you have a stuborn trace that wants to touch neighboring traces, use a non-
conductive material, (wood, plastic) as a spacer to separate them.
Use podding compound, (readily available at any electrical shop.)
Pour podding compound slowly over the entire bottom of the relay board,
ensuring all metal surfaces are covered.
Allow to cure.
Replace the voltage regulator's original pointed sheet metal mounting screws with
flat bottomed phillips head machine screws and nuts.
I've refurbished four of these boards in the same manner and I never have been
attacked by gremlins again.