I wonder if there is some fail safe circuit protection of the relays in the build.
The pdf below has a wealth of info that I will need to look again
Here are some specs on relays from OMRON
Durability
Mechanical 15,000,000 operations min. (at 36,000 operations/hr)
Electrical 100,000 operations min. (at 1,800 operations/hr)
AC: 100,000 operations min.,
DC: 300,000 operations min.
(at 1,800 operations/hr)
• Long-term Continuously ON Contacts
Using the Relay in a circuit where the Relay will be ON
continuously for long periods (without switching) can lead to
unstable contacts because the heat generated by the coil itself
will affect the insulation, causing a film to develop on the contact
surfaces. Be sure to use a fail-safe circuit design that provides
protection against contact failure or coil burnout.
http://www.omron.com/ecb/products/pdf/precautions_pcb.pdf
■ Contacts
The contacts are the most important constituent of a relay. Their
characteristics are significantly affected by factors such as the.
material of the contacts, voltage and current values applied to
them (especially, the voltage and current waveforms when ener-
gizing and de-energizing the contacts), the type of load, operating
frequency, atmosphere, contact arrangement, and bounce. If any
of these factors fail to satisfy predetermined values, problems
such as metal deposition between contacts, contact welding,
wear, or rapid increase in the contact resistance may occur.
PCB Soldering
...However, unless
the relay is fully sealed, when soldered onto a PCB, flux may pen-
etrate into the housing, adversely affecting the internal circuitry.....
PCB Selection
....Although seemingly an uninvolved process, soldering and its
related processes of flux application, relay mounting, heat appli-
cation, and washing can be detrimental to a relay’s performance.