So this is just grim - one of my wires going to my "out" plug was bad, and when using my voltmeter on the relay / output, I was using the tip of the red lead on one side of the relay, which seems to be having difficulty - when I put the red lead on my meter on the cone below the tip it starts to work again.... grim... I discovered it after taking apart my plug and using a real receptacle. I don't get it as my meter has always worked really well just touching the tip of the leads...
Chris C. - I never noticed the 220mA rating on the unit - strange because the controller and relay are marked as 5A units on their casings. Chris M - I may take you up on your offer? I'll PM you?