It's appreciated.
In my very limited little brain, does the low voltage circuit have something to do with the fans when they are on the 'normal airflow' setting, and then when you increase demand to boost or purge the system it gets a higher voltage? That may explain why the fans were running at full pelt before it blew, if the low voltage circuit was damaged. Then the overrun caused the internal fuse to blow?
That doesn't explain the new noise from the relay though, I'm not sure replacing that will fix the issue. I can send the file of the noise via email if that helps?