Have you considered and ICP test? Your Zoas are definitely alive, but should be open. Maybe it will just take a lot more time for them to be happy, but an ICP test would rule out anything in the water.
When you say old poly-fil, are you referring to a Poly Filter that has chemicals in it or are you just talking about fill used to filter out larger debris? If it is just fill, maybe try not changing it as often to keep NO3 up instead of using old fill. If it is a Poly-filter, I would not use an old one IMO. I would be worried that after it dried out, it might release substances into the tank when it was re-used.