Well, had a bit of excitement (not really, just unusual activity) the past week, didn't want to post about it until I knew better what was going on. Friday a week ago, I get this automated text that starts with just "Tesla: ", and says they'd scheduled a service appointment for Tuesday of this week (no reason indicated), and provided a 650- number (not the one the text came from) to call for questions or to re-schedule. Since I hadn't complained about anything I wasn't sure at first that this wasn't some sort of spam/phishing thing. After a bit of googling to try to determine if either number had fraud/robocalls associated with them I decided to give the callback number a try (the suggested time didn't work for me, anyway). The phone answered right away, and an automated voice simply said that the current wait time was over an hour and started playing music (didn't say welcome to Tesla service or anything like that). So I hung up because I didn't have an hour to spend on the phone Friday, and sent an email to my installer lead and energy advisor asking if this was legit. The advisor confirmed it was legit, though he didn't volunteer anything more about the reason for the appointment (didn't know, I guess).
So Monday I found some time where I could sit on the phone on in my office while still getting work done and called again, got the same over an hour message, but it "only" took about 30 minutes before someone connected. They rescheduled me to Friday afternoon (today), and said that they had detected a "performance issue" so that triggered the service call. I went back and took a closer look at the data I've collected and didn't see anything particularly off (I look at the app and my PVOutput data every day and extract the inverter's Production History screens every week, so I'm sure I'd have caught anything gross), but the inverter input that was affected by the "wiring issue" I referred to in post #69 was perhaps reporting some more wildly-variable output than the rest. I guess I'd never expanded upon that issue at the time, the boxes they used to bring the PV wiring from above the roof deck to inside the house are pre-wired on the outside, but were just bare leads on the inside (I assume to keep the roof hole size down). Well, when they added the MC4 connectors on one of the 6 string's the connectors were done backwards, i.e. the + wire used the MC4 connector the other 5 sets used on their - wire, and vice-versa. And the PV wiring had already been connected to the RSDs in the attic, so this one RSD was seeing around -300V, and according to its datasheet it's not OK with any negative voltage. I pointed this out to the technician at the time, and he corrected the plug genders, but he felt the RSD was probably OK, he offered to replace it if I really wanted to, but clearly didn't sound thrilled about spending more time in the attic. I figured let's just go with it, and assumed that if it was damaged it would be obvious looking at the inverter data (given that at the time we hadn't turned anything on yet, in fact I don't think the wiring from the RSDs to the inverters was finished).
Anyway, as soon as the technicians (not ones I'd dealt with before) showed up today and confirmed it was a production issue I mentioned the original mis-wiring, and they felt that was likely the issue. So they went in the attic and that particular RSD was ticking. That string is S4 from my picture on post #73, and it gets combined with S6 (post-RSD, S6 has an RSD in the garage and S4's RSD is in the attic). The technicians were a bit confused by the wiring, so they also inspected the RSDs in the garage, and noticed that S6's RSD was also ticking. So they wound up replacing both of them. The one technician was also concerned about how hot the RSDs were upon opening the service boxes they're installed in, and wound up calling first Tesla's hotline then Delta (RSD manufacturer) tech support, to see what the acceptable operating temperature really was. He said in traditional panel installs when they're used they're left unboxed mounted under the panels, so they get lots of air flow around them, but in this case they're each in their own box in a hot attic, so they're already in a hot space and might be worse-off getting next to no air flow. Well, Delta said they were aware of how they were being used with Solar Roofs, and that they're comfortable with the application (they're spec'ed to operate in ambient temperatures up to 70C [158F]), but the guy on the phone apparently said that he'd feel better if the RSDs had date codes beyond a certain number, when repeating the information to me the Tesla tech must have botched the number because the week code he mentioned (1932) would be ~2 weeks from today (we're at the end of week 29 in 2019). I didn't have the current week number handy until I got back to my computer so I didn't question it while he was around. But he had determined that none of my RSDs met the date code requirement (the two that were replaced were 1830 and 1849, so if he meant 1832 instead of 1932 one of them might have been OK, or maybe he meant to say 1923 or 1922 or something). Anyway, apparently Delta was going to send the Tesla tech 5 RSDs beyond the preferred date code, as I guess they've either expanded the temperature range even farther, or made some other change to improve high-temperature operation, perhaps without modifying the overall spec.
So I currently have 2 replacement (but apparently still not new enough, I didn't see their date codes) RSDs, and it sounds like I should expect another appointment to replace all 5 sometime in the future. The solar was out from 3-6, and the sun was far-enough down by the time the inverters were online again that it would be difficult to see any difference right now. Will have to see if over the next few days the behavior of that one inverter channel stabilizes or not. Personally I'm hoping it was just 'walking wounded' behavior from the initial reversed wiring, not that I'd object to getting newer RSDs if Delta thinks they're better.
And since I just threw the initialism around a lot above, if anyone was wondering, the "RSD" is a Rapid Shutdown Device, which is basically just a relay but it works based on a signal received by the inverter, each one is about the size of a college textbook. The point is that when the inverter stops sending the signal the RSD opens the circuit, blocking the array's voltage/current from going to the inverter. As I understand it the point is to make the PV wiring safe, presumably in case firefighters end up cutting through the conduit or the like. So they're required to be placed within a certain distance of where the PV wiring enters the house to limit the amount of wiring left at higher voltages (and able to produce lots of watts if accidentally shorted together) once everything is switched-off. One thing I learned today, I had assumed that turning off the DC disconnect switch on the inverters would cause the RSDs to shut down, but the technicians claimed that the signal makes it to the RSD regardless of the position of this switch, and that the inverters have to have their AC disconnects (i.e. breakers) thrown to stop sending the signal. This still seems a bit suspect to me, as I don't know what the DC disconnect switch in the inverter is really doing if it's not breaking the connection such that the signal would no longer make it through, I guess the inverter might be injecting the "signal" on the RSD-side of the DC disconnect switch.