little help needed with a SB1800 [RE-wrenches]

[brian]

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Hello wrenches people... i've been reading along for a while, and now i 
have a small problem that on the surface seems very simple... and yet, I 
am still stumped.

A customer of mine had a small grid-tied PV system with 16 Siemens SP-75 
and an AEI GC1000.  You can guess what happened to the GC1000 (loose 
fuse holder melted the dc input main fuse, melted entire panel.  side 
note: the fuse holders in those inverters are el cheapo, but i've found 
that bending them really tight against the fuse, and using liberal 
amounts of electrical grease helps keep the fuse holders a bit cooler, 
and prevents these commons meltdowns). 

Anyway... I added 8 more modules, and installed an SMA SB1800.  To avoid 
having to rewire a lot of the existing array, I came up with a somewhat 
odd wiring schematic;  but the voltage string sizing work out fine on 
paper, and even SMA saw no problem with it.  Here is a simple version of it:

http://www.paloaltohardware.com/temp/

So the problem... is that in 1424 hours of operation, the SB1800 has 
only produced 440 kWH.  The most I've ever seen the thing put out is 
about 990 watts AC.  (the array faces just about due south, no shade at 
all, about 25degree slope.

Any ideas?  I've check all connections and checked voltage on each 
subarray of 4 modules.  My next step will be to start checking each 
idividual module... but i wanted to ask you guys first, as it will be a 
major PITA to get to each individual connection.

thanks in advace,

-Brian

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