jmchzn, sorry to hear about your problems.
Thankfully, I have a more positive report to make. My Solaris fixture (36" 20K version) arrived from Premium Aquatics the other day (I love PA - Jay is great!).
There were two screws loose inside, but I was able to find where one of them went almost right away. I called PFO and they immediately knew where the other one was from - apparently its maybe an issue with their assembly on some of the earlier units and they are taking care of it for future fixtures. It was crazy, I said "there was a screw loose inside" and the guy instantly said "yeah, sorry about that, its one of the screws that holds the heatsink to the fixture. Once they told me where it went, I just screwed it back in, no problem (but the heatsink was still sturdily mounted even without it, just FYI).
The fixture came without the feet to mount it on the tank or the eye hooks to suspend it. That was kind of a drag, but on the same phone call to PFO, they said they would send them out ASAP (I don't have them yet, but I only talked to PFO last night, so hopefully they will get here soon).
Everything else about the fixture is great. I am going to use it on a new tank that I am setting up (which does not have water in it yet, but I am getting close - my Oceans Motions order should arrive Monday and that's the last piece I'm waiting for to finish the plumbing). I've used PC, VHO and MH on tanks I have had in the past. The fixture does not seem as bright as say, a 10K MH bulb, but I think a good part of that is because of the 20K color temperature. It is way brighter than the PCs I have used by a long shot, and it seems lots brighter than actinic VHOs.
The unit runs pretty darn cool - mine sits at 90 degrees internal temperature and the ambient in the room is 76. So this thing is definitely not putting out a lot of heat, which is awesome. The plexiglass that shields the LEDs is not even warm in the least. The heat internally is mostly from the heatsinks - as far as I can tell there is no heat whatsoever directed toward the tank.
The fans in the fixture are pretty quiet. You can hear them if you are standing to the side of the fixture (which is where the fans are located), but not from in front of it if you are about 2 1/2 feet away. The fans in the ballasts/power supplies, however, are not so quiet (but I'm a quiet freak, so you can take that with a grain of salt). I talked to PFO about that, too, and they are a standard size like you would use for a computer case, so I'm going to swap them out for something really quiet, which should make me happy.
Sorry I don't have water in the tank yet so I can't get actual pictures of the light over a tank, but if anyone has any questions that I can help with, please let me know!
Brad