Well this is a truly dumb argument to be involved in. They replaced it because it didn't work as advertised. That is called good customer service. If you read what I wrote, I already indicated that I used PBW and sanitizer, as instructed by Blichmann. I'm guessing they are familiar with their own products. Call me crazy for expecting a product to work as advertised. Don't overthink it, if a product doesn't work as advertised, contact customer service and get the issue resolved.
In 9 years of brewing I have never lost a batch of beer to sanitation issues. So I think I know how to measure and mix Star San.
as a side note, don't store plastics in sanitizer. Star San says "it is safe for use on all surfaces, but use caution since it is an acid; contact with soft metals, rubber, and plastic should be kept to a minimum."
and BTW thanks for letting me know you are an awesome DIYer. I like the way you slipped that in at the end.