We can continue to go back and forth on this, and I think we have all made all the comments we can intelligentlymake based on a photograph, however, the reality is that there are hundreds of thousands of these AC units, different manufacturers, same basic design, and all installed the same way, that have been in use for years and this is the first I've read of any incident of this type.
This is an installation problem going back to manufacturing. The dealer repaired the roof without diagnosing the cause and re-created the problem.
Personally, I would get another "eyes on" opinion from a different shop, as the repairing dealer obviously missed this or simply chose to accept the factory installation to be correct. There just simply isn't anything on or about these units that when properly installed is going to cause that kind of roof damage. To go back to the same shop with the same problem, talking to the same people and expecting a different answer is going to be the ultimate exercise in futility.
One thing that I have not mentioned, nor has anyone else, is that the gasket material is i" thick, as well as any strips that may be included. With a new gasket properly installed, and the unit(s) correctly installed, the air conditioner is resting on a foam cushion, not even touching the roof
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