So back on topic... moved my box, freaked out when only one blade came fully online with a few chips on each of the other showing up. Powered down, open the case, and didn't see anything amiss. Closed it back up, powered it back up, and everything magically appeared!
Had it running back at 200MH stock speed, at 0.72 volts, overnight and noticed just a couple of HW blips, so just nudged it up to 0.725 to see if that makes it 100% clean.
Oh, also discovered the reason the alarm was randomly going off, hashing going to zero, and then recovering... the multicoinpool I used switched coins! Disabled the alarm for the nth time.
Vaguely related:
http://www.multicoinpool.org now has a 2048 min. diff port (3321) setup for SHA256 miners like the S3 and S4. We have noticed the S4 jumping up to 4096 occasionally, but the 2048 min. seems to have addressed the poor performance after a coin switch. FWIW: that was done per my request - great sysop there!
Cassey
update: After 90 minutes of runtime, my S4 is running at an 8192 diff on multicoinpool.