Hi there rc4flying, Yes, I did check and rechecked all wiring from IGN to Batt, to Regulator then to Charge Sw itself. all appears to be fine. I took great pains in Isolating all leads from the effects of vibration. They all appear to be intact.
I talked with Fromeco today and explained that I charged my batterys before I went flying.. and then checked voltages after I got home. He explained that the Li Ions shelf life does start from the day of Manufacture. So my 1 year and 5 month old Batterys were in fact on there way out. As the Ign and one main pack had approx 20% less capacity from when they were new.
They were more than Happy to send me a complete set of 4400's and a new Ign Batt for a modest 50% off.
I think that I got great customer service and a good deal on a fresh set of Batterys.
Lesson Learned.
1, Dont take for granted that your charger completely charged your batterys after just one cycle. RECHECK with Voltmeter/Loadmeter.
2, Check voltages after each flight... I never used to do this..... but I damn sure will now.
3, 7.0 volts on a 1 amp load is definelty time to recharge.
4, Thank God for listening to your prayers when you deadstick your high dollar plane down wind and come out smelling like a rose.