So to finish the follow up. I swapped in a previously unused/spare Chalice III and as of yet no failures of any kind. It seems I have an intermittent short in the Chalice or by coincidence had the button stick....on 3 occasions in 2 different Grands. I'm leaning towards a bad Chalice that ohms out just fine otherwise. Brew
Thanks again for your welcome answers. This particular Grand had just been swapped in when my other Grand was assumed to have the same issue. The button on this one was not gummed as I had given it a bath and cleaned out prior to setting it back in my spares inventory. So this issue has now happened on (2) grands with the same Chalice. Today I have a fresh spring installed and will be swapping in a yet unused Chalice from my spares. We will see where this goes from here. I did check the battery voltage and found it at 3.97VDC. When I put this atty on my screw-on resistance checker it showed 1.39Ω. This is exactly what I saw with the previous (3) spring drops and is what is driving my batty. I use (8) AW 18650s in rotation and I'm sure it has happened on varying batteries. I did not see any wire ends hanging or problematic although I'm no spring chicken and didn't use a jewler's loop to magnify. I have a Grand, Mini 2.0 and Mini 1.0 all with Chalices and this particular setup is the only one to give me trouble. I can say that I do crank down a bit on the post connections and wonder if I hosed something there. This is my primary 8-hours a day unit so not sure if it might be an insulator that's intermittently failing. I'll follow up in a few days or if this fails quickly to finish the thread. NEED MORE SPRINGS ;-) I still have 4 springs left but I'm getting a few more and I need repair or replacement of a badly glued Mini door. The magnet polarity is fine but too much glue keeping magnet from sitting flush...Brew