Thanks, I got your message & will email as requested. 

This does appear to be a loose connection issue as for some reason I now intermittently get up to 13Mhs.  And you are right, the units are packed very well. The only thing I can think of is that the screw must've been relatively loose to start with because there was no damage whatsoever to the box exterior.

FYI for other miners:
- similar to jjj0923 I had an issue with the Pi. My keyboard wouldn't work with it until I swapped the 2pin cable for another power connector I had for another device. It does seem that that 2pin cable doesn't supply enough power if anyone else is scratching their heads. (or we both got faulty cables perhaps).
- My Launcher is running at 500w at the wall
- You really don't want this unit in your living room like I have it. I thought Gridseeds were loud but man...lol
- Poolside my top hash is usually 10-20% lower than the Controla says it is but I'm not sure if that is an issue with reporting or if the pool doesn't handle large hash miners well. Could well be a pool issue.
- Acc / Reject rate is 2.66%.  HW is 11% which seems rather high to me.