Allright, so it happened again and i got pissed.
After many months of this not occurring, bam. i get a shutoff at 2.8 amps, and had to reduce it to 1 amp.
The worst part is that it hasn't been telling me it's overheating or reducing the current like it says it will in the manual, so it is shutting down some other way.
Apparently i have been resting the hottest part of my iCharger on top of the hottest part of my radioshack PSU.
I was not aware of this until i opened my power supply and iCharger up.
Now look at this crap. The fan seems to only blow air off of the resistors for the balancing section. It really contributes minimally to actually cooling the fets, which are obviously encased below the board, not allowing heat to naturally rise upwards.
FETs are pressure mounted ( badly ) just like the iCharger 3010b+. But there seems to be a good amount of variance in how badly they are mounted.
I cannot tell how bad they are mounted due to the fact that the circuit board is glued somehow to the aluminum. I only see one FET not looking so good, the others look okay. No idea how many there are though.
Now i understand why i get a funny smell charging above 150 watts. I've had to stay below about 3.1 amps to avoid the funny smell. It is probably the little heat pad burning, because this unit is overheating and not telling me
Now there's also a problem with the heat sensor - it's on the power input side and not the other side. If your FETs are overheating on the other side, it may not detect that and trip the alarm. I think that is what's happening here.
This is terrible thermal design. The heat is in the worst place, and doesn't really even transfer to the top part of the case.
I guess i will keep this unit elevated now, with some rubber feet or something.. And i am going to find a massive industrial power supply / audio amplifier heatsink for it. I want to get closer to the full 5-7 amps at 10S that this unit promises on the box. Now that i have a 20AH pack, this is pretty imperative.
I still love this charger but it seems to be engineered for repeat business
. This explains why some people have their higher power units violently explode and some people have flawless operation forever.. keeping the unit elevated and luck of the draw with the pressure mounted FETs is paramount to a long life with these.