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Hondo,
Glad to hear everything is working for you.
I don't know if Kelly has changed their design but a year ago they were over rating their controllers. I went through several and the last one that I got (which is still working) was sent to me pre-programed for 80% of peak power. I think they realized they were overating them and simply lowered the peak output. I looked inside one of the first ones that blew up and was quite surprised at what I saw. They actually don't have a metallic path for the heat to transfer to the outside cover. It is basically a small oven in there which eventually conducts heat to the outside cover. This is a very poor design which causes the controller to fold back rather quickly due to temperature limits.
Paul connected his mosfets to an aluminum heat spreader that was directly connected to the outside cover. This is a much better design.
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