BFL (through this post, BFL refers to the company, not to Sonny personally),
with due respect, while the Singles are lovely devices, your customer service sucks. Since the run for your products started, I contacted you 6 times with concrete technical inquiries and got zero responses (just ask BFL-Engineer, and FYI, that's why I did not order a (Mini) Rig). Therefore I preferred to get support from the community.
Plus it should be in BFL's best own interests when existing issues are discussed here openly and workarounds are made available publicly (or you add the related information at your product pages). Like Inspector said above, most of us would prefer fixing it by ourselves over waiting months for a RMA replacement.
That said, you need to clarify how you define ambient temperature. My setup is in a fairly large room in my basement with currently around 19°C room temperature. Naturally, as I approach the mining rig, local temperature gradually climbs and reaches ~23°C at half a meter distance. Given that the exhaust temperature right above the Singles is somewhere between 30 and 40°C, it's a physical imperative to have a local area with >22C° (or 72°F; any chance US is going to use SI-metrics soon?
).
I strongly believe that my operational environment is within specs, though the problematic device averaged down to 705MH/s after a continuous run for days. Again, I'm with Inspector arguing better to have it running at 500MH/s than waiting weeks for a replacement at 0MH/s. Therefore I'm going to first try the proposals the community posted, thanks to all.
While I am at it, I figured out a SW issue that could be quite relevant for all multi-Single setups driven by cgminer: while I removed the throttling device from the setup for further inspection, the average hashrate of the remaining 4 climbed up noticeably. To double check, I repeatedly run it long enough to exclude variation and this is what I get:
1) running all 5 devices the hashrate for all of them starts at 828 and after running a day the throttling settles at 705 all-time-average, while the properly working ones settle at 790
2) running the 4 proper ones alone, all start at 828 and after the day they are still at ~825
In other words, the throttling one is not just reducing its own hashing power but also those of the proper ones. In my 5-units setup the estimated loss is ~250MH/s.
This could be caused by the communication between PC and Single being frozen during the throttling. From the SW design view there should theoretically be no inter-dependencies, since every device is handled by its own threads. But in practice if the device throttles while communicating to the host and thereby stalls, the related thread will eat its scheduling quantum busy looping the serial port.
Luckily ckolivas is not only cgminer developer but also a Linux scheduler guru, so I'll sort this SW issue out in his thread. Meanwhile I will separate the throttling device from my setup and run it from a different host.
Tl;dr: if you have a multi-BFL Singles setup with one or more throttling units (front LED is blinking now and then) you should consider operating the throttling ones from a different host for a better overall hashrate.