If I were returning a PSU back to Be Quiet, I would go and use their PSU calculator first and make up a rig that draws less power than your current one so that they cant turn round and tell you that the PSU isn't up to the job...
Their PSU calculator is well dodgy, it claims that 1 GTX280 will draw 700w of power itself!!!
I just bought the 850w Dark Power Pro myself, and since purchasing I have noticed a couple of threads about people complaining about their PSU's... I hope my one doesn't go bad!!!
He shouldn't have to do any of that it if his rig is using less power than it says and according to all the people here that's the case.
Even if it was using more juice I really don't think it should go bang, I'm sure there would be a fuse or thermal cutout that should work if over loaded.

i finally know now what that noise was comming from my old gaming rig!