Your latest test, where the AMNPS went out makes it look like air flow is at the root of the problem. This reminds me of the solution I came up with. (This was prior to building my own version of the "mailbox mod," something which completely and totally fixed the problem of too-fast or too-slow burns). Here's the short version of the story.
I read a lot about people pulling the chip loader out a little, or enlarging the chip loader air holes. The former "solution" seemed to be too inconsistent, as you just found (how do you get the chip loader tube pulled out to the exact same position each time?). The latter solution irrevocably alters the function of the smoker and it may, or may not, ever function the same again. What if you make the holes too larger?
Many months ago I posted in some other threads my simple mod to take avoid both problems I replaced the chip loader with a duct elbow that has a tin can attached to it. In the end of the tin can, I drilled five holes that are larger in diameter than the three holes in the chip loader. This provides several times the amount of air that can make its way through the chip loader holes. I've shown this pic before, but here it is again. The crinkled end goes into the chip loader hole. If I make the holes too large, I simply get another tin can and try again. This can, as shown, worked pretty well.