If you are testing the SMT-024-096VP, which is our 24vdc 4A power adapter 96w. The temperature went as high as 92C (too hot) at a load of 6.44A (@23.35VDC) I would need for the unit to go into overload at 5.5A? At 6 A the unit should have one into overload.

Our power adapter will start overcurrent/overload protection when the current is over 1.5 to 2 times of their rated current. That is to say, the overcurrent protective device for our SMT-024-096VP(24v 4A) ETL listed power adapter will be activated  when the circuital current is above 8A.  The reason for this design is to avoid the inrush current too large and the overload protection mis-operated.

It is OK that if you are required that the 24v 4A 96W power adapter start overload protection when it at a load of 5.5A. But it is not a recommended practice.  

As per our experience, Loading at 80% is the perfect connection scheme. It will reduce lifetime of the power adapter if overload connection.