Many power supplies have a paper or plastic shroud inside that is supposed to act as an insulator to keep high voltages from comoing into contact with the metal of the case. It sound like you may have one that has become slightly warped and has begun to come into contact with the fan. Also, that PSU has variable fan speed control that causes the fan to speed up when the PSU gets warm enough. That would explain why it doesn't click until you have been drawing a substantial amount of power for quite awhile. When the fan speeds up, it draws more air and that causes the shroud to bend into the fan blades slightly causing the clicking.
RMA the PSU and get a new one that is built correctly.