I encountered this problem as well. First you will want to unplug the camera and remove the battery pack. Install the battery pack and leave the cover off. Plug the Flip back into the computer. I've found that if your plugging into a USB extension, it's more likely to show the error. SO plug directly into the computers USB.
This is just a temporary fix as the error still randomly apears for me. I've found different computers (like my laptop) will cause the camera to show the error more often, while others allow the camera to charge with no heat warnings.
this is an internal problem, I would say that something has burned out and therefore you are getting an overheating problem. This is normally on the circuit board and needs to be repaired by a licenced dealer or technician. Hope this helps.
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