Actually, if set to ask, it might still over-write if the response-time expires (depending on your setting). There's no way to force it to resume if the auto-resume fails (well, there is, but chances are, the end-result would be corrupted). Even though you've never had this problem before, I'm still laying my bet on your system caching the partial file, as it seemed like you aborted and resumed quickly. If you did, the write-behind cache may not have updated the partial file to report the right size. When resumed, the cache gets flushed, and the size is corrected, but mis-matches the reported size.
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