I had a PLM melt. I just got the replacement. I lost the lights on my ISY and I thought I heard a bang from the computer room a couple of days before I noticed that. A bit of a smell but I could not figure out where it was coming from, and everything seemed to be working. I opened the case and saw a small cap under the interface card that had burst, and maybe something else next to it (or just ooze from the cap). The case was melted all around in the area of the transformer. I did not write down the version, but I had just purchased it.
I tried searching the forum for the issue and got one hit that simply referred to it as an existing problem. No real details nor any indication of if it has a fix. I am a bit concerned that the device can reach those temperatures. There is a fuse in there, but it apparently does not interrupt this behavior because it still appeared to by OK.
There where some versions of the PLM that have a charge pump enabled on them and it is possible, rare, but possible for that charge pump to lock on when connected to a computer that is using the device as a gateway. We have disabled that feature recently but in the event of a failure the case will contain the heat even though it may slightly deforms or discolor. I believe the charge pump helps with the signal strength when devices are using the PLM's power to power it.
If you get a replacement this has been turned off.
Is there a setting or jumper that the user can change to control this feature. If it really improves the signal level, some other fix may be called for. For example a power limiter built into the device. I got this PLM a month or so ago.
It was not a user defined setting. The current shipping version of the relay switch has a new power supply design and other products will have that design implemented as well including the PLM.
Could you perhaps define the "current shipping" ID of the relay switches? I have several of these delivered at the same time as the PLM. I am not real keen on distributing modules with similar settings around my house.
The PLM is the only device with this circuit. I was answering the statement about "some other fix" and sharing the fact the the relay switch now shipping has the power supply technology and other devices as well as the PLM will be able to see the bennifit of that in future designs. It is the size of the transformer that in the current PLM that made it possible for you to see the effects you did.