Just saw that post there too. This one explanation of the issue seemed to be the most clear…What is this? Is QC really that bad?
“It's the design of the 4.4mm jack combined with poor output control on the amp. The ground pin on the 4.4mm plug is at the base, so the ground connection on the amp's jack is the outermost one. Thus as you insert the plug, each pin on the plug will make contact with the ground pin in the jack. If another pin on the plug is touching one of the signal output pins, then you're effectively grounding that output. Since the 4.4mm allows for bridged amping (called balanced in the headphone world but that's inaccurate), you're effectively grounding a bridged output which you must never do. That effectively short-circuits the amp and can release the magic smoke amongst other things.
Amps should have some sort of relay that only allows output when the plug is fully inserted to prevent this. Some amps like the ones in the Sony Walkmans simply don't connect the ground pin (it's not needed for bridged amping). And in all cases, as a precaution, inserting and removing a 4.4mm plug should always be a single swift motion so that the plug pins are never touching the wrong jack pins for long.”
So how do we avoid this? Use the XLR balanced and/or only plug in headphones when the switch on the back is off. Mine has been working fine for several months. I mainly use the XLR though.