Hey  @geoff-plitt,

When the behavior occurs are you able to see or control the device from the Kasa App?

When you are interacting with the switch while in this state, does the LED change at all?

If you raise the dimming calibration so that the light is not potentially at its absolute minimum, does the behavior continue? Is there a brightness cutoff you have seen?

You might consider checking your wiring setup for any exposed wires or insecure connections. You should also try to estimate the length of the wires and your fixture power consumption. If your wires are too long, it is very possible that the signals are not passing correctly. Similar behaviors can be seen if the current is able to leak between the two travelers.