could be low quality sample rate conversion at the TV ?
for example, plexamp sends 44.1kHz over HDMI to the TV, and the TV then converts it to 48kHz for its optical output … TVs don’t always do this well
audio from your other apps (HTPC, Plex web) might take a different route (pulseaudio?) which resamples to 48kHz with higher quality before sending to the TV, which would avoid the TV’s low quality conversion
Noticed in the PC’s Audio Settings amplification was 100%. When I reduced that I was able to increase the Plexamp’s pre-amplification without risking distortion. The effect is not linear- reducing Audio Settings > Amplification to 90% allows Plexamp’s pre-amplification to be ramped up above the default without introducing noticeable distortion.
Conclusion: In regard to plexamp, It seems about achieving the right balance with the PC’s “Audio Settings” amplification. The only mystery is why only plexamp is affected?