I'm suddenly having the same problem with one of my Q50s. I just replaced a device (swapped an IR DVD player for a serial DVD player), and even deleted a couple devices that I'm not using in that configuration anymore. The memory usage before all that had been around 58%.

Now, I try to download this updated configuration and it fails, telling me it's too large. If anything, I think the configuration would be smaller than it was before, but there is no way it is suddenly that much larger.

I'm at a bit of a loss here.

UPDATE: Something is very amiss. I deleted another device from that configuration (so it's definitely smaller than it was before), restarted NSP, and it's still telling me it's too large. I'm in quite a fix if I can't update the configuration. I considered doing a factory reset on the remote itself to wipe out its existing data, but then if I still can't download to it I'll be completely up a creek.

Any ideas?