I think it's definitely something with conversions to be aware of, that Healing in a 4e game may seem easier, but is actually a *limited* resource, given how potions are done in 4e. I don't think this is a 'flaw'.
The guy is a melee ranger.
The module is Paizo's "Hangman's Noose", by Nicolas Logue. In it, the jury that sentenced a man to death is brought back to the courtroom where the verdict was passed, 10 years later. As midnight approaches, the PC's must solve a murder-mystery or become the Hangman's next victims.
Please - no spoilers about the module.
It's well-written, but has some awkward logistic issues. The time frame of the module is 6 hours (so no resting), puts the PC's in a supernatural lockbox that they can't easily leave (haunted courthouse) and it has enough content to take the PC's to 3rd level (in 3.0/3.5). It solves the HP issue by loading up potions everywhere. It doesn't solve the 'wizard with one spell issue' however.
It's a horror module, and I picked it as a test to see how well horror translates the editions. It fits easily into what I'm running. I already modified some things about it before going into it (Tervin's suggestion about the Paladin was something I already thought of, for example. Still a great suggestion though!).
I thought healing might be an issue going into it, due to the difference in how potions work, the inability to rest, etc. I think this specific problem with a player running out of surges isn't necessarily a problem on my end (The DM) but more on party's end of things. The Cleric in the party could have been using his Healing Word between encounters to save some of those surges, for example, had he known the player in question was running low.
I think "Suck it up" is a viable solution and answer - but was just wondering if some people had other ideas.