Sequences with audio crashing FPP at random

[voik]

I have FPP v5.4.1 running a Pi zero W with an USB sound card. Sequences without audio run fine. After successfully playing a few (3-7) sequences with audio, I get the dreaded "Audio has stalled" and "Stalled audio, buffers still filling" in fppd.log. FPP becomes non-responsive and the Pi requires a hard reboot (as in unplugging it). If the sequences are in a playlist, FPP will blink the lights to the end of the playlist without audio then go dark, all while the interface is non-responsive, clock stopped. 

The problem goes away when using the "ALSA (pi onboard audio)" sound card, but this is a Pi zero, so the USB port is the only way to get decent audio out of it. The sound card is NOT powered from the Pi. I have tried to resolve this by doing the following:

- removing all "special" characters from sequence and audio files. No spaces, _, -, ', etc. Only letters.
- ensuring all mp3s are 128Bit CBR
- ensuring multi-sync and mqtt are off (I don't use them anyway)
- running the system with only the Pi and sound card (disconnected all relays, lights, FM transmitter)
- different sound cards, I've tried the Sabrent AU-MMSA and the Sound Blaster Play! 3
- different power supplies (up to 2A)
- upgrading, downgrading, upgrading again (tried 5.3, 5.4, and 5.4.1)
- restarting FFPD at the end of each playlist

I'm at my wit's end. Is there something I've missed? Anyone else having the same problem? I've tried searching this forum, but the server seems to be perpetually "busy."

I've included a notated fppd.log with "Media Out" and "Playlist" set to excessive. I've culled it for repetitive lines.

[robbiet]

I know this topic is old, but was a solution ever found?  I am having the same identical issue on a Pi Zero running FPP 7.5

[tbone321]

Are you at the most current update?