Hi Terry,

> I'm leaning towards the multi-core effect as being the reason that the
> bigger Pis work.

Quite possibly.  Andrew's good idea of two Pis with their UARTs
connected so you've a serial console might actually give useful
information when it freezes rather than all this guesswork.

> Your suggestion to use a HDMI adaptor has merit and in fact was one
> solution that I looked at very early on in the design.  I will still
> need a hub though, because we said that we would put the MP3 files
> onto a USB stick, so that the WMT staff can change them without having
> to speak linux.

You don't make it easy, do you.  :-)  The Zero can have its audio out
jack restored if that would give a separate playback to HDMI.
https://learn.adafruit.com/introducing-the-raspberry-pi-zero/audio-outputs
Or there's investigating playing one MP3 on HDMI's left channel and
another on its right.  Staff would just dish up two MP3s without caring.

-- 
Cheers, Ralph.
https://plus.google.com/+RalphCorderoy

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