Thanks all for the responses!
Unfortunately I don't have access to the PC right now but here are some answers:
Awesome Donkey: I tried increasing buffer from 6s to the next step up but no better.
Manfred: I will try to check bit depths of MC and ASIO, though I'm not sure I completely understand that. ?
I'm using asynchronous USB between PC and DAC.
I have set MC to load complete converted files for playback but no change.
Running Windows 10 Pro.
JimH: Media files are all on a Synology NAS.
When I get a chance I will try to get the Zotac and new PC running together and compare every setting/option that seems relevant. Excuse my ignorance but is there a way of exporting the options from one PC to another?
If I can't figure it out, I'll just switch back to the micro PC, which works but not reliably when driving my TV at 4K. The new PC is solid and handles multitasking with ease. Ah well.