Well... after much testing it is definitely the length of the audio. I cut it in half and that seems to work but way too much work to do it on the PC. Looks like my Halloween show will have to sequenced from my MacBook Pro. As long as my company doesn't take it away from me between now and Halloween no worries.
Ron
PS I really hope that xLights runs in 64bit mode one of these days. That would be a game changer for us pixel hogs.