The file wasn’t too big… something stupid with the forums.
Default rollover count of 5 fits in about 5-6 MB… never been an issue. 
I see the error occur after several playback+terminate from iOS.
Here’s the actual error happening
Jan 25, 2023 15:41:38.636 [0x7fb32b3b7b38] ERROR - [Req#1952/Transcode/D05D1F40-FDAD-490B-906C-C1AB7DAC194E/5d3353b4-58d7-4257-acac-b35c1042a437] Error while processing the decoded data for stream #0:0
Jan 25, 2023 15:41:38.636 [0x7fb333acbb38] DEBUG - Completed: [127.0.0.1:45950] 200 POST /video/:/transcode/session/D05D1F40-FDAD-490B-906C-C1AB7DAC194E/5d3353b4-58d7-4257-acac-b35c1042a437/progress/log?level=0&message=Error%20while%20processing%20the%20decoded%20data%20for%20stream%20%230%3A0 (18 live) 0ms 195 bytes (pipelined: 28) (range: bytes=0-)
Jan 25, 2023 15:41:38.661 [0x7fb333d11b38] DEBUG - Jobs: '/usr/lib/plexmediaserver/Plex Transcoder' exit code for process 7731 is 1 (failure)
Jan 25, 2023 15:41:38.661 [0x7fb32f19fb38] DEBUG - Streaming Resource: Changing client to use software decoding
Jan 25, 2023 15:41:38.661 [0x7fb32f19fb38] DEBUG - TranscodeUniversalRequest: adapting profile with augmentation data: add-direct-play-profile(type=videoProfile&protocol=http&container=mkv&videoCodec=*&audioCodec=*&subtitleCodec=*)+add-direct-play-profile(type=videoProfile&protocol=hls&container=mkv&videoCodec=*&audioCodec=*&subtitleCodec=*)+add-transcode-target(type=videoProfile&context=streaming&protocol=hls&container=mkv&videoCodec=h264,hevc,png,apng,bmp,mjpeg,thp,gif,vp8,vp9,dirac,ffv1,ffvhuff,huffyuv,rawvideo,012v,ayuv,r210,v210,v210x,v308,v408,v410,y41p,yuv4,ansi,h263,mpeg1video,mpeg2video,mpeg4,vc1&audioCodec=ape,aac,aac_latm,alac,dca,vorbis,opus,pcm,pcm_alaw,pcm_mulaw,pcm_bluray,pcm_dvd,mp1,mp2,eac3,ac3,flac,mp3&subtitleCodec=vobsub&replace=true)+add-transcode-target-settings(type=videoProfile&context=streaming&protocol=hls&CopyMatroskaAttachments=true)+add-limitation(scope=videoAudioCodec&scopeName=*&type=upperBound&name=audio.channels&value=10&replace=true)+add-limitation(scope=videoCodec&scopeName=*&type=upperBound&name=video.bitDepth&value=10&replace=true)+add-limitation(scope=videoCodec&scopeName=*&type=notMatch&name=video.separateFields&value=dummy&replace=true)+add-limitation(scope=videoCodec&scopeName=*&type=upperBound&name=video.width&value=4096&replace=true)+add-limitation(scope=videoCodec&scopeName=*&type=upperBound&name=video.height&value=2160&replace=true)+add-limitation(scope=videoCodec&scopeName=*&type=upperBound&name=video.width&value=4096&onlyTranscodes=true&replace=false)+add-limitation(scope=videoCodec&scopeName=*&type=upperBound&name=video.height&value=2160&onlyTranscodes=true&replace=false)
while here it play3ed ok
Jan 25, 2023 15:41:37.982 [0x7fb32b3b7b38] DEBUG - [Req#18ee/Transcode] [FFMPEG] - Slice 0 data buffer (47 bytes) is 0x2.
Jan 25, 2023 15:41:37.982 [0x7fb32b3b7b38] DEBUG - [Req#18ee/Transcode] [FFMPEG] - Decode to surface 0x13.
Jan 25, 2023 15:41:37.983 [0x7fb32b3b7b38] DEBUG - [Req#18ee/Transcode] Codecs: 10-bit HEVC test succeeded
Jan 25, 2023 15:41:37.983 [0x7fb32b3b7b38] DEBUG - [Req#18ee/Transcode] MDE: Inglourious Basterds (2009): Audio Direct Streaming is disabled, so video's audio stream will be transcoded
Jan 25, 2023 15:41:37.983 [0x7fb32b3b7b38] DEBUG - [Req#18ee/Transcode] MDE: Cannot direct stream audio stream due to profile or setting limitations
Jan 25, 2023 15:41:37.983 [0x7fb32b3b7b38] DEBUG - [Req#18ee/Transcode] MDE: Inglourious Basterds (2009): selected media 0 / 90497
Jan 25, 2023 15:41:37.984 [0x7fb32b3b7b38] DEBUG - [Req#18ee/Transcode] Streaming Resource: Reached Decision id=86395 codes=(General=1001,Direct play not available; Conversion OK. Direct Play=3000,App cannot direct play this item. Direct play is disabled. Transcode=1001,Direct play not available; Conversion OK.) media=(id=90497 part=(id=127013 decision=transcode container=mkv protocol=hls streams=(Video=(id=128031 decision=transcode bitrate=9006 encoder=h264_vaapi width=1920 height=1080) Audio=(id=128032 decision=transcode bitrate=127 encoder=libopus channels=2 rate=48000))))
Jan 25, 2023 15:41:37.985 [0x7fb333acbb38] DEBUG - Completed: [192.168.1.187:65528] 200 GET /video/:/transcode/universal/decision?advancedSubtitles=text&audioBoost=100&autoAdjustQuality=0&directPlay=0&directStream=1&directStreamAudio=1&location=lan&mediaBufferSize=40000&partIndex=0&path=%2Flibrary%2Fmetadata%2F86395&protocol=hls&subtitleSize=100&subtitles=auto&videoBitrate=10000&videoResolution=4096x2160 (15 live) TLS GZIP 27ms 5760 bytes (pipelined: 16)
Jan 25, 2023 15:41:38.001 [0x7fb32d48eb38] DEBUG - Request: [192.168.1.187:65526 (Subnet)] GET /hubs/metadata/86395/related?includeAugmentations=1&includeExternalMetadata=1&includeMeta=1 (15 live) #18f9 TLS GZIP Signed-in Token (gobigdave) (iPad)
Jan 25, 2023 15:41:38.003 [0x7fb32b1b4b38] DEBUG - Request: [192.168.1.187:65528 (Subnet)] GET /:/timeline?bufferedTime=24&col=9&context=source%3Acontent.library&duration=26000&key=%2Flibrary%2Fmetadata%2F86395&location=lan&playQueueItemID=74378&playbackTime=10&ratingKey=86395&row=9&state=buffering&time=0 (15 live) #18fd TLS GZIP Signed-in Token (gobigdave) (iPad)
Jan 25, 2023 15:41:38.004 [0x7fb32b1b4b38] DEBUG - [Req#18fd] Client [778A4500-2235-4B04-A3EE-3B736E3D62C4] reporting timeline state buffering, progress of 0/26000ms for guid=, playbackTime=10ms ratingKey=86395 url=, key=/library/metadata/86395, containerKey=, metadataId=86395, source=
Jan 25, 2023 15:41:38.004 [0x7fb32b1b4b38] DEBUG - [Req#18fd] [Now] User is gobigdave (ID: 1)
Jan 25, 2023 15:41:38.004 [0x7fb32b1b4b38] DEBUG - [Req#18fd] [Now] Device is iOS (iPad).
where the previous run exited normally (exit code for process 7697 is 0)
Jan 25, 2023 15:41:35.271 [0x7fb3338c8b38] DEBUG - Completed: [127.0.0.1:45934] 200 POST /video/:/transcode/session/0EE8C813-DEE4-4B58-A956-EA278CA12F72/89de3902-0524-445b-afb7-38c7cdab1ddf/manifest (18 live) 0ms 166 bytes
Jan 25, 2023 15:41:35.275 [0x7fb32ec47b38] DEBUG - Request: [127.0.0.1:45944 (Loopback)] POST /video/:/transcode/session/0EE8C813-DEE4-4B58-A956-EA278CA12F72/89de3902-0524-445b-afb7-38c7cdab1ddf/manifest (18 live) #18c1 Signed-in
Jan 25, 2023 15:41:35.275 [0x7fb32ec47b38] DEBUG - [Req#18c1/Transcode/0EE8C813-DEE4-4B58-A956-EA278CA12F72/89de3902-0524-445b-afb7-38c7cdab1ddf] Transcoder segment range: 0 - 25 (25)
Jan 25, 2023 15:41:35.276 [0x7fb32d48eb38] DEBUG - Request: [127.0.0.1:45488 (Loopback)] PUT /video/:/transcode/session/0EE8C813-DEE4-4B58-A956-EA278CA12F72/89de3902-0524-445b-afb7-38c7cdab1ddf/progress?progress=96.0&size=-22&remaining=0&vdec_packets=603&vdec_hw_ok=603&speed=5.2&vdec_hw_status=1 (18 live) #18b3 Signed-in Token (gobigdave) (range: bytes=0-)
Jan 25, 2023 15:41:35.276 [0x7fb3338c8b38] DEBUG - Completed: [127.0.0.1:45944] 200 POST /video/:/transcode/session/0EE8C813-DEE4-4B58-A956-EA278CA12F72/89de3902-0524-445b-afb7-38c7cdab1ddf/manifest (18 live) 0ms 166 bytes
Jan 25, 2023 15:41:35.276 [0x7fb333acbb38] DEBUG - Completed: [127.0.0.1:45488] 206 PUT /video/:/transcode/session/0EE8C813-DEE4-4B58-A956-EA278CA12F72/89de3902-0524-445b-afb7-38c7cdab1ddf/progress?progress=96.0&size=-22&remaining=0&vdec_packets=603&vdec_hw_ok=603&speed=5.2&vdec_hw_status=1 (17 live) 0ms 355 bytes (pipelined: 19) (range: bytes=0-)
Jan 25, 2023 15:41:35.298 [0x7fb333d11b38] DEBUG - Jobs: '/usr/lib/plexmediaserver/Plex Transcoder' exit code for process 7697 is 0 (success)
Jan 25, 2023 15:41:35.302 [0x7fb32e031b38] DEBUG - [Req#18b8/Transcode/0EE8C813-DEE4-4B58-A956-EA278CA12F72] Returning segment 24 from session
Jan 25, 2023 15:41:35.302 [0x7fb32e031b38] DEBUG - Content-Length of /transcode/Transcode/Sessions/plex-transcode-0EE8C813-DEE4-4B58-A956-EA278CA12F72-89de3902-0524-445b-afb7-38c7cdab1ddf/media-00024.ts is 817511 (of total: 817511).
Jan 25, 2023 15:41:35.310 [0x7fb333acbb38] DEBUG - Completed: [192.168.1.187:52487] 206 GET /video/:/transcode/universal/session/0EE8C813-DEE4-4B58-A956-EA278CA12F72/base/00024.ts (16 live) TLS 107ms 817511 bytes (pipelined: 13) (range: bytes=0-)
Jan 25, 2023 15:41:35.310 [0x7fb333acbb38] DEBUG - Removed transcode data consumer, active count 1 => 0
Jan 25, 2023 15:41:35.322 [0x7fb330dd9b38] DEBUG - Request: [192.168.1.187:65526 (Subnet)] GET /transcode/sessions (16 live) #185b TLS GZIP Signed-in Token (gobigdave) (iPad)
Jan 25, 2023 15:41:35.322 [0x7fb32b3b7b38] DEBUG - Request: [192.168.1.187:65528 (Subnet)] GET /:/timeline?bufferedTime=3&context=&duration=25150&key=%2Flibrary%2Fmetadata%2F98547&location=lan&playQueueItemID=74379&playbackTime=0&ratingKey=98547&state=playing&time=0&timeToFirstFrame=4 (16 live) #1860 TLS GZIP Signed-in Token (gobigdave) (iPad)
What changed to cause the different playback conditions?