I can not figure this one out by myself or through search; this must be a plex app/Roku software issue. HD (1080p, 7.1 HE-AAC) TV episodes will stop ~5min before the end of the episode on Roku Ultra devices only (I have 2 of them; one on 4k and other on 1080p TVs and they both do this). When playing on the plex app on android cell phones, xBox series X, PC or on the server itself they play until the end without issue. The issue on the Roku seems to be with the audio encoding/decoding process as when audio settings are changed the episode will play until the end but without audio. The message I get is “Playback Terminated - Conversion failed. The transcoder process crashed.” Other non HD (480p, Stereo AAC) play normally to the end on the Roku devices. System specs: Plex server 1.25.2.5319 running on a Dell server Intel© Xeon© CPU E3-1225 v5 @ 3.30GHz × 4, 32GB ram running Linux Kernel 5.4.0-91-generic on Mint 19.3 Cinnamon 4.4.8 with nvidia quadro P2200. Roku Ultra is a 4660RW running 10.5.0 build 4208-46 running plex app 6.9 build 14.
P.S. this happens on every (7.1 HE-AAC encoded) episode, not just one but all of them. Anything encoded with stereo AAC, every episode plays fine until the end as it should. Also FYI; There was an issue with h.265 encoded media on an older release of Plex media server but that has since been resolved, thank you so much (I had to revert my server to an older version for quite some time, that was a real PITA on mint ;).
We’ve moved off Roku and over to Shield in our house but a long time ago we had this issue. What fixed it for us at the time was to change the Transcoder default throttle buffer to 15 in Settings → Transcoder.

This may or may not help you but its worth a try. I also assume you have Use hardware acceleration when available enabled, right ?
Thanks, the buffer was set to 60, I set it to 15, still had the same transcoder crash issue (but in fairness I did not watch from the beginning, I just forwarded to the end of the episode). I did not re-boot the server after the buffer change, I will try that next and tomorrow morning I will try it again from the beginning of the next episode. I do have use hardware acceleration when available enabled (that’s why I have a quadro P2200 installed ;). There is never more than 3 or 4 users using the system at a time and 90% of the server is 1080p and very limited 7.1 audio encoded (most is 5.1 and stereo AAC). Its just funny that the whole episode plays fine and then ~5min until the end it crashes with encoder error and I whip out my cell phone and watch the last 5min on my cell LOL
Good luck. A plex server restart might be needed for this setting change so worth doing that also when you do a real test. Hope it helps if not then maybe someone else has an idea.
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