Hello @CHonning, welcome to the Sonos Community!
I am sorry to hear you are experiencing an issue with no audio output on your Sonos Connect.
Thank you for the very detailed thread, it seems you’ve tried all basic troubleshooting I would have suggested.
I recommend you to Submit Diagnostics after reproducing this issue and then reach out to our Support Team for some live troubleshooting.
They have tools at their disposal to provide you with information and advice specific to your system and what it reports.
I hope this helps.
Just to make sure: A ZP90’s Line-In is not automatically patched through to its Line-Out. Line-In is simply a resource on the network that is physically hosted in the same box. Given your points (1) & (2) above you have probably selected Line-In, but I want to be sure.