net net is crestron changed the way they generate the sb program from the composer.
recompiled an older system and found that it works AOK.
don't know why i didn't think to immediately do the following days ago:
compared the output feedback settings in the two zone extender and there is a difference. in the newer built system the global display on on preset is run from the Source_'xxx' select line level rising, in the old system it is run from the extender zone 1 power on.
and that makes the not-working/working difference for my system. this is because the display pwr on preset is now back wehre it belongs in the run sequence - and the initial timeout set in Properties for the 2 zone vol extender PROPERTY - Receiver/Display Power Time - is obeyed.
hope this helps (and if it did wouldn't mind hearing so)
(still don't know why the darn panel wouldn't power up - suspect the ir receiver was getting jammed by the immediate input set command - but thats just a guess)