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Which mixer board?

Mine hasn't failed in near 2 years. I know 3 other guys with the 16.4.2 and no failures there either. As far as the fire wire cable falling out, that is a function of the FW400 connector and socket design. There is no strain relief there. I personally haven't had that happen but then again I am at east somewhat thoughtful on how I have my system arranged and there is no strain on the FW cable.

That 90% number is BS at best... I'm pretty regular on the Presonus forum and there is nothing like that level of complaint - there are complaints from folks who dive and start with the board before they understand how routing works but that isn't the boards fault... When I bought mine, it replaced my board plus 2 racks of external processing stuff. EQ's Gates, comps, effects - that analog system wouldn't have been all that straight forward for someone new to my system to setup from scratch and run either... I had the advantage of learning that system as I expanded it a piece at time - with the SL it is welcome to the deep end of the pool. You need to know all this stuff now! I spent a couple of days time over a month to grasp how to work with an SL board. When it made sense to me, I migrated away from my old setup very quickly.

If you want to record from the AH or the Presonus to the Zoom, if the Zoom has individual channel inputs, use a TS snake or a bunch of TS -TS guitar cables, insert the cable on theboard end half way into the channel insert and it will function as a send for that channel.
Quality matters on cable selection...

Personally I would still do a mac and use Studio One. A mac mini or macbook would do you good service.

As far as harsh goes, I don't hear that. If the board is setup properly... It is different from running an analog board like my old Yamaha or a MixWiz for sure. You can push individual channels harder on the analog's without hearing the clipping. On a digital board, you absolutely never allow clipping... I find the SL board to be pretty much transparent. It is more or less sterile until you work the 'fat channel' and warm it up. In that sense I can understand 'harsh'. Once setup though, I don't hear that at all.

Lastly as far as digging through digital board menus, why do that when there is the extremely easy to use iPad and SL remote app ? I almost never go more that 1 layer deep anymore...
 
Do NOT get a PreSonus 16.4.2!!! They have over an 90% failure rate. There is a bad solder joint, and it causes the entire board to fail.

This is outright false. If it were true they'd have had to recall the whole line.

The PreSonus is perfectly acceptable for this application. IMO there are better boards out there, but for the OP's needs they should be perfectly fine.

It won't be as reliable as a Yamaha but there are plenty of StudioLive owners that have owned the mixer since it first came out and it still works.