It seems that Bitrate viewer does not always get things right, sadly.
5810 + 192 + 192 + 192 = 6236, which is well under the spec limitation of 10.08Mbps for the full multiplex.
Are you absolutely certain that the transcode setting is not set to PCM, by any chance?? I did this once & it took me a whole day to work out where I had screwed up.......
Yes, I am certain. I first tried this with PCM (.wav) files as the math still seemed like it would go lower than 9.6 Mbps. I then tried with the 192's.
3 PCM files would indeed have tripped the error.
I wonder if Encore is still thinking there are PCM audio streams instead of DD?
Can you please try killing the project & starting over with just the AC3?
Alternatively it may help to delete all cache files as it is quite possible the PCM are still the referred files here