I've set up the SD card for a couple of Zero Ws, one being for Hyperion, using a 2 for the convenience of plug and and play connections before soldering up the Zero Ws and both worked fine. Need to watch the IP addresses where relevant but I wouldn't have thought that had anything to do with whether Hyperion starts.
Sorry this doesn't offer an answer but just to say it should work in both, have you tried updating with the card in the Zero W?