Hello Alastair,
The first 1,280 samples of each waveform are stored in a RAM buffer on the microcontroller. When a waveform is played, these initial samples are read out to the DAC while the microSD read operation is initialized.
If your microSD card failed in a way that returns 0's instead of data, the samples in RAM buffer would still play, lasting 64ms at 20kHz.
It seems unlikely (yet possible) that the microSD cards in both of your analog modules have failed. We had a series of unfortunate experiences with unreliable vendors of SanDisk Industrial microSD cards, before we found a reliable source here.
If you're able to find one in the lab, please try swapping the card to determine whether that is the issue. You'll need a card with at least 8GB, and U1 rating, ideally SanDisk brand. To open the enclosure, press on the lid overhang and feed it through the horizontal slot.
Please let me know if this works!
Thanks,
Josh