Jon,
Mine was like static/crackling noise and started only at warmup when I first heard it but over a few weeks it was doing it 100% of the time in all DSP modes.
As my thread on it explains that I sent the cards individually to Meridian UK but they were fine. It was only when I sent the entire 861 over they eventually noticed my CO00 in J25 and I was told Bob Stuart identified a problem in some 861's with the CO00 in that location etc so they changed mine to J17 and it fixed the problem and have never played up since.
The PDF Bob Stuart released in 2010 with the new CO00 location can be found
HERE It like a 10 min fix so if I were you I would at least try it as you have nothing to lose and it will save a lot of grief if it is indeed the problem.