Hi Joe,
Although I can't help with your problem as I'm unsure as to the cause, but this has also happened to me a few times when playing GM files from the internal disk drive.
This nasty distorted sound is very loud isn't it? Enough to cause serious damage to both ears and speakers if I weren't quick enough at turning the amp down. I enquired at Roland UK about this but they hadn't heard of such a problem. I've only seen about 2 other references to this problem on the web....so maybe it is a rare one.
But think what the consequences could be if this were to happen during a gig? For this reason I'm reluctant to use the XP-80 as a sound source when playing GM files during a gig...instead relying on an SC-880.
Regards
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Rich