Hi MC, thanks for the response and the additional information. The ADI-2 Pro is in low power mode. However the scenario is now clearer to me - when I turn the ADI-Pro on, it starts set to 176.4k as that is how the Mac has it set in Audio MIDI setup. (The ADI-2 Pro is also set to INT 176.4k, but the Mac's setting in Audio MIDI Setup overrides what the ADI-2 Pro setting anyway.) When I started playback with a 44k1 track, the player switches it to 44k1 i.e. "the sample rate switches over a bigger range while USB is connecting". The player being used was Audirvana+ v3.
If I set the ADI-2 Pro to INT 44.1k while USB is disconnected, then turn it off, reconnect and turn it on, the ADI-2 Pro is immediately changed to the setting the Mac has for the ADI-2 Pro in Audio MIDI setup. It's not really possible to force the Mac to stay at one sample rate in Audio MIDI Setup as some players change that setting. And even if I could, it would only avoid this problem in the case where I start playback with a 44k1/48k file - if I inadvertently started playback with a 176 or 192k file, I _may_ get the large pop again (correct?).
I will try reproducing it with the current firmware (but with output connected to a recorder not my ears ). At any rate this seems unrelated to the firmware update. Thanks
[Edited for clarification - I hope ]