OP here. I blew the dust of this card recently and found I still have
the same problem... but I've found a fix which appears reasonably
robust.

1. run 'aplay -L' to get the name of the iec958 device (my EMU10K1 is
'pcm iec958:Live"). You'll see something like this:

iec958:CARD=Live,DEV=0
    SBLive! Value [CT4832], Multichannel Capture/PT Playback
    IEC958 (S/PDIF) Digital Audio Output

2. create the file '/etc/asound.conf' and write the following to it (substitute 
your iec958 device):
#----------------
pcm.!default rate_convert

pcm_slave.sl2 {
    pcm iec958:Live
    rate 48000
}

pcm.rate_convert {
    type rate
    slave sl2
}
#---------------

This forces ALL output to SPDIF by default, and also resamples
everything to 48KHz. This particular card won't to 96KHz, so this is
required for a 96KHz source to play (but downsampled to 48KHz).

I guess the fix is similar to what Jean-Francois Lalande said. Results
may vary.

I think it can be done in one line without all of the resampling stuff,
but it doesn't seem to play when the input and output rates differ.

I also suspect (as above) the file which makes this bug persistent
between reboots is asound.state. It's changing something in it when the
mixer/AC3 clash, and it doesn't change itself back.

-- 
SPDIF won't play PCM after playing AC3
https://bugs.launchpad.net/bugs/25632
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