Hello again;
I replaced the discard Deck with a Zone as mentioned previously. The other changes were: Return To Deck replaced with Send To location, Discard Deck replaced with a Multi Zoned Grid and a Module Level Global Key Command which replaces the "send entire Deck to another Deck function in the Deck properties. The GKC now moves all Discards to the original Deck as part of the same automated process used previously. The fault has disappeared and the cards loop from Deal/Move/Discard/Return Discard/Shuffle without any cards going astray.
I am no expert but I believe the problem is with the Deck sub-component for the following reasons.
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When using the Deck sub-component for Discards, an entire Deck was cycled without error until after the Discard Deck returned the Discards.
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When the errant discard was placed manually in the correct position, the cycle continued indefinitely without fault.
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When the Discard Deck is replaced with a Zone, no fault occurs at all.
The sample module described in (3.) can be downloaded [here]
Thank you for your time.
Regards;
Darren