Is this not a problem with a run of new C machines? That does not sound like software. My bet is that there has been a run of some part which is defective. A part to do with the z encoder or controller. What effect would a poorly etched encoder disc have? What about bad EEPROM storing the z parameter data? I think some of these parts need to be swapped around to narrow down which hardware is causing the problem. Someone with this problem may have to send their machine in to LHR.