Hi Steve,
Thank you for your post. I'm concerned about your comment that NRG has not responded to you. Our last record of your correspondance with NRG was in April of 2009 for a PIN encryption issue. Since then, you have been pretty quiet. You may want to consider contacting tech support directly with queries of this type.
support@nrgsystems.com
You mention that a #40C had issues. Have you tested against an alternate #40C? It's possible that your unit is faulty. We have implemented very tight production controls on the #40C manufacturing process over the last 9 months, but as I'm sure you will understand, no process is perfect.
All of our products carry a 2-year warranty against manufacturing and workmanship defects. If you are concerned about any NRG product you have, please contact us for a Return Materials Authorization.