out of curiosity what is your ser#? Supposedly after 800 (last dig) it was supposed to be fixed. but I did see where if you simply email them and tell them they will send you a plug in emitter installsupport@AM.soncy.com
I'm at 14' and 126" diagonal (110" wide) and I like RC at 20 or below but I also have a Darbee in the chain. I also think that RC is very source dependent and some sources will make it appear much more grainy even with a lower setting. I would recommend trying a Darbee before giving up on it altogether though. That should still be significantly less expensive than a HW95 (unless you're doing CIH and need the added features of the 95?).