Sorry again for late reply, taking advantage of the sun here in UK and we don't get much !
So I ran again with the sine wave shifted so does not start at beginning of session.
See attached image ....
1st recording sine wave starts at 1/128th note from beginning
2nd recording sine wave starting at 648 samples from beginning
3rd recording sine wave starting at 325 samples from beginning.
The problem seems to be at exactly 630 samples when the waveform is truncated and then fades in.
Previous test show that the 630 samples is not project sample rate dependent.
So I can work around by adding a bar or more count in at beginning of project, means doing to multiple projects and then when I send files to clients they have rest all their projects to match ....
I have temporarily gone back to Mixbus 8 as easier.....