I don't think a format is in order Wotan.. It seems to be more like a logic bug in the Humax software do to with encryption. So it will happen regardless if the scenario is right for it.
Its been mentioned before, but it is like the box forgets its encryption key or corrupts it for that one recording, therefore it wont play it back. The encryption key is tied to the box the recording was made on.
I've not formatted since my issue and its not happened again.