Having looked this up I’ve found mentions of nzb clients running post processing scripts and issues around that but don’t think it’ll apply here.
Noticed this happening several days ago and after a restart it stopped doing it, but now it’s cropped up again.
Set up:
Sonarr passes download to uTorrent
uTorrent downloads to E:\Downloads\In Progress
uTorrent completes download and moves to E:\Downloads\Completed\tv
uTorrent runs WinRAR on the download, extracts files and removes all archive files - At this point the video file is good matches the CRC from the archive
Sonarr picks up the completion around 30 seconds later (for this download in particular and checked from Date Created of unrar’d mkv and compared to log from Sonarr)
Sonar correctly identifies (multiple times from the looks of the log) the episode and proceeds to move it to D:\TV<showname> (a different drive)
The renamed episode exists now in the TV<showname> dir but the original release named file is still in the completed download dir.
It’s at this point that something goes wrong. When played back the renamed file ends prematurely and comparing CRC’s of renamed to not renamed they differ. The file sizes are exactly the same
Log of file move: http://pastebin.com/GH7Vs9ag
Putting the working video file in the drone sorter folder (different folder to completed downloads), it correctly overwrites the corrupted file and renames.
I suspect restarting the Sonarr service will fix this again for a short time.