This is a challenge. ....It could be a problem in your Outlook settings. See if this helps:
1. Start Outlook.
2. On the Tools menu, click E-mail Accounts.
3. Click View or change existing e-mail accounts, and then click Next.
4. Click your POP3 account, and then click Change.
5. Click More Settings.
6. Click the Advanced tab.
7. Increase the server timeout setting and see if that will resolve the problem.
I'm suggesting this because you said the problem is sporadic. Any luck this time?
BTW, Castle Cops is a great forum and both Kaspersky & Zone Alarm Pro are great programs. I agree with your findings.