I had the wrong diagram. Range is even more limited for the M20iD/35M. I think you are running in the "no go" area.
I think your only solution is a mechanical change. It you need that reach, you may need to add in an angle plate to get that area of the envelope back.
Thanks for your input, and not really what I wanted to hear.
You obviously have more knowledge on this topic than I, but for obvious reasons, I have to explore all my options. What I find puzzling is the fact that I can jog the robot in this position if I SHIFT/RESET and confirm overriding Collision Detect with no issues. The other thing is that setting Collision Detect to 1% makes no difference from 100% or 200%. I have to rule out anything else may be wrong in my configuration.
By "add in an angle plate", are you saying I need to turn the base of the robot 90 degrees so that X is along the rail direction? Or mount it upside down (ceiling mount)? This is a very large structure, so any changes mechanically would be a huge undertaking.