Ok, so I did a controlled start today and went to the maintenance menu to view the AUX axis settings and everything was identical. The gear ratio, the motor type, speed, ect ect. As far as the software and memory available and all things related everything is the same between the two robots as well. I did make one change to the "problem" robot though. I dropped the speed down from 18,000 to 16,000 to match the other robots and then COLD started the robot.
As far as the processing speed of the pendant display I can try to swap the pendants tonight at their lunch break and see if the issue follows the pendant to the opposite robot. I was really hopeful that I was on to something here with maybe the CPU running slow and not sending/receiving data fast enough causing a communication type fault. I'll pocket that idea for now so i can focus on some more likely culprits. If it's just a separate pendant issue then i'm not concerned with it at the moment.
This is the only active alarm of any importance besides the miscellaneous TP faults and the CNTR-009 I mentioned a few posts above. And this is a Group 2 Axis 1 servo set up as Continuous turn for a deburring process.
I have also been monitoring the torque values recorded on these axes and comparing them. I'd like to see if I notice a spike of any kind during the fault.
*EDIT* I did see a higher "Max Torque" on this axis than the other robot. At the time of the fault the torque recorded was 20.015 MAX and the Average was 17.153 whereas the other robot saw a max of around 3.6xx.