Sorry its been a while but I have an update on this. We got the new access 1 installed and updated the software and we still had the same issue. So we dug a little deeper (3 of us). Going through the steps of each code we had showing up. Everything seemed to check out. I came into work one morning and the tech on first shift says you wont believe this one. He found the K2 relay was sticking intermittently. Switched the relay from another machine and VOILA it works like its supposed to...
It was definitely a learning experience for a newer tech like myself...just one more to put in the "tool box" to save for another time. Thanks for the help, greatly appreciated!