IMac Won't Boot With USB Keyboard Connected

We have a suite of 10 iMacs (10,1 - 21.5 inch), but one of them will not boot and has issues coming out of sleep while a USB keyboard is plugged in.
Have tried swapping the keyboard with another iMac - the other iMac still boots but the problem iMac continues to play up.
Tried plugging the mouse into the iMac's USB instead of the keyboard's.
Tried SMC reset, PRAM reset.
Re - imaged the machine from a time machine backup of one of the other iMacs, which made the issue go away for about a month... but then it returned.
Using a magic keyboard is fine as a workaround, but the users need the number pad, and if possible I'd rather fix the issue than buy a clunky separate keypad.
Does anyone have any ideas? Any help would be very appreciated!

Hello strathglass
The same thing can also happen with other connected devices such as external HD's and iPods, the Startup Manager is lost and searching for a boot volume.
1. You may be able to fix it by going to: *System Preference / Startup Disk* and select the *Mac OS X 10.5.5 on Macintosh HD* then *Click the lock to prevent further changes.*
2. Leave those devices that cause boot issues disconnected until the iMac is up and running!
3. Only sleep the iMac, and be sure to disconnect those devices be for shutting down or updates that require a restart!
As a habit, I have always ejected and disconnected all mounted USB devices (flash driver, iPods, cameras, card reader, etc.) from my hub be for sleeping, restarting or shutting down...
Dennis

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