Thanks for the reply Gr5,
Corrupted firmware was the culprit.
Nothing worked after many failed attempts using a different setup every time. Tried a much smaller piece after tightened everything up (nothing loose). It went bad at the same spot on a smaller piece ( after first layer fan starts, outline goes good and then bam! It goes all out of whack.
Slowed the print speed way down since this is the second layer when everything speeds up.
This problem occurred once before because of a firmware problem.
After trying different methods, the firmware finally reset and once again everything is fine.
Perhaps you have a loose wire on one of the z endstops and a certain movement shakes the ultimaker enough to trigger the problem?
What would be nice is a utility that shows the state of all 6 endstops so you can shake the ultimaker and jiggle all the wires and move the head around and see if something will trip one of the endstops.
I would consider disconnecting the *bottom* z endstop - you probably don't need it anyway - just to see if that helps. Could it be though that it's the Y endstop that is triggered and it's just the message that is wrong?
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