All Callibration tests pass but prints still fail  

All Callibration tests pass but prints still fail

I use Simplify 3D(Ver 3.1.1) and I have a i3 mk2(FW 3.0.10) and I've replaced the original hotend with an E3Dv6 some weeks ago. Yesterday I decided to run some test prints adjusting settings a tiny bit at a time to see if I could increase quality. On the last print test I was amazed at how smooth it look, bottom and top.

I then choose a project I've printed many times created in Fusion 360 and put it through Simplify 3D then, gcode then printer through Octoprint as usual. Right way after the initial 9 bed calibration checks instead of printing the nozzle clearing strip along the X axis it took off straight way to the print job and preceded to print just slightly above the bed. About 2-3 mm maybe.

Thinking that was odd I resaved -> STL -> restarted S3D -> add STL -> recheck settings -> save to gcode -> off to Octoprint. And again it shot off to the center with out clearing and did the same thing.

I figured it might be a bug in S3D so I pulled up an older gcode file I had printer last week and started the printer again. And again it did the same thing, just weird. I tried this again but this time I start the live Z setting to lower it closer to the bed and it refused. I set it up to 1,900 and it didn't move at all.

So, I uninstalled S3D, pulled down the FFF file from Prusa support and imported it. Went back and put all the PLA setting back to where I had them. This fixed the issue with the printer not printing the nozzle clear strip along the X axis but the print job was a mess. Same problem, Z axis was noticeable off.

So next, I reset Z back to 0 and ran a Z calibration test which passed. I then did XYZ Calibration which also passed. I choose Auto Home calibration and that pass but the nozzle was a little high. I then took a business card out and manually set Z axis. From a SD card I got the Prusa default VCalibration gcode file and ran it through the printer.

At first the print job was a bit "bunchy" and wouldn't stick to the bed but, I adjusted Live Z down a bit more until I got a prefect print out of the printer. Confident it was now correct I ran another older gcode print project that was known to work in the shape of a 20x20mm cube. It failed, same problem Z was off.

I stopped the printer, clean the nozzle and set Auto Home. The printer responded correctly but the business card easily slipped under the nozzle and it appeared as through it has changed. I check the Live Z setting and it was where I left it.

Normally all the usual troubleshooting gets me back up and running within an hour or so. I've been at this all day and my feeling toward lighting my printer on fire are starting to get the better of me.

I think my next task will be to revert firmware on the printer. But not knowing what could be wrong. I'm not confident anything will change. Anyway, any help would be appreciated. I've only been designing and printing for 4 months now and I'm definitely enjoying it. Just wish I could design more and tweak my printer less.

Cheers!