So I think I'm good to go now. I'll send some longer print jobs through Octoprint this weekend to confirm. Last night, I setup octoprint again from scratch. A few things to note on:
This does not appear to have been a hard disk issue, rather an issue with Etcher. When I originally flashed the SD with Etcher, I walked away and closed out the window so quick when I returned that it apparently unmounted the disk and I failed to realized the error on the screen of it displaying " 1 failed device" (Flash Successful to 100%. Verification Failed at 100%).
There is a lot of issues right now with newer versions of Etcher and Windows 10 x64. If you Google the error, you'll find a lot out there:
To get around this error, I went out to GitHub and downloaded and tried several versions of Etcher. I believe I finally ended up at 1.5.11 before it successfully flashed and verified correctly with no issues.
Amazon did send me the new pi as well and I did use it instead of the other - but there is no real evidence that hardware is the cause. I used OctoPrint to print my Bed level test and did not come up with 1 single error this time ((VERY POSITIVE SIGN)). This was a 50 min print job.
Here is the log output for this job:
2019-12-06 04:30:44,527 - octoprint.printer.standard.job - INFO - Print job selected - origin: local, path: CE3_bed_level_test.gcode, owner: USER, user: USER
2019-12-06 04:30:47,914 - octoprint.util.comm - INFO - Changing monitoring state from "Operational" to "Starting"
2019-12-06 04:30:47,925 - octoprint.printer.standard.job - INFO - Print job started - origin: local, path: CE3_bed_level_test.gcode, owner: USER, user: USER
2019-12-06 04:30:47,942 - octoprint.util.comm - INFO - M110 detected, setting current line number to 0
2019-12-06 04:30:47,988 - octoprint.util.comm - INFO - Changing monitoring state from "Starting" to "Printing"
2019-12-06 04:30:48,674 - octoprint.plugins.tracking - INFO - Sent tracking event print_started, payload: {'origin': 'local', 'file': '09d2f6d2cf473483c7d4e56a6818360f93a13d38'}
2019-12-06 04:36:42,841 - octoprint.util.comm - INFO - Printer seems to support the busy protocol, will adjust timeouts and set busy interval accordingly
2019-12-06 04:37:11,570 - octoprint.util.comm - INFO - Telling the printer to set the busy interval to our "communicationBusy" timeout - 1s = 2s
2019-12-06 04:38:50,178 - octoprint.server.util.flask - INFO - Passively logging in user USER from ::ffff:X.X.X.X82
2019-12-06 04:38:50,293 - octoprint.server.util.sockjs - INFO - Client connection closed: ::ffff:X.X.X.X82
2019-12-06 04:38:50,736 - octoprint.server.util.sockjs - INFO - New connection from client: ::ffff:X.X.X.X82
2019-12-06 04:38:50,837 - octoprint.server.util.flask - INFO - Passively logging in user USER from ::ffff:X.X.X.X82
2019-12-06 04:38:51,776 - octoprint.server.util.sockjs - INFO - User USER logged in on the socket from client ::ffff:X.X.X.X82
2019-12-06 04:40:34,984 - octoprint.server.util.flask - INFO - Passively logging in user USER from ::ffff:X.X.X.X82
2019-12-06 04:40:35,132 - octoprint.server.util.sockjs - INFO - Client connection closed: ::ffff:X.X.X.X82
2019-12-06 04:40:35,432 - octoprint.server.util.sockjs - INFO - New connection from client: ::ffff:X.X.X.X82
2019-12-06 04:40:35,511 - octoprint.server.util.flask - INFO - Passively logging in user USER from ::ffff:X.X.X.X82
2019-12-06 04:40:36,826 - octoprint.server.util.sockjs - INFO - User USER logged in on the socket from client ::ffff:X.X.X.X82
2019-12-06 04:45:23,767 - octoprint.server.heartbeat - INFO - Server heartbeat <3
2019-12-06 04:45:30,624 - octoprint.plugins.tracking - INFO - Sent tracking event ping, payload: {'octoprint_uptime': 26097}
2019-12-06 04:46:27,279 - octoprint.server.util.sockjs - INFO - Client connection closed: ::ffff:X.X.X.X82
2019-12-06 04:48:32,413 - octoprint.server.util.sockjs - INFO - New connection from client: ::ffff:X.X.X.X82
2019-12-06 04:48:32,538 - octoprint.server.util.flask - INFO - Passively logging in user USER from ::ffff:X.X.X.X82
2019-12-06 04:48:32,579 - octoprint.server.util.sockjs - INFO - User USER logged in on the socket from client ::ffff:X.X.X.X82
2019-12-06 04:48:38,376 - octoprint.server.util.flask - INFO - Passively logging in user USER from ::ffff:X.X.X.X82
2019-12-06 04:48:38,551 - octoprint.server.util.sockjs - INFO - Client connection closed: ::ffff:X.X.X.X82
2019-12-06 04:48:39,101 - octoprint.server.util.sockjs - INFO - New connection from client: ::ffff:X.X.X.X82
2019-12-06 04:48:39,185 - octoprint.server.util.flask - INFO - Passively logging in user USER from ::ffff:X.X.X.X82
2019-12-06 04:48:40,470 - octoprint.server.util.sockjs - INFO - User USER logged in on the socket from client ::ffff:X.X.X.X82
2019-12-06 04:49:50,385 - octoprint.server.util.sockjs - INFO - Client connection closed: ::ffff:X.X.X.X82
2019-12-06 04:49:50,455 - tornado.access - WARNING - 404 GET /favicon.ico (::ffff:X.X.X.X82) 20.49ms
2019-12-06 04:50:53,238 - octoprint.server.util.sockjs - INFO - New connection from client: ::ffff:X.X.X.X82
2019-12-06 04:50:53,332 - octoprint.server.util.flask - INFO - Passively logging in user USER from ::ffff:X.X.X.X82
2019-12-06 04:50:54,493 - octoprint.server.util.sockjs - INFO - User USER logged in on the socket from client ::ffff:X.X.X.X82
2019-12-06 04:57:38,554 - octoprint.server.util.flask - INFO - Passively logging in user USER from ::ffff:X.X.X.X82
2019-12-06 04:57:38,714 - octoprint.server.util.sockjs - INFO - Client connection closed: ::ffff:X.X.X.X82
2019-12-06 04:57:39,071 - octoprint.server.util.sockjs - INFO - New connection from client: ::ffff:X.X.X.X82
2019-12-06 04:57:39,162 - octoprint.server.util.flask - INFO - Passively logging in user USER from ::ffff:X.X.X.X82
2019-12-06 04:57:40,563 - octoprint.server.util.sockjs - INFO - User USER logged in on the socket from client ::ffff:X.X.X.X82
2019-12-06 04:58:24,443 - octoprint.server.util.sockjs - INFO - Client connection closed: ::ffff:X.X.X.X82
2019-12-06 04:59:00,542 - tornado.access - WARNING - 404 GET /msdn.cpp (::ffff:176.58.124.134) 10.90ms
2019-12-06 04:59:27,567 - octoprint.server.util.sockjs - INFO - New connection from client: ::ffff:X.X.X.X82
2019-12-06 04:59:27,691 - octoprint.server.util.flask - INFO - Passively logging in user USER from ::ffff:X.X.X.X82
2019-12-06 04:59:28,843 - octoprint.server.util.sockjs - INFO - User USER logged in on the socket from client ::ffff:X.X.X.X82
2019-12-06 05:00:03,825 - octoprint.util.comm - INFO - Changing monitoring state from "Printing" to "Cancelling"
2019-12-06 05:00:03,836 - octoprint.util.comm - INFO - Force-sending M108 to the printer
2019-12-06 05:00:03,856 - octoprint.printer.standard.job - INFO - Print job cancelled - origin: local, path: CE3_bed_level_test.gcode, owner: USER, user: USER
2019-12-06 05:00:04,588 - octoprint.plugins.tracking - INFO - Sent tracking event print_cancelled, payload: {'origin': 'local', 'file': '09d2f6d2cf473483c7d4e56a6818360f93a13d38', 'elapsed': 1755}
2019-12-06 05:00:05,295 - octoprint.plugins.tracking - INFO - Sent tracking event print_failed, payload: {'origin': 'local', 'reason': 'cancelled', 'file': '09d2f6d2cf473483c7d4e56a6818360f93a13d38', 'elapsed': 1755}
2019-12-06 05:00:12,078 - octoprint.util.comm - INFO - Changing monitoring state from "Cancelling" to "Operational"
2019-12-06 05:00:23,769 - octoprint.server.heartbeat - INFO - Server heartbeat <3
2019-12-06 05:00:30,628 - octoprint.plugins.tracking - INFO - Sent tracking event ping, payload: {'octoprint_uptime': 26997}
2019-12-06 05:01:35,244 - octoprint.server.util.sockjs - INFO - Client connection closed: ::ffff:X.X.X.X82
2019-12-06 05:02:48,950 - octoprint.server.util.sockjs - INFO - New connection from client: ::ffff:X.X.X.X82
2019-12-06 05:02:49,043 - octoprint.server.util.flask - INFO - Passively logging in user USER from ::ffff:X.X.X.X82
2019-12-06 05:02:49,083 - octoprint.server.util.sockjs - INFO - User USER logged in on the socket from client ::ffff:X.X.X.X82
2019-12-06 05:04:06,309 - octoprint.util.comm - INFO - Changing monitoring state from "Operational" to "Starting"
2019-12-06 05:04:06,321 - octoprint.printer.standard.job - INFO - Print job started - origin: local, path: CE3_bed_level_test.gcode, owner: USER, user: USER
2019-12-06 05:04:06,343 - octoprint.util.comm - INFO - M110 detected, setting current line number to 0
2019-12-06 05:04:06,384 - octoprint.util.comm - INFO - Changing monitoring state from "Starting" to "Printing"
2019-12-06 05:04:07,027 - octoprint.plugins.tracking - INFO - Sent tracking event print_started, payload: {'origin': 'local', 'file': '09d2f6d2cf473483c7d4e56a6818360f93a13d38'}
2019-12-06 05:04:18,818 - octoprint.server.util.sockjs - INFO - Client connection closed: ::ffff:X.X.X.X82
2019-12-06 05:05:34,653 - octoprint.server.util.sockjs - INFO - New connection from client: ::ffff:X.X.X.X82
2019-12-06 05:05:34,783 - octoprint.server.util.flask - INFO - Passively logging in user USER from ::ffff:X.X.X.X82
2019-12-06 05:05:34,988 - octoprint.server.util.sockjs - INFO - User USER logged in on the socket from client ::ffff:X.X.X.X82
2019-12-06 05:05:46,899 - octoprint.server.util.flask - INFO - Passively logging in user USER from ::ffff:X.X.X.X82
2019-12-06 05:05:48,046 - octoprint.server.util.sockjs - INFO - New connection from client: ::ffff:X.X.X.X82
2019-12-06 05:05:48,189 - octoprint.server.util.flask - INFO - Passively logging in user USER from ::ffff:X.X.X.X82
2019-12-06 05:05:48,266 - octoprint.server.util.flask - INFO - Passively logging in user USER from ::ffff:X.X.X.X82
2019-12-06 05:05:48,342 - octoprint.server.util.sockjs - INFO - Client connection closed: ::ffff:X.X.X.X82
2019-12-06 05:05:49,062 - octoprint.server.util.sockjs - INFO - New connection from client: ::ffff:X.X.X.X82
2019-12-06 05:05:49,225 - octoprint.server.util.flask - INFO - Passively logging in user USER from ::ffff:X.X.X.X82
2019-12-06 05:05:51,415 - octoprint.server.util.sockjs - INFO - User USER logged in on the socket from client ::ffff:X.X.X.X82
2019-12-06 05:05:52,857 - octoprint.server.util.sockjs - INFO - Client connection closed: ::ffff:X.X.X.X82
2019-12-06 05:05:52,917 - octoprint.server.util.sockjs - INFO - Client connection closed: ::ffff:X.X.X.X82
2019-12-06 05:06:12,188 - octoprint.server.util.flask - INFO - Passively logging in user USER from ::ffff:X.X.X.X82
2019-12-06 05:06:13,058 - octoprint.server.util.flask - INFO - Passively logging in user USER from ::ffff:X.X.X.X82
2019-12-06 05:06:13,355 - octoprint.server.util.sockjs - INFO - New connection from client: ::ffff:X.X.X.X82
2019-12-06 05:06:13,424 - octoprint.server.util.flask - INFO - Passively logging in user USER from ::ffff:X.X.X.X82
2019-12-06 05:06:14,672 - octoprint.server.util.sockjs - INFO - User USER logged in on the socket from client ::ffff:X.X.X.X82
2019-12-06 05:07:37,372 - octoprint.server.util.sockjs - INFO - Client connection closed: ::ffff:X.X.X.X82
2019-12-06 05:08:00,898 - octoprint.server.util.sockjs - INFO - New connection from client: ::ffff:X.X.X.X82
2019-12-06 05:08:01,033 - octoprint.server.util.flask - INFO - Passively logging in user USER from ::ffff:X.X.X.X82
2019-12-06 05:08:01,076 - octoprint.server.util.sockjs - INFO - User USER logged in on the socket from client ::ffff:X.X.X.X82
2019-12-06 05:08:07,978 - octoprint.server.util.flask - INFO - Passively logging in user USER from ::ffff:X.X.X.X82
2019-12-06 05:08:08,182 - octoprint.server.util.sockjs - INFO - Client connection closed: ::ffff:X.X.X.X82
2019-12-06 05:08:08,629 - octoprint.server.util.sockjs - INFO - New connection from client: ::ffff:X.X.X.X82
2019-12-06 05:08:08,701 - octoprint.server.util.flask - INFO - Passively logging in user USER from ::ffff:X.X.X.X82
2019-12-06 05:08:09,967 - octoprint.server.util.sockjs - INFO - User USER logged in on the socket from client ::ffff:X.X.X.X82
2019-12-06 05:15:23,771 - octoprint.server.heartbeat - INFO - Server heartbeat <3
2019-12-06 05:15:30,626 - octoprint.plugins.tracking - INFO - Sent tracking event ping, payload: {'octoprint_uptime': 27897}
2019-12-06 05:17:53,511 - octoprint.server.util.sockjs - INFO - Client connection closed: ::ffff:X.X.X.X82
2019-12-06 05:18:49,266 - octoprint.server.util.sockjs - INFO - New connection from client: ::ffff:X.X.X.X82
2019-12-06 05:18:49,382 - octoprint.server.util.flask - INFO - Passively logging in user USER from ::ffff:X.X.X.X82
2019-12-06 05:18:50,693 - octoprint.server.util.sockjs - INFO - User USER logged in on the socket from client ::ffff:X.X.X.X82
2019-12-06 05:21:42,612 - octoprint.server.util.flask - INFO - Passively logging in user USER from ::ffff:X.X.X.X82
2019-12-06 05:21:42,788 - octoprint.server.util.sockjs - INFO - Client connection closed: ::ffff:X.X.X.X82
2019-12-06 05:21:43,314 - octoprint.server.util.sockjs - INFO - New connection from client: ::ffff:X.X.X.X82
2019-12-06 05:21:43,402 - octoprint.server.util.flask - INFO - Passively logging in user USER from ::ffff:X.X.X.X82
2019-12-06 05:21:44,806 - octoprint.server.util.sockjs - INFO - User USER logged in on the socket from client ::ffff:X.X.X.X82
2019-12-06 05:22:24,825 - octoprint.server.util.sockjs - INFO - Client connection closed: ::ffff:X.X.X.X82
2019-12-06 05:30:01,294 - octoprint.server.util.sockjs - INFO - New connection from client: ::ffff:X.X.X.X82
2019-12-06 05:30:01,444 - octoprint.server.util.flask - INFO - Passively logging in user USER from ::ffff:X.X.X.X82
2019-12-06 05:30:01,483 - octoprint.server.util.sockjs - INFO - User USER logged in on the socket from client ::ffff:X.X.X.X82
2019-12-06 05:30:06,060 - octoprint.server.util.flask - INFO - Passively logging in user USER from ::ffff:X.X.X.X82
2019-12-06 05:30:06,219 - octoprint.server.util.sockjs - INFO - Client connection closed: ::ffff:X.X.X.X82
2019-12-06 05:30:06,801 - octoprint.server.util.sockjs - INFO - New connection from client: ::ffff:X.X.X.X82
2019-12-06 05:30:06,879 - octoprint.server.util.flask - INFO - Passively logging in user USER from ::ffff:X.X.X.X82
2019-12-06 05:30:08,116 - octoprint.server.util.sockjs - INFO - User USER logged in on the socket from client ::ffff:X.X.X.X82
2019-12-06 05:30:23,772 - octoprint.server.heartbeat - INFO - Server heartbeat <3
2019-12-06 05:30:30,649 - octoprint.plugins.tracking - INFO - Sent tracking event ping, payload: {'octoprint_uptime': 28797}
2019-12-06 05:33:53,920 - octoprint.server.util.sockjs - INFO - Client connection closed: ::ffff:X.X.X.X82
2019-12-06 05:45:23,775 - octoprint.server.heartbeat - INFO - Server heartbeat <3
2019-12-06 05:45:30,667 - octoprint.plugins.tracking - INFO - Sent tracking event ping, payload: {'octoprint_uptime': 29697}
2019-12-06 05:52:00,010 - octoprint.server.util.sockjs - INFO - New connection from client: ::ffff:X.X.X.X82
2019-12-06 05:52:00,129 - octoprint.server.util.flask - INFO - Passively logging in user USER from ::ffff:X.X.X.X82
2019-12-06 05:52:00,171 - octoprint.server.util.sockjs - INFO - User USER logged in on the socket from client ::ffff:X.X.X.X82
2019-12-06 05:53:15,804 - octoprint.server.util.flask - INFO - Passively logging in user USER from ::ffff:X.X.X.X82
2019-12-06 05:53:15,950 - octoprint.server.util.sockjs - INFO - Client connection closed: ::ffff:X.X.X.X82
2019-12-06 05:53:16,438 - octoprint.server.util.sockjs - INFO - New connection from client: ::ffff:X.X.X.X82
2019-12-06 05:53:16,509 - octoprint.server.util.flask - INFO - Passively logging in user USER from ::ffff:X.X.X.X82
2019-12-06 05:53:17,926 - octoprint.server.util.sockjs - INFO - User USER logged in on the socket from client ::ffff:X.X.X.X82
2019-12-06 05:53:58,339 - octoprint.util.comm - INFO - Finished in 2992.030 s.
2019-12-06 05:53:58,341 - octoprint.util.comm - INFO - Changing monitoring state from "Printing" to "Finishing"