Just an update so if anyone searches for this problem they will know the fix for it..
Summa called me directly and through a face time call saw what was going on. They remoted into my
computer and looked at all the settings and said everything looked correct to them.. We looked in Illustrator and the layers and all the setting I had done in the file.. Everything was correct that they looked at.. Went through every setting on the machine and verified I was on the latest firmware.. Everything was correct..
Now for the fix.. Months ago I updated the firmware and had no issues until now. Don't know why it never acted up before...
The firmware update was corrupted somehow. Reinstalled the latest firmware and now everything is working perfectly again...
I give a big shout out to Summa for calling me and spending almost three hours on the phone working this out with me.. Tech said they have seen machines where for some reason the firmware upgrade does not go as planned and problems don't show up for months or even longer..