Stack Overload When Formating HD

Was cleaning up some PC’s and redoing the HD’s. On one machine, after partitoning it(single), I was formating it and at the end it said, “Stack Overload caused recovery to cancel. Reset settings in Config file and re-format.”

I’ve tried this going from no stack settings to 64=512, and sizes in between, and I still get the same message.

Any suggesstions? Thanks.