So far my experience with our VG-540 has been mixed, but after ironing out some wrinkles things are pretty smooth now. We are not having issues with cut accuracy (longest cuts we do are about 8-9ft on 3M IJ180), but we did have some issues with crop mark detection at the start. Having the crop mark filter installed on the sensor solved that problem completely. The colors are definitely brighter than our XC-540, and I like the fact that the new ink dries a lot faster than the old ink did. Right now we still have some unresolved issues but production is running smoothly so it's not the end of the world. It should also be noted that due to the low install base in our area our techs are largely unfamiliar with common problems on the machine, so they are generally learning along with us. The saving grace is that they are interested in learning and have been responsive when I report new issues.
Currently unresolved issues:
These are the biggest but I think are design flaws so would need substantial hardware changes to solve.
1. Media lays flat at the start of a print but a few inches in the edges lift up like there's not enough vacuum suction. This causes the head guards to scrape through the print. This requires us to use the media clips on every print even on thin flat media. Uninstalling and reinstalling them after every print is tiresome.The XC-540 didn't have this issue.
2. This ties in with issue 1. I am unable to get satisfactory print quality with the print heads in the high position. Greens get streaky and bidirectional printing gets blurry with fine detail. Requiring us to print everything in the low head height setting.
3. Large amounts of yellow over spray even with low head height. Its all over the pinch rollers and the sheet cutting mechanism. I think this is the main reason for the uneven printing of greens when the head height is raised. It's not visible on the prints though so that's good.
4. When humidity is low and static levels are high I get more interference with the ink than we do with the XC-540. The XC had some but it's much more noticeable with the VG.
Now the smaller issues. None of these affect printing or job efficiency. They're just annoying.
5. Usually over the weekend we get a pump protection error during overnight cleaning. No one's ever been present when it happens we just come in to it in the morning. Stated reasoning is that the cleaning cycle is running too long causing a shut down to protect the pump motor. Roland has not been able to provide a solution for this as of yet.
6. About once a day one or two random ink carts will back out like a hairs width. Enough to trigger the machine to swap to the other cart. Pushing the cart you can't feel it move at all but it must seat it enough to reengage it. We're running dual CMYK so it never causes the printer to pause but it seems like a design flaw. Other people have talked about getting a kink in the bag where the sensor bar sits causing the printer to say the bag is empty, although we have not experienced that yet.
7. SOLVED! Have not been able to get Versaworks Dual to run normally on our Windows 10 machine. Requires Administrator mode. This disables drag-n-drop importing. Inconvenient. ---Finally had some time to mess around with this today. I had to purge the machine of all things Versaworks Dual related (search explorer for "Versaworks Dual" and delete all). Reinstalled and now it seems to be working as intended.
I feel like no matter what there's always going to be some issues with a large complex machine like this, but I do feel like I'm sort of beta testing this one. There were always idiosyncrasies with the XC but it was our first machine so we had nothing to compare against so our perspective was that it was great and ran smooth. The new machine has different ones but I also think there are more of them and some of them effectively disable features. The machine I think was released a bit early. Another year or so in the oven may have prevented some of these problems, like shipping without the crop mark sensor since the cutting feature literally doesn't work without it.