VersaCamm VS-540 puking ink from cartridge holder

I have seen many ink carts like yours coming out of the Roland VS models, usually it's a by product of using white and metallic inks. The printer prompts you to shake the cart, which means removing and inserting the same cart, it puts stress on the plunger...aka causes some leakage. Looks like your are using dual cmyk config, so don't think the printer is prompting you to shake your inks, but if it is then that could explain why the little leakage.

Just my .02

 

As GTS said, it's most likely the septum in the ink cartridge not sealing with the needle properly. Whether that's because they have been taken in and out too many times or a defective cartridge is hard to say but to have that many defective cartridges would be pretty rare. One is rare even. The melting is from the ink though for sure. I don't think it's an electrical short as there are no real electronics around the needle. If this machine is older maybe the needle is just dull or broken and so it doesn't puncture properly. That would be my guess but this is a unique issue for sure.

 

I think there was a firmware version that did ask to agitate the cartridges no matter which ink setup there was. I your printer asks you to remove and shake the cartridges, try updating the firmware.

You've already got the ink station upgrade on there, which was supposed to help with the leaking ink problem. It would be worth a look at the needle assemblies to make sure that they are straight and sharp. And just make sure that you're going in straight.

Good Luck

 

VS 540 user here.
Bought it new in 2015. I have dual CMYK setup and it does ask me to shake cartridges every now and then.
Never had this issue and i have even put in refilled cartridges from leftover carts that had been punctured many times over by filling it up.

I too suspect used, faulty or damaged needles inside the printer.