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I'm pretty sure the only remedy will be a head replacement.

Don't worry. The final "ink empty" comes from a switch that is tripped by the plastic thing that protrudes from the cartridge when it's empty. When one of these switches is pressed, no printing or cleaning takes place.

This is normal behaviour of the system. It also happens, when there is a pump defect and the cap isn't emptied properly. I'd just pull the cartridges, this way the pressure should be equal. I seriously doubt the usefulness of a 24h soak anyway. If it doesn't get better after a one hour soak...

The BN-20 does ask you to shake the cartridges from time to time. All pigments settle eventually and the ink throughput in such small and slow printers like the BN-20 or the LEF's doesn't help.

This sounds like something got wrecked with the dancer bar/sensor. Try starting the TU with the dancer at different angles, to see if it changes.

A problem with the APS would have been my next guess, because different colors are affected... (AirPressureSystem) Most of the times, I had troubles with it, it was too little pressure because of leakage or failing pumps...

Could be a bad batch of Luer connectors... or the plastic of the PIPs is more brittle... I also never encountered it multiple times on the same unit in such a short time.

By the way, starting with version 6.15.1 win32 is no longer supported. Windows 7 isn't supported for a looong time. It worked, but was never guaranteed to. Minimum was 8.1, now it's 10/11 64bit only...

The MG is more like a successor of the LEC2-640. It has nothing to do with a LG.

Did you try starting Versaworks "open as administrator"? Does it happen only when you add it to the queue by " drag and drop", or also using file/add to queue? When you want to do a clean reinstallation of Versaworks, you need to use the uninstall function from windows. Then you need to delete...

Still on Max3 ink?

You have to be more spezific. Do you want the rip to print with black only? You can define a CMYK color with k component only. Then in Versaworks you can set use linearisation only in color management. This way, the color is printed with k only. But this doesn't give a neutral gray. To get a...

The problem is highly likely the lamination. Opos cam is fast in recognition, but less accurate and versatile, than standard OPOS.

The wayback machine doesn't save all old website content. Think of the amount of storage they would need.

That's why I changed to Max2.

The FB550 heads are closer together, than the 500.

Here you go...

You need to check the alignments. Print a hairline square 20x20mm or one inch with CMYK 100,100,100,100 first unidirectional, then bidirectional. Then you should see, if it's a bidirectional, or horizontal misalignment.

Replug the flat cable on both sides and be sure to close the locking mechanism. If it doesnt't help check the coils resistance.

Definitely not normal for a VG3. Looks like something on the encoder strip, as Solventinkjet pointed out.