I often do quite large panoramas and the roll ( cut up before using ) is the only way to achieve these.
Also the idea was to not waste paper when doing 4x5 or 4x3 ratio prints.
and I got it to work often enough. well, not really enough as you are reading above.
with the ImagePrint software it worked everytime.
Also with the photocards, the behaviour is nonconsistent.
So which info would you need to judge if we can solve this ?
Marc is more experienced in Lightroom's quirks, so I'll leave that to him (or others) to answer.
My observation though is that many people seem to have difficulties with letting LR do what they intuitively expect it to do. When even presets stop working between sessions, I'm out, not going to waste time, material, and thus money.
I am an extremely happy camper with printing from Qimage (already for some 15 years), nowadays I'm using the latest Ultimate version. Pricing is very very modest (if not plain cheap), upgrades and updates are very affordable (one can even skip a year and resume with the latest version for only a modest upgrade fee) and, more important, image quality is second to none (maybe ImagePrint matches it, I have no direct comparison between the two). Qimage Ultimate supports any printer that is supported by the operating system, no limits on size, brand or model.
The only drawback for some is that it's a Windows OS application, but it apparently runs fine under Parallels (or Virtual PC) on Mac OS.
The user interface tends to get some flak by purists, but it is made for brutal functionality, achieving regular tasks with as few mouse-clicks or keystrokes as possible. Image resizing happens on the fly, depending on output dimensions and it matches the printer-driver's native resolution automatically, and performs very good halo-free Smart output sharpening.
Of course it also offers good options for automatic nesting if one wants to use paper more efficiently when printing different sizes of images, or multiple sized versions of single images. Panos are no problem, as long as the printer driver allows custom paper sizes that are long enough, and even then there may be workarounds with printing multiple pages edge to edge. Also things like centering prints on arbitrary physical paper sizes is simple to do and it doesn't even require wasting a single printed test page (everything is set/aligned from the user interface, with direct feedback in fractions of millimeter or inch accuracy).
Just mentioning an alternative in case you can't get the issue resolved.