Thanks for the update. It is puzzling that your resetters (how many do you have?) are going thru batteries like crazy. In my experience (with dozens of different resetters), a set of 3 batteries should last at least a year if not two- though I have damaged a few resetters by accidentally dropping them onto the hardwood floor, and apparently broke something loose inside- the ones I haven't dropped have been working well with their original batteries for years, and I would estimate hundreds of resets...
There have been a few rare situations over the years where it seems the resetters caused chip failure, though the resetter seemed to be working correctly (flashing red a few times then turning solid green). Also, occasionally a bad chip can cause the resetter to short out, but works again after removing + reinserting the batteries (resetting the resetter), then using on a different chip to test the resetter. If it works correctly on the second chip, but shorts out with the first, then something with the first chip is causing an issue with the resetter- this is resolved by replacing the chip.
In the situations where the resetter occasionally caused chip failure, once we determined the resetter was causing chip issues, a new resetter (and replacing the chips the first one fried) solved the issue.
I have also heard of the printer's chip sensors wearing out over years, causing on and off sporadic chip errors.
I hope this is helpful, and sorry I don't have the magic answer up my sleeve. Yes, the chip-less printers are nice for this reason, and we love our Roland for this and many other reasons.
All the best~ Dana