ZD621 Initial Setup and Configuration
Follow these steps precisely to connect and configure your printer for the first time.
1. Physical Connection and Power-Up
Connect Power: Connect the Power Adapter (D) to the Power Cable (B). Connect end (A) to the printer and end (C) to a power outlet.
Ethernet Connection (Optional): Plug an Ethernet Cable from the router’s LAN port into the Ethernet port behind the printer.
Power On: Push the Power Button (left of the display). The printer will take up to 20 seconds to boot up and should display “Printer Ready”.
2. Badge Stock Loading
Open Printer: Pull the 2 Yellow Latches on each side to open the printer lid.
Load Stock: Pass the Badge stock from the back of the printer through the Yellow media guides on the inside, all the way to the front, and through the cutter, leaving a small piece sticking out.
Adjust Guides: Scroll the yellow roller inside the printer to adjust the media guides. The stock should not move freely, but also should not be too tight.
Verify Orientation: Ensure the badge stock is placed correctly with the Black Marks facing down and the arrow facing towards the front of the printer.
Close Lid: Press down the printer lid until you hear a light snap. The LCD Screen should display “Printer Paused”. Tap under the warning on the screen to proceed.
3. Wi-Fi Connection Wizard (LCD Screen)
Start Wizard: From the screen options, select ‘Wizards’ and then choose “Connection”. Select ‘Wi-Fi’ and tap.
Network Settings:
Accept the default ports 6101 & 9100.
Set IP Protocol to All or DHCP. (Use Permanent when directed by venue or third-party software).
For Wi-Fi Country Code, leave it in “Not selected”.
Security and Password:
Set Wi-Fi Security to WPA PSK (recommended for rental/mobile routers).
Tap on Pre-shared Key to input the router's password. Tap ENTER then tap again.
SSID and Band:
Set Wi-Fi Band to All and tap.
Set your router’s ESSID (Wi-Fi name).
Finish: Tap “End Wizard” to finish the connectivity setup. Wait a few minutes for the printer to connect to Wi-Fi. Go Back to the Home Screen.
4. Print Configuration Wizard (LCD Screen)
Start Print Wizard: From the screen options, select ‘Wizards’ and then choose “Print”. Press “Start Print” and navigate through the wizard.
Media Settings:
Select Direct Thermal and tap.
Set Media Type to match your badge stock, or set it to Auto Detect. Tap.
Leave Label Width (Dots) at 832, tap.
Set the Media Handling to Cutter or Tear off then tap.
Calibration & Testing:
The printer will Auto Calibrate and then prompt you to print a test label.
(Troubleshooting) If Auto Calibration fails: Select “Calibrate” from the pop-up. Un-pause the printer, then un-pause it again. The printer will feed one or two badges to re-calibrate.
TearOff & Quality (Optional):
TearOff Adjustment: The next screen adjusts the “TearOff” setting for cutting accuracy. Leave at 0 if calibration was successful.
Print Quality: Select “Set Manually” to adjust “Darkness” and “Print Speed” if needed.
Finish: Press EXIT to close the Wizard. When all steps are completed and settings configured, you can proceed to un-pause the printer.
II. Troubleshooting Common Printer Issues
1. Printhead Open Alert (Red Light Visible/Flashing)
If the printer shows a red or flashing status light, the issue is typically physical obstruction or closure failure.
Possible Causes | Resolution |
Improper Seating | Pull both yellow latches to open the printhead. Gently lower the printhead and apply firm, even pressure until you hear a distinct click. The light should turn green. |
Badge Stock Obstruction | Check that the badge stock is running straight and smooth through the yellow guides and is not snagged, which can prevent proper closure. |
Foreign Object or Damage | Inspect the latches and printhead rim for any small objects. Check the yellow latches for any visible damage or breakage. |
2. Media Feeding & Print Quality Issues
These faults include double printing, blank badges, or improper positioning.
Possible Causes | Resolution |
Incorrect Loading | Ensure the badge stock is inserted with the timing mark facing down and the arrows (if present) pointing toward the front output slot. |
Improper Guide Adjustment | Adjust the yellow media guides so they hold the material snugly to prevent movement, but do not bind the material. |
Mismatched Settings | Access printer settings and confirm that the configured Badge Stock Specifications match the exact material loaded. |
3. Calibration and Connectivity Faults
These steps address specific calibration messages and persistent errors.
Possible Causes | Resolution |
Calibration Required | Run the dedicated calibration routine from the printer utility. This process resets previous settings and teaches the printer the new stock specifications. |
Data or Sensor Error | Verify that the printer is receiving data correctly. Ensure the internal sensor responsible for detecting the timing mark is clean and correctly positioned over the badge stock path. |