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This guide is for setting up or resetting a Zebra ZD621 (or similar ZD620) printer that is using custom TEKControl 4" x 6" visitor passes. Prerequisites: - Zebra Setup Utilities installed; on most PCs this application will require admin rights to open/run, so be sure to have those if needed. - Printer has been installed, plugged into the PC, and powered on.
1. On the PC that the printer is plugged into, click "Zebra Setup Utilities" or search for it in the Programs list.
2. If prompted with the User Account Control pop-up, click Yes and enter admin credentials if needed.
3. Click on the printer you are working on. If the printer does not appear here, then the PC does not have the printer installed; refer to THIS LINK for instructions.
4. Click "Configure Printer Settings"
5. Wait a moment for the printer information to be collected. If the firmware version does not appear here, then there is an issue with printer communication, and you should swap the printer-to-PC USB cable first before uninstalling and reinstalling the printer.
6. For the Width setting, ensure it is set to "4.00".
7. For the Height setting, ensure it is set to "6.00".
8. Click "Next"
9. You can leave the speed settings alone in most cases and click "Next".
10. For Print Mode, ensure it is set to "Direct".
11. For Media Type, ensure it is set to "Mark Sensing;" if Mark Sensing is not an option, ensure you have the latest version of Zebra Setup Utilities installed.
12. Click "Next"
13. For most situations, ensure the Backfeed option is set to "No Backfeed".
14. Click "Next"
15. Continue to click "Next" until you reach the final page, where you will see "Next" is grayed out. Here, click "Finish" to save and send the settings to the printer.
16. Pull both yellow release latches on the side of the printer forward to open the printer.
17. Ensure the passes are loaded through the slot in the back of the printer, with the blank side facing up.
18. The labels should be going between the yellow arms on the side, and below the two guide pieces towards the front. The small yellow wheel at the bottom (inside of the printer) can be used to move the arms in or out to ensure the passes can go through without friction, but without moving around.
19. Just inside the front edge of the printer, below the paper, is a sliding yellow sensor with a small glass square and an arrow on it. That slider should be centered on the second-to-last notch from the edge of the printer.
20. Ensure the passes are loaded properly, and that part of one label is sticking out past the edge, and close the printer.
21. Press and hold the Pause "||" and Cancel "X" buttons to perform a manual calibration. Once the paper begins to move, you can release the buttons.
22. The printer should move the paper back and forth briefly, ending on a clean break between labels, and will be paused once finished. If this does not occur, check all settings and printer characteristics to ensure everything is set properly and try again. If it does end on a clean label break, you can un-pause the printer and the process is complete.
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