This guide walks through each step of loading badges into your ZD620 printer and calibrating the printer. If you have trouble during setup and configuration, check out the troubleshooting section at the end of the article. If you need further assistance, please get in touch with us by filling out this form.

We use two different Zebra ZD620 printer sub-models with identical controls and very similar appearances. These are:

  • ZD62142-T21F00EZ - Direct thermal and thermal transfer

  • ZD62142-D41F00EZ - Direct thermal only

Regardless of which model you use, check out the video below for a walkthrough, or keep reading for written instructions. 📖

As you load badges and calibrate the printer, you'll use the arrow buttons and the two buttons below the display to navigate the printer's menus. The left button is called the HOME button. The right button is used to start actions or select items.

⚠️ Caution! If you try to use any printer except the Zebra ZD620, we cannot guarantee its compatibility with Socio Onsite.

Loading badges

There are two types of badges: fanfold badges which look like a stack of long, narrow paper, and badge rolls. How you load badges depends on which type of badge you're using.

⭐️ Keep in mind, you should keep extra badges near each printing station so you can quickly refill printers when they run out. Always calibrate the printer after loading badges!

Fanfold badges

This badge type typically looks like a stack of paper, and they're not usually printed using ribbon. Set the stack of badges directly behind the printer so they'll feed straight into the back without bending.

  1. Pull the two yellow tabs on either side of the printer toward the front and lift the top of the printer to open it.

  2. Feed the first badge into the slot at the back of the printer, and pull it forward.

  3. Use the yellow knob between the yellow media guides to adjust the width of the guides. They should be wide enough to keep the badges centered in the printer. Be sure the badges slide easily between the guides without bending.

    Illustration showing the steps just described.
  4. Bring the first badge over the black roller at the front of the printer. Feed it through the slot so an inch or so hangs out the front of the printer. Make sure the black bar on the back of the badges is facing down and the arrow on the back is pointing toward the front of the printer.

    Illustration showing the step just described.
  5. Close the top of the printer tightly. If the screen shows HEAD OPEN, the printer isn't fully closed.

  6. Now, calibrate the printer using the instructions below.

Badge rolls

A roll of badges is loaded inside the printer, and some types of badges may require a ribbon roll. If the type of badges you ordered require ribbon, the ribbon will be included in your Onsite hardware kit.

  1. Pull the two yellow tabs on either side of the printer toward the front. Lift the top of the printer to open it.

  2. Pull one of the yellow guides toward the side of the printer to allow room for the badge roll, and place the roll in the printer. The leading edge of the roll should fall to the front of the printer as shown below.

    Illustration showing the steps just described.
  3. Bring the first badge over the black roller at the front of the printer. Feed it through the slot so an inch or so hangs out the front of the printer.

    1. If the badges require using ribbon, follow the instructions on the sticker inside the printer to load the ribbon and the cardboard rewind tube.

  4. Close the top of the printer tightly. If the screen shows HEAD OPEN, the printer isn't fully closed.

  5. Now, calibrate the printer using the instructions below.

Calibrating the printer

Before you begin calibration, press home, then press the (✔) button to enter SETTINGS. Press the right (▶) button until you see PRINT MODE. Press the up (▲) button to select TEAR OFF, then press the home button twice. This ensures that badges aren't wasted while calibrating. When calibration is done, go back to the PRINT MODE setting and set it to CUTTER.

Calibration

  1. Press HOME (lower left button), then the right (▶) arrow to select TOOLS. Press the select (✔) button.

  2. Press the right (▶) arrow 4 times until you see MEDIA/RIBBON CAL. Press START (lower right button).

  3. The screen shows LOAD BACKING. Press the pause (II) button.

  4. The screen shows CALIBRATING PLEASE WAIT for a few seconds, then RELOAD ALL CONTINUE appears. Press pause (II) again.

  5. CALIBRATING PLEASE WAIT appears one more time, and badges begin feeding through the printer. When the badges stop feeding through, the pause light above the screen should be on, and no errors should appear.

  6. Press pause (II), and the pause light should turn off.

  7. Open the printer again, and pull back the badges that were fed through back onto the roll so they're not wasted. After you close the printer again, the pause light will be on. Press the pause button.

Now, change the PRINT MODE selection back to CUTTER as described above.

You're ready to print! Now is a good time to set up your kiosk iPads.

Testing

You should always test your badge print to ensure the printer has been correctly loaded and calibrated. Use the Onsite App on one of the kiosk iPads to print a badge, and use the troubleshooting steps below to resolve any errors or problems.

Be sure to set up and test at least one day before check-in begins and then test each morning of the event to ensure everything is still working properly.

Troubleshooting

⚠️ Caution! Follow the troubleshooting steps in the order in which they're presented, testing before continuing to a further step. Don't see your problem listed? Click the button below and fill out the form. We'll get back with you as soon as we can.

Calibration failed

  1. Calibrate again! The printer may simply need another look at the badges.

  2. If you're using badges with a hole in the backing, make sure the yellow sensor is positioned so the gaps pass over it. Otherwise, position the yellow sensor in the middle of the printer.

  3. Make sure the right type is selected. Press home, then press the (✔) button to enter SETTINGS. Press the right (▶) button until you see MEDIA TYPE. Use the up (▲) and down (▼) arrow buttons to change the type.
    Badges with a black bar on the back should use MARK. Badges with a hole or a gap between badges should use GAP/NOTCH.

  4. Make sure the right sensor type is selected. Press home, then press the right (▶) button, then the down (▼) button to highlight the SENSORS menu.
    If you're using badges with a hole in the backing, choose TRANSMISSIVE. If you're using any other type, choose REFLECTIVE.

"MEDIA OUT"

Do a media calibration, and make sure the yellow media guides fit closely, but not tightly against either side of the badges.

"CUTTER ERROR"

This message means the cutter is likely jammed. To fix a cutter jam, follow the video below, or read the steps.

  1. Open the printer by pulling the release levers forward.

  2. Remove the badge stock from the printer, and check the slot at the front for any debris that could be obstructing the cutting area.

  3. Reinsert the badge stock, making sure it’s inserted correctly with the black bar on the back of the badges facing down.

  4. As you insert the badge stock, make sure there’s no debris in the slot at the front of the printer that could obstruct the cutting area, then firmly close the printer.

  5. If the screen shows HEAD OPEN, simply open the printer again, and then close it firmly. The error should disappear.

  6. Press the pause button. The cutter will activate, and a badge will feed forward. If the cutter is still jammed, repeat these steps until you see PRINTER READY.

Badges are cut at the wrong place

This means you should adjust the TEAR OFF setting. Press home, then press the right (▶) button to select SETTINGS. Press the select (✔) button, then press the right (▶) button until you see TEAR OFF. This setting defaults to 0. For fanfold badges, we recommend a setting of 65. Press the HOME button twice to save your settings.

Printer feeds out blank badges before printing a badge

This is likely caused by the MEDIA TYPE setting being set incorrectly.

Press home, then press the (✔) button to enter SETTINGS. Press the right (▶) button until you see MEDIA TYPE. Use the up (▲) and down (▼) arrow buttons to change the type.
Badges with a black bar on the back should use MARK. Badges with a hole or a gap between badges should use GAP/NOTCH.

Print is too light

This means the Darkness setting needs to be adjusted. Press home, and go to Settings. The first setting is DARKNESS. Press the up (▲) button to increase the darkness. We recommend a darkness setting of 10. Darkness should never be over 20.

Print is crooked

If the print is crooked on the badge, make sure your badge stock is properly aligned. If you're using roll stock, make sure the yellow guides aren't too tight against the badge. If you're using fanfold stock, carefully align the stack of badges with the printer so they enter the printer as straight as possible.

Print is too close to one edge

If the print is too close to one edge of the badge, you can adjust the position of the print to center it. This often involves some trial and error.

Press home, then press the right (▶) button to select SETTINGS. Press the select (✔) button, then press the right (▶) button until you see either LABEL TOP or LEFT POSITION. Start by adjusting whichever one is necessary by increments of 5.

LABEL TOP - Increasing top position nudges the print down

LEFT POSITION - Increasing left position nudges the print to the left

⭐️ Keep in mind, these adjustments are very fine, so it may not seem as if anything changed if you make small adjustments.

Did this answer your question?