MagTek 9000 User Manual
InSpec 9000 TM
ENCODED CARD TESTER
INSTALLATION AND OPERATION MANUAL
Manual Part Number 99875049 Rev 12
AUGUST 2004
REGISTERED TO ISO 9001:2000
1710 Apollo Court
Seal Beach, CA 90740
Phone: (562) 546-6400
FAX: (562) 546-6301
Technical Support: (651) 415-6800
or: (562) 546- 6803
www.magtek.com
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Copyright© 1996-2005
MagTek®, Inc.
Printed in the United States of America
Information in this document is subject to change without notice. No part of this document may be
reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose,
without the express written permission of MagTek, Inc.
MagTek and InSpec 9000 are registered trademarks of MagTek, Inc.
Microsoft, MS, and MS-DOS are registered trademarks, and Windows is a trademark of Microsoft
Corporation.
REVISIONS
Rev
Number
1 9/27/96 Release for Pre-Production Beta Units
2 12/18/96 Deleted Calibration, added Setup, and complete revision except for
3 1/16/97 Changed Setup screen to add “Cleaning Cycles” and “Total Setup”
4 2/24/98 Updated all screen captures to Windows 95; Changed
5 4/2/98 Added Product Information to front matter. Changed analysis area in
6 8/4/98 Added phone number on title page. Section 1: added part numbers.
7 4/21/99 Sec 1. Clarified note to state that cards within ISO 7810 spec can be
8 9/6/01 Front Matter: Updated agency approval status and Safety page.
9 4/15/03 Front Matter: added ISO line to logo, changed Tech Support phone
10 7/13/04 Sec 1, Requirements, MagTek Supplied: Test Cards (2) Changed
11 8/5/04 Sec 1, Requirements, MagTek Supplied: Deleted 3 ½ “ disk and
12 8/24/04 Throughout: Deleted references to Windows 95. Sec 2: Replaced
Date Notes
Appendices
in Section 2. Spec change, Card Parameters, Section 1
Requirements and Specs Sec 1; Added Roller Cleaning, added
Security to Main Screen Fig 3-2, Sec 3; Added Card Failures and
Noise Detection and Security to Sec 3, Figs 3-4, -5, -6, -7, -8; Added
Calibration and Verification Procedure, and Fig 3-11 to Sec 3;
Added new Figs 4-2, -5, Sec 4; Added message to troubleshooting
table Sec 5; Added Appendix D, Error Messages; Added Index.
Spec, Sec 1. Changed cleaning procedure, Sec 2. Added Noise
Detection description, and changed Figs 3-2, 3-7, and 3-11, Sec 3.
Changed Figs 4-4, 4-5, 4-6, and 4-8, Sec 4.
Section 2: added installation disks; added cleaning, test card, and
head polishing procedures. Section 3: added 'password' to index.
Section 4, Figure 4-2 and 4-3: changed illustration and related text
to update.
read. Added card-cleaning precaution. Sec 2. Combined Head and
Roller cleaning procedure to reflect software change which adds
second cycle to cleaning; Added caution note for letting unit dry
before inserting a card.
number, added new warranty statement.
P/N 96700033 to 96600033.
added CD P/N 39810316.
Software Section.
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LIMITED WARRANTY
MagTek warrants that the products sold to Reseller pursuant to this Agreement will perform in accordance with
MagTek’s published specifications. This warranty shall be provided only for a period of one year from the date
of the shipment of the product from MagTek (the “Warranty Period”). This warranty shall apply only to the
original purchaser unless the buyer is authorized by MagTek to resell the products, in which event, this warranty
shall apply only to the first repurchase.
During the Warranty Period, should this product fail to conform to MagTek’s specifications, MagTek will, at its
option, repair or replace this product at no additional charge except as set forth below. Repair parts and
replacement products will be furnished on an exchange basis and will be either reconditioned or new. All replaced
parts and products become the property of MagTek. This limited warranty does not include service to repair
damage to the product resulting from accident, disaster, unreasonable use, misuse, abuse, customer’s negligence,
Reseller’s negligence, or non-MagTek modification of the product. MagTek reserves the right to examine the
alleged defective goods to determine whether the warranty is applicable.
Without limiting the generality of the foregoing, MagTek specifically disclaims any liability or warranty for
goods resold in other than MagTek’s original packages, and for goods modified, altered, or treated by customers.
Service may be obtained by delivering the product during the warranty period to MagTek (1710 Apollo Court,
Seal Beach, CA 90740). If this product is delivered by mail or by an equivalent shipping carrier, the customer
agrees to insure the product or assume the risk of loss or damage in transit, to prepay shipping charges to the
warranty service location and to use the original shipping container or equivalent. MagTek will return the product,
prepaid, via a three (3) day shipping service. A Return Material Authorization (RMA) number must accompany
all returns.
MAGTEK MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED, AND MAGTEK DISCLAIMS ANY
WARRANTY OF ANY OTHER KIND, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE.
EACH PURCHASER UNDERSTANDS THAT THE MAGTEK PRODUCT IS OFFERED AS IS. IF THIS
PRODUCT DOES NOT CONFORM TO MAGTEK’S SPECIFICATIONS, THE SOLE REMEDY SHALL BE
REPAIR OR REPLACEMENT AS PROVIDED ABOVE. MAGTEK’S LIABILITY, IF ANY, TO RESELLER
OR TO RESELLER’S CUSTOMERS, SHALL IN NO EVENT EXCEED THE TOTAL AMOUNT PAID TO
MAGTEK BY RESELLER UNDER THIS AGREEMENT. IN NO EVENT WILL MAGTEK BE LIABLE TO
THE RESELLER OR THE RESELLER’S CUSTOMER FOR ANY DAMAGES, INCLUDING ANY LOST
PROFITS, LOST SAVINGS OR OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT
OF THE USE OF OR INABILITY TO USE SUCH PRODUCT, EVEN IF MAGTEK HAS BEEN ADVISED OF
THE POSSIBILITY OF SUCH DAMAGES, OR FOR ANY CLAIM BY ANY OTHER PARTY.
LIMITATION ON LIABILITY
EXCEPT AS PROVIDED IN THE SECTIONS RELATING TO MAGTEK’S LIMITED WARRANTY,
MAGTEK’S LIABILITY UNDER THIS AGREEMENT IS LIMITED TO THE CONTRACT PRICE OF THE
PRODUCTS.
MAGTEK MAKES NO OTHER WARRANTIES WITH RESPECT TO THE PRODUCTS, EXPRESSED OR
IMPLIED, EXCEPT AS MAY BE STATED IN THIS AGREEMENT, AND MAGTEK DISCLAIMS ANY
IMPLIED WARRANTY, INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
MAGTEK SHALL NOT BE LIABLE FOR CONTINGENT, INCIDENTAL, OR CONSEQUENTIAL
DAMAGES TO PERSONS OR PROPERTY. MAGTEK FURTHER LIMITS ITS LIABILITY OF ANY KIND
WITH RESPECT TO THE PRODUCTS, INCLUDING ANY NEGLIGENCE ON ITS PART, TO THE
CONTRACT PRICE FOR THE GOODS.
MAGTEK’S SOLE LIABILITY AND BUYER’S EXCLUSIVE REMEDIES ARE STATED IN THIS SECTION
AND IN THE SECTION RELATING TO MAGTEK’S LIMITED WARRANTY.
iii
This product has been evaluated, tested, and certified by the Canadian Standards Association (CSA 22.2), No.
950, and Underwriters Laboratories (UL1950). In order to insure that it maintains the safety integrity that was
designed into the product, and for which it has been evaluated by the Safety Certification Agencies, compliance
with all Installation Instructions and Safety Requirements is essential.
SAFETY REQUIREMENTS
Never do any of the following:
• Use a ground adapter plug to connect equipment to a power source receptacle that lacks a ground connection
terminal.
• Attempt any maintenance function that is not specifically described in this Manual or any other MagTek
InSpec 9000 Manual.
• Remove any of the covers or guards that are fastened with screws. There are not operator-serviceable areas
within these covers.
• Override or “cheat” electrical or mechanical interlock devices.
• Use supplies or cleaning materials for other than their intended purposes.
• Operate the equipment if unusual noises or odors are noticed.
Consider the following before operating the InSpec 9000:
• Connect equipment to a properly grounded power source receptacle. If in doubt, have the receptacle checked
by a qualified electrician.
• Improper connection of the equipment grounding conductor can result in risk of electrical shock.
• Locate equipment on a solid support surface with adequate strength for the weight of the machine.
• Be careful in moving or relocating the equipment. Use the proper lifting techniques.
• Use materials and supplies specifically designed for MagTek equipment. Use of unsuitable materials may
result in poor performance and can possibly create a hazardous situation.
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FCC WARNING STATEMENT
This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part
15 of FCC Rules. These limits are designed to provide reasonable protection against harmful interference when
the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful
interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful
interference in which case the user will be required to correct the interference at his own expense.
FCC COMPLIANCE STATEMENT
This device complies with Part 15 of the FCC Rules. Operation of this device is subject to the following two
conditions: (1) This device may not cause harmful interference. And (2) this device must accept any interference
received, including interference that may cause undesired operation.
CANADIAN DOC STATEMENT
This digital apparatus does not exceed the Class A limits for radio noise for digital apparatus set out in the Radio
Interference Regulations of the Canadian Department of Communications.
Le présent appareil numérique n’émet pas de bruits radioélectriques dépassant les limites applicables aux
appareils numériques de las classe A prescrites dans le Réglement sur le brouillage radioélectrique édicté par les
ministère des Communications du Canada.
CE STANDARDS
Testing for compliance to CE was performed by an independent laboratory. The unit under test was found compliant
to Class A.
UL/CSA
This product is listed per Underwriter Laboratories and Canadian Underwriter Laboratories 1950.
v
Product Information
The InSpec 9000 Encoded Card Tester is a real-time, continuous feedback, production line card tester.
Because the parameters that appear on the screen are color coded, and warning screens advise when a
card “MAY NOT BE READABLE IN THE FIELD,” the tester is relatively easy to operate. The Tester
is intended to be a reliable instrument of in-line testing that does not require a technician or an engineer
to operate; nor does it require extensive technical knowledge of magnetics to operate and to interpret the
parameters on the screen. The InSpec 9000 Tester is designed to complement the more expensive,
highly complex, precision, laboratory test equipment. MagTek recommends that out-of-spec cards
from the Tester should be confirmed periodically by an independent laboratory.
Because the InSpec 9000 is a cost-effective tradeoff compared with a precision laboratory test unit,
some policy judgment is required to interpret ISO limits and the machine tolerances or “measurement
uncertainty.” ISO limits and measurement uncertainties are listed in Section 3, Figure 3-11, and
examples are shown in Section 4, Figures 4-2 and 4-3. Measurement uncertainty for average amplitude,
average bit size, and start sentinel are concerns of management for acceptance or rejection of cards. If
these parameters are centered on the screen between minimum and maximum limits (centered in the
green), the card will be acceptable even if the measurement uncertainty is worst case. If these
parameters are near maximum or minimum limits when worst case measurement uncertainty is
projected, the following precautions should be considered: the Tester should be checked; the sample
may need to be expanded; or the cards may need to be physically checked to ensure they are clean and
flat. Ultimately, judgment is required, and a policy decision should be in place for the operator.
The screen may also warn of two other parameters that concern noise detection: Added Pulse Detection
and Wave Form Distortion. Tests of these parameters are critical in HiCo material testing. Exceeding
the ISO limit by even a small percentage may affect read reliability. Since these two parameters are
characteristic of the magnetic stripe and not encoding, issuers who have prequalified their stripes at a
testing laboratory will rarely see this warning. If the warning appears frequently, sample cards should
be sent to a testing laboratory for investigation and confirmation of the absolute values for the added
pulse and waveform conditions.
For accurate card reading, normal preventive maintenance is the guideline. Consult the following:
Card size and thickness (Section 1, Specifications)
Card and Tester Cleaning (Section 2, Cleaning)
Calibration (Section 3, Calibration and Verification)
For corrective maintenance, consult Section 5, Troubleshooting and Appendix D, Error Messages.
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vii
TABLE OF CONTENTS
SECTION 1. FEATURES AND SPECIFICATIONS.....................................................................................1
FEATURES...............................................................................................................................................1
REQUIREMENTS.....................................................................................................................................1
MagTek supplied ..................................................................................................................................1
User supplied........................................................................................................................................2
SPECIFICATIONS....................................................................................................................................2
SECTION 2. INSTALLATION......................................................................................................................3
UNPACKING.............................................................................................................................................3
HARDWARE.............................................................................................................................................3
SOFTWARE..............................................................................................................................................4
SETUP......................................................................................................................................................5
Keyboard Protocol................................................................................................................................6
Taskbar Removal .................................................................................................................................7
CLEANING................................................................................................................................................7
Card Cleaning.......................................................................................................................................8
Head and Roller Cleaning - Standard Card, P/N 96700004................................................................8
TEST CARDS ...........................................................................................................................................9
Head Polishing - 0.5-micron (Abrasive Card), P/N 96700014 ...........................................................10
SAMPLING TECHNIQUES.....................................................................................................................10
SECTION 3. OPERATION.........................................................................................................................13
OPENING THE TESTER PROGRAM....................................................................................................13
MAIN SCREEN.................................................................................................................... ...................14
Windows Screen.................................................................................................................................14
CARD STOCK, SYSTEM, SHIFT...................................................................................................... .....17
SECURITY..............................................................................................................................................18
READING A CARD.................................................................................................................................19
CARD FAILURES...................................................................................................................................19
PARAMETERS .......................................................................................................................................21
ISO Limits and Measurement Uncertainty..........................................................................................23
Amplitude............................................................................................................................................24
Bit Size................................................................................................................................................25
Sub. Int. ..............................................................................................................................................25
Adj. Bit ................................................................................................................................................26
Adj. Sub..............................................................................................................................................26
Start Sent............................................................................................................................................26
CALIBRATION.................................................................................................................... ....................27
CALIBRATION VERIFICATION..............................................................................................................28
SECTION 4. GRAPHICS PRESENTATIONS ...........................................................................................29
ISO PARAMETERS................................................................................................................................30
CARD PROFILES...................................................................................................................................31
PERFORMANCE CHARTS............................................................................................................. .......36
INTERPRETING PERFORMANCE CHARTS........................................................................................36
DATABASE.............................................................................................................................................40
SECTION 5. TROUBLESHOOTING..........................................................................................................43
TROUBLESHOOTING TABLE ...............................................................................................................43
CARD EXTRACTION..............................................................................................................................44
APPENDIX A. MAGNETIC ENCODING....................................................................................................47
HISTORICAL BACKGROUND ...............................................................................................................47
BASICS OF MAGNETIC RECORDING..................................................................................................48
Magnetic Tape....................................................................................................................................48
Modern Magnetic Tape.......................................................................................................................50
Encoding Process...............................................................................................................................50
Magnetic Tape Characteristics...........................................................................................................52
DIGITAL MAGNETIC RECORDING.......................................................................................................54
F2F Encoding .....................................................................................................................................54
APPENDIX B. GLOSSARY.......................................................................................................................61
APPENDIX C. CARD STANDARDS.........................................................................................................65
ISO PARAMETERS................................................................................................................................65
HIGH COERCIVITY MAGNETIC MEDIA ...............................................................................................69
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CARD STANDARDS LISTING ...............................................................................................................69
APPENDIX D. ERROR MESSAGES.........................................................................................................73
INDEX..........................................................................................................................................................79
ILLUSTRATIONS
Figure 1-1. InSpec 9000 Card Tester ..........................................................................................................x
Figure 2-1. Fuse Holder ...............................................................................................................................4
Figure 2-2. Unit Not Set Up..........................................................................................................................5
Figure 2-3. Setup Screen.............................................................................................................................5
Figure 2-4. Successful Setup.......................................................................................................................6
Figure 2-5. Setup Previously Performed......................................................................................................6
Figure 2-6. Setup Database.........................................................................................................................7
Figure 3-1. Opening Display ......................................................................................................................13
Figure 3-2. Main Screen.............................................................................................................................14
Figure 3-3. Archive Database ....................................................................................................................15
Figure 3-4. Security Screen .......................................................................................................................18
Figure 3-5. LRC Failure..............................................................................................................................20
Figure 3-6. LRC or Parity Check Failure....................................................................................................20
Figure 3-7. Start Sentinel Not Found .........................................................................................................20
Figure 3-8. Added Pulse Detected.............................................................................................................21
Figure 3-9. Max/Min ISO Parameters ........................................................................................................22
Figure 3-10. Average ISO Parameters.......................................................................................................23
Figure 3-11. ISO Limits ..............................................................................................................................24
Figure 3-12. Reference Amplitude.............................................................................................................25
Figure 3-13. Bit Size...................................................................................................................................26
Figure 4-1. ISO Parameters.......................................................................................................................30
Figure 4-2. Numerical Parameters.............................................................................................................32
Figure 4-3. Numerical Printout...................................................................................................................33
Figure 4-4. Amplitude Graph......................................................................................................................34
Figure 4-5. Start Sentinel ...........................................................................................................................35
Figure 4-6. Performance - Amplitude.........................................................................................................37
Figure 4-7. Performance - Bit Size.............................................................................................................38
Figure 4-8. Performance - Start Sentinel ...................................................................................................39
Figure 4-9. Card Database Search............................................................................................................40
Figure 4-10 Card Database Records.........................................................................................................41
Figure 5-1. CET Orientation.......................................................................................................................44
Figure 5-2. CET Insertion...........................................................................................................................44
Figure 5-3. CET Rotation ...........................................................................................................................45
Figure 5-4. CET Extraction.........................................................................................................................45
Figure A-1. Magnetic Field.........................................................................................................................48
Figure A-2. Reverse Polarity......................................................................................................................49
Figure A-3. Encoding Head Model.............................................................................................................50
Figure A-4. Magnetic Tape Model..............................................................................................................51
Figure A-5. Flux Transitions.......................................................................................................................52
Figure A-6. Encode Current Level..............................................................................................................52
Figure A-7. Signal Amplitude .....................................................................................................................53
Figure A-8. Bit Cell - Flux Transition..........................................................................................................55
Figure A-9. Card Coding ............................................................................................................................56
Figure A-10. Bit Cells for 0 and 1 Bits........................................................................................................58
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x
Figure 1-1. InSpec 9000 Card Tester
SECTION 1. FEATURES AND SPECIFICATIONS
The InSpec 9000 Encoded Card Tester measures parameters of magnetic stripe encoding. The
parameters are shown on a computer screen and compared with ISO (International Standards
Organization) standards. Because the parameters are presented as graphic illustrations, they are
easy to read and easy to understand. The Tester also provides performance trends based on a
database of test results.
FEATURES
• Measures amplitude, bit size, and start sentinel, and compares results with ISO standards and
presents data in various graphs, charts and tables
• Provides previous measurements of individual cards or daily summaries to establish trends
• Presents card profile graphs of each measured parameter
• Easily installed and easy to use Windows-based software
• Uses specially provided cards for easy head cleaning
• Maintains database files
• On-site calibration from user collected data on a test card compared to a factory-provided
card
• Security password to restrict access or permit controlled use access to certain data
REQUIREMENTS
Equipment needed to operate the Tester is either supplied by MagTek or the customer. These
items are listed below.
MagTek supplied
• InSpec 9000 Card Tester hardware, P/N 39810003; Software-CD, Noise Detect, P/N
39810316
• Cable, 9 pin male Tester to 9-pin female PC Adapter, P/N 21015823
• Cable, power from Tester to wall receptacle, P/N 71100001
• Cleaning Cards, P/N 96700004
• Polishing Card, 0.5 micron (1), P/N 96700014
• Test Cards (2), P/N 96600033
• Setup Cards (2) - InSpec 9000, unit specified, P/N 96600036
• Card Extraction Kit, P/N 39814801
1
InSpec 9000 Encoded Card Tester
User supplied
The recommended minimum requirements are as follows:
• Pentium Computer System
• VGA color monitor (resolution 800 x 600 pixels or higher)
• 8MB RAM (recommended 16MB)
• 10MB of hard disk space
• 1 Serial Port
• Windows 98, ME, NT, or 2000
• Color Printer
SPECIFICATIONS
Operational
Operating Voltage: 100 – 240 VAC
Operating Current 1.0 amp
Operating Temperature: 50oF to 122oF (+10oC to +50oC)
Humidity: 10% to 90% without condensing
Card Speed: 8 inches per second, typical
Resolution 10µ inches
Analysis Area All three data tracks excluding 0.130 inch at each end
Measure Limits Conform to ISO 7811 within Analysis Area
Mechanical
Depth: 13.3 inches
Width: 7.5 inches
Height: 7.1 inches
Weight: 8 lbs.
Card Parameters
Width and Length: Per ISO/IEC Specification 7810:1995(E)
Thickness: 0.030 in ± 0.003 in (0.76 mm ± 0.08 mm)
Note
The InSpec 9000 may not accurately read cards whose thickness and/or warpage
exceed the ISO 7810 specification. In addition, cards that are not properly
cleaned may give poor results along with contamination of the card path and
head face.
2
SECTION 2. INSTALLATION
This section provides instructions for installing the Tester. There are five parts to the installation
of the InSpec 9000 Tester: unpacking, hardware installation, software installation, setup, and
cleaning. Because card sampling is required for production, some examples are referenced in this
section.
UNPACKING
Remove all material from the shipping carton and check the material with the shipping invoice
to ensure everything on the invoice is contained in the carton. If there is damage to the unit or
material on the invoice is missing, notify MagTek and the carrier.
Note
Retain the shipping carton and all packing material. The Tester
may be packed and shipped back to the factory periodically for
calibration or warranty service .
HARDWARE
Install the hardware as follows:
1. Place the Tester near the PC and a wall receptacle so that the cables can be installed.
Caution
Ensure power is off before plugging in cables, or
damage to equipment or the program may result.
2. Plug the cable with the 9-pin connector into the Tester and the other end to the PC Com
Port. It may be necessary to use a DB9 to DB25 adapter for the Com port.
3. Plug the power cord into the Tester and the wall receptacle.
4. Power up the computer and press the power on (I) switch on the rear panel of the Tester.
5. The LED on the front of the Tester should be green. If the LED does not come on,
check to ensure the cables are properly connected.
6. If the LED still does not light, press the power switch off, remove the cables, and check
the fuse, located next to the power switch as shown in Figure 2-1.
7. Replace the fuse if necessary, reconnect the cables, and power up. If the LED still does
not light, call for technical or supervisory personnel.
3
InSpec 9000 Encoded Card Tester
Figure 2-1. Fuse Holder
SOFTWARE
To begin the installation, insert the CD into the appropriate drive. The installation program will
automatically start. If the installation program does not start automatically, select Run from the
Start menu. Within the open field, type x:\setuup, where x: is the drive letter of your CD ROM
drive. Click OK to begin the installation. The installation program will guide you through the
setup process.
Note for International Users
The Inspec 9000 software requires regional settings be set to
English (United States). Some features may not work correctly if
other settings are used.
4
Section 2. Installation
SETUP
To setup the unit for operation, perform the following steps:
1. From the Windows Program Manager, open the InSpec 9000 program. (If more details
are required for opening the program, refer to the next section, Operation.)
2. After the opening screen briefly flashes on the screen and the main menu appears, click
on the Read Card button. If the unit is not set up, the dialog box shown in Figure 2-2 will
appear. Error messages are listed in Appendix D.
Figure 2-2. Unit Not Set Up
3. From the Main Menu select Setup, select Hardware, then Setup and the following screen
will appear:
Figure 2-3. Setup Screen
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InSpec 9000 Encoded Card Tester
The ID number is a unique number for that unit that also identifies the firmware. If a problem
exists with the unit, this number will be needed by technical support personnel.
4. Click on Setup unit. The dialog box to appear will request the Setup Card: Insert
Setup Card No: A000000. The number that appears on the box will be the
number on the Setup Card that was shipped with the unit.
5. Insert the Setup Card, and the next dialog box to appear is shown in Figure 2-4
Figure 2-4. Successful Setup
If the unit has been previously set up, the screen shown in Figure 2-5 will appear:
Figure 2-5. Setup Previously Performed
To obtain information about the database setup, select View from the Main Menu, then Setup
Database. Figure 2-6 shows the Setup Database screen. The screen lists the identification
numbers, the date and time of setup, the total number of cards read, and the number of reads
since the last cleaning. Information at the bottom of the screen is for maintenance personnel.
Keyboard Protocol
The keyboard protocol of the InSpec 9000 follows the protocol of Windows; for example, if a
keyboard is to be used instead of a mouse, the underlined letter in the dialog box can be typed
instead of clicking on it with a mouse. In Figure 2-5, if the previous setup is to be overwritten,
instead of clicking on Yes with the mouse, type Y. Sometimes the keys Ctrl or Alt are used with
the underlined letter. Check the Windows documentation for details.
6
Section 2. Installation
Taskbar Removal
If the taskbar at the bottom of the screen is in the way of viewing the screen, it may be necessary
to remove it. Click on Start, then Settings and Taskbar. When Taskbar Properties appears,
click on Taskbar Options, then Auto hide, then OK. The Taskbar will then go below the
bottom of the screen. To reposition the taskbar, move the cursor to the bottom of the screen, and
the taskbar will reappear.
Figure 2-6. Setup Database
CLEANING
Accurate signal amplitude measurements (described in Section 3) depend on high quality contact
between the Tester’s magnetic head and the magnetic stripe under test. If the head does not
make good contact by even a small amount, the resulting signal amplitude measurement value
will be lower than it would have been with proper contact. A separation between the head and
stripe of only 0.0005 inches (13µm) can lower the signal amplitude result by 50%.
Aside from surface distortions on the magnetic stripe or card, contamination is primarily
responsible for poor head to stripe contact.
7
InSpec 9000 Encoded Card Tester
Offset powder sometimes used in card manufacture to prevent blocking (powder can cause a
significant decrease in amplitude and can contaminate the read head giving false readings for
many cards.)
• Packing materials; fibers from containers
• Hologram/Signature, Panel/Magnetic media particles “flash” not adhering to the card as
intended
• Cards can also become statically charged making them attract airborne dust.
Card Cleaning
To optimize test results, MagTek recommends cleaning the magnetic stripe cards with ammoniabased glass cleaner before testing.
Caution
Do not clean magnetic stripe cards with alcohol or damage to the
magnetic stripe may occur.
Head and Roller Cleaning - Standard Card, P/N 96700004
The Tester can only provide reliable results if it is clean. As a result, the Tester will issue a
warning after 50 card read cycles. When the warning is received, the cleaning procedure should
be performed. The warning will appear for each card tested until the cleaning procedure is
performed.
Caution
Do not run the 0.5-micron card (abrasive stripe) for this procedure
or damage to the cleaning card and the Tester may result.
Use the cleaning card and clean the head as follows:
1. From the Main Menu, select Options and select Clean Unit.
Note
Ensure the cleaning card is flat. If it is not flat, straighten it as
required before using.
2. When the following prompt appears,
Insert Card Fabric Side UP!
8
Section 2. Installation
Insert the cleaning card into the Tester with the fabric side up (shiny side down) and
press Clean Unit.
3. The cleaning card will move in and out of the Tester three times. When completed,
follow the prompt:
Remove card and press OK to continue.
4. The next prompt will be:
Insert Card Fabric Side DOWN!
Turn the cleaning card over and insert it into the Tester with the fabric side down (shiny
side up).
5. The cleaning card will move in and out of the Tester three times.
6. Remove and discard the card.
Caution
Wait approximately 2 minutes before performing card analysis.
This will allow the unit to dry and thereby prevent damage to the
magnetic stripe to the next cards to be analyzed.
TEST CARDS
Two test cards are shipped with each unit for the purpose of verifying that the Tester is within
tolerance. Each card has a serial number on the face. The values that should appear when a test
card is inserted into the Tester are also listed on the InSpec 9000 Test Card Report that is
shipped with each unit. The cards are listed on the Report by serial number. Use the cards as
follows:
1. Insert a sample production card that is out of ISO specifications; that is, a card that shows
yellow or red bars on the ISO Parameters screen when it is inserted into the Tester. (See
Section 3, Operation and Section 4, Graphics Presentations.)
2. Insert a MagTek test card into the Tester, and check the ISO Parameters screen. All the
bars on the screen should be green for the test card. If there is any doubt about the
validity of the test, check the values of the test card on the screen against the InSpec 9000
Test Card Report. The values should be approximately the same*. Both should be
within tolerance. Compare the production card with the Test Card.
*Tolerances for the test cards are as follows:
• Average Amplitude = ± 15%
• Start Sentinel = ± 0.007 inch
• Average Bit Size = ± 2%
9
InSpec 9000 Encoded Card Tester
3. If there is still some doubt about the accuracy of the Tester, run the other test card and
check the values as described in step 2. If necessary, perform the 0.5-micron head
polishing procedure below.
Head Polishing - 0.5-micron (Abrasive Card), P/N 96700014
If the Tester shows a change in amplitude of approximately 15% to 20% after the Test Card
Procedure is run, use the 0.5 micron (abrasive) head-polishing card, P/N 96700014, and clean the
head as follows:
1. With the abrasive stripe up and to the left, insert the card and click on Clean Unit.
2. The card will move in and out of the Tester three times.
Caution
Do not run the head-polishing card with abrasive stripe down, or
damage to the roller surface and the Tester may result.
3. Remove the head-polishing card from the Tester, and run the cleaning card.
Note
Do not discard the head-polishing card after one use; this card is
for multiple use.
4. Perform the Test Card procedure to ensure the Tester is within tolerance. If the results
are not within spec, call service personnel.
SAMPLING TECHNIQUES
The InSpec 9000 Encoded Card Tester is designed for a production environment; that is, samples
are taken from a large production run and tested on the InSpec 9000. The samples tested
represent a lot or batch. The lot or batch is accepted or rejected on the basis of these samples.
More than sampling lots for acceptance or rejection, the Tester also reveals problem trends with
the processes of producing, encoding, or testing cards. Because of the graphics presentations
and database in the Tester, problem trends are easier to identify. (See Section 4, Graphics
Presentations, Interpreting Performance Charts.)
There are many techniques for sampling, and the example below is commonly used in industry.
The example is taken from the following publication:
ANSI/ASQC Z1.4 - 1993, American National Standard, Sampling Procedures and Tables for
Inspection by Attributes, American Society for Quality Control.
10
Section 2. Installation
In the following table, the "Single Normal Plan, General Inspection Level I, AQL .010"
designates the criteria used in sampling. In the Table, the Lot Size is equivalent to the card
production run; the Sample Size is the number of randomly selected cards to be run on the
Tester; the Accept and Reject columns are the number of samples for rejecting or accepting the
Lot. If, for example, Accept is 1 and Reject is 2, the Lot will be accepted if there is 1 card out of
spec, but rejected if there are 2 cards out of spec. If the Lot is rejected, the process is repeated.
If rejected again, 100% evaluation is required.
Example of Single Normal Plan, General Inspection Level I, AQL .010
Lot or Batch Size Sample Size Accept Reject
2 to 8 All 0 1
9 to 15 All 0 1
16 to 25 All 0 1
.
.
.
151 to 280 13 0 1
281 to 500 20 0 1
501 to 1200 32 0 1
The following procedure is only an example using ANSI/ASQC Z1.4 - 1993 as a guideline for
sampling:
1. Determine the Lot size, and remove the number of samples listed in the table.
2. For a Lot size of 501 to 1200, remove 32 samples and run them on the
Tester.
3. If all 32 cards are within spec, accept the Lot.
4. If 1 card is out of spec, repeat steps 2 and 3.
5. If 1 card is out of spec, test the entire Lot.
Consult ANSI/ASQC Z1.4 - 1993, for actual techniques and values for sampling.
11
InSpec 9000 Encoded Card Tester
12
SECTION 3. OPERATION
The operation of the Tester includes opening the tester program, cleaning, reading cards and
interpreting the results, obtaining performance charts and interpreting trends. Also included in
this section are descriptions of Windows-style buttons and Tester icons on the main screen.
OPENING THE TESTER PROGRAM
After the InSpec Tester program is opened from Windows, a picture of the Tester with the
version number will appear as shown in Figure 3-1. In this example the unit is installed, and the
firmware version number and the Unit ID are listed. When the unit is not properly installed, the
message “Unit Not Installed...” appears where the firmware and ID numbers are.
Figure 3-1. Opening Display
This screen will disappear in a few seconds leaving the main screen showing.
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InSpec 9000 Encoded Card Tester
MAIN SCREEN
At the top of the main screen, shown in Figure 3-2, the buttons are similar to Windows buttons
but are specific to the Tester. The screens selected from the main screen are shown in this
section and in “Section 4. Graphics Presentations”.
Figure 3-2. Main Screen
Windows Screen
Brief descriptions of the routines that are presented by the Windows menu bar are as follows:
14
Section 3. Operation
File
Open Card - The Open button is for a unique card-specific file used for previous card reads that
have been saved on an individual basis. Card profile charts, which are normally used by
technical personnel, are not saved in the database but may be accessed by using this button when
saved with the save button.
Save Card - The Save Card button is for a unique card-specific file used for saving a card, bar
chart, and card profile information for future reference. This does not save the card in the
database. See Section 4, “Graphics Presentations”, for a description of card profiles.
Archive Database - Allows the operator to move all data before a selected date from the database
to an archive file. If the size of the database is reduced, working with performance charts is
faster. The screen is shown in Figure 3-3. An example of the date for 2 Jan 99 is written as 01
02 99. Any year less than 90 will be considered to be after 2000; for example, 59 will be 2059;
the year 98 will be 1998. MagTek recommends the database should be archived monthly.
Reset Security – See Reset Security below.
Exit - Standard Windows exit from this program.
Figure 3-3. Archive Database
iew
V
ISO Compliance - The bar chart that appears represents the most recent card that was read. After
a graph or chart has been canceled, this button will retrieve only the most recent card viewed.
Card DataBase - The screen Card Database Search Parameters permits search of data base by
time and date, card stock, system type, and shift. When the parameters are selected, the screen
Card Database Records gives results for amplitude, bit size, adjacent bit, start sentinel, and track,
all of which are listed in Section 4 under Database.
15
InSpec 9000 Encoded Card Tester
Setup Database - Refer to Setup in Section 2 and see below.
erformance Charts - Presents individual card or daily summary of amplitude, bit characteristics,
P
start sentinel and specified time period. This is used to obtain Performance Trend Charts which
alert the operator to take action when parameters begin to drift out of specification. The user
may also specify a printout of numerical data with all ISO parameters, or for a single Track, a
graph, a print out of the screen, or exit from the screen. For the numerical data screen, as the
cursor is positioned on each parameter, ISO specifications for that parameter appear at the
bottom of the screen.
Archived Data Charts -Permits viewing of archived data (See Archived Database above).
ISO Limits - Lists ISO limits for new cards (also called unused encoded cards) and used cards
(also called returned cards, which are cards that have been issued and returned for evaluation).
Error Log - Lists Date, Time, Error Code, Error Description, and Error Location. Used by
technical personnel for troubleshooting.
Setup
Presents screen for Software and Hardware Setup. Software includes Parameters and Security.
Parameters is for adding or removing card stock, system type, and shift as described below.
Security restricts access to certain data and is also described below. Hardware lists and permits
selection of PC Com Ports 1 through 4. If a Com Port is not selected, a dialog box will appear:
“Com port not selected. Please select a com port from the Options menu!” Refer to Section 2,
Installation, Hardware Setup for further installation setup information.
Options
Allows operator to select the functions of Clean Unit or Eject Card. When Clean Unit is
selected, a prompt appears for cleaning. When Eject Card is selected, the unit should eject the
card. If the card does not eject, see Section 5, Troubleshooting, for removing the card.
Help
Contents gives extensive on-line “How to” presentations and other operational
descriptions. About shows opening screen which lists the firmware and unit ID numbers
Read Card
Before “Read Card” is selected, selections from “Card Stock”, “System”, and “Shift” selections
must be highlighted. When the ISO screen appears, the operator may add to the
database or cancel (not add to the database). See the subsection “Reading a Card”
below.
16
Section 3. Operation
Clean Unit
When Clean Unit is selected, the program will prompt to insert the cleaning card. Insert the card
with the soft side up (shiny side down). The unit will then move the card in and out
three times, and the head will be cleaned. To clean the rollers, turn the card over and
insert it with the soft side down (shiny side up). The unit will move the card as
previously described to clean the rollers.
Reset Security
When the software starts up, or when Reset Security is clicked, the standard restriction is
activated. The standard restriction may be changed or modified as described below
under Security.
CARD STOCK, SYSTEM, SHIFT
Before a card can be read and the information stored in the database, the card stock, system type
and shift must be highlighted. The titles “Card Stock, System, Shift” may be changed by the
user as required. To change the entries, select Setup and Software Setup from the main menu,
double click on the entry to be changed, and when the dialog box appears type in the new title
and click on OK.
To Setup the database, perform the following steps:
1. From the main screen select the Setup button then Software.
2. Under Card Stock type in the name of the card manufacturer and the batch number of the
cards, or equivalent for identification. (MagTek recommends this information. The user
may require more or less.) An example is: 1st Stock Mfr -Visa Gold.
3. Press the Add button.
4. Under System, enter the name of the encoder. MagTek also recommends the model, and
the serial number. An Example is: 1st Encoder, Mod 1, SN 12345678.
5. Press the Add button.
6. Under Shift, enter the name of the shift when the tests are performed (another entry may
be Employee).
7. Press the Add button.
8. Press the OK button.
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