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4k smart cards invalid after voting in test count

Here's the scenario
load election on TS  3-13-9-2
program spyrus card manager
program 4 k cards from spyrus
go to test count - vote - no problem
exit test and print results
go back to test and totals appear to be there -6 original votes cast
insert voter card - remove invalid card -
program card again from same spyrus
insert voter card in TS - remove invalid card
tried it 4 times and each time card is invalid
Am I doing something wrong?  do i need to reload spyrus -
this would imply that once a card is voted at precinct it cannot be reprogrammed for next voter...
which could be a disaster..
so I must be doing something wrong