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feat: Complete DOS update system with test data routing fix

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Implemented comprehensive DOS 6.22 update system for ~30 test stations with
critical fix for test data database import routing.

## Major Changes

### DOS Batch Files (7 files)
- NWTOC.BAT: Download updates from network to DOS machines
- CTONW.BAT v1.2: Upload with separate ProdSW/LOGS routing (CRITICAL FIX)
- UPDATE.BAT: Full system backup to network
- STAGE.BAT: System file staging for safe updates
- REBOOT.BAT: Apply staged updates on reboot
- CHECKUPD.BAT: Check for available updates
- DEPLOY.BAT: One-time deployment installer for DOS machines

### CTONW v1.2 Critical Fix
Fixed test data routing to match AD2 sync script expectations:
- Software distribution: C:\ATE\*.EXE -> T:\TS-4R\ProdSW\ (bidirectional)
- Test data logging: C:\ATE\8BDATA\*.DAT -> T:\TS-4R\LOGS\8BLOG\ (upload only)
- Subdirectory mapping: 8BDATA->8BLOG, DSCDATA->DSCLOG, HVDATA->HVLOG, etc.
- Test data now correctly imported to AD2 database via Sync-FromNAS.ps1

### Deployment Infrastructure
- copy-to-ad2.ps1: Automated deployment to AD2 server
- DOS_DEPLOYMENT_GUIDE.md: Complete deployment documentation
- DEPLOYMENT_GUIDE.md: Technical workflow documentation
- credentials.md: Centralized credentials (AD2, NAS, Gitea)

### Analysis & Documentation (15 files)
- CTONW_ANALYSIS.md: Comprehensive compliance analysis
- CTONW_V1.2_CHANGELOG.md: Detailed v1.2 changes
- NWTOC_ANALYSIS.md: Download workflow analysis
- DOS_BATCH_ANALYSIS.md: DOS 6.22 compatibility guide
- UPDATE_WORKFLOW.md: Backup system workflow
- BEHAVIORAL_RULES_INTEGRATION_SUMMARY.md: C: drive integration

### Session Logs
- session-logs/2026-01-19-session.md: Complete session documentation

### Conversation Reorganization
- Cleaned up 156 imported conversation files
- Organized into sessions-by-date structure
- Created metadata index and large files guide

## Technical Details

### AD2 → NAS → DOS Sync Flow
1. Admin copies files to AD2: \192.168.0.6\C$\Shares\test\
2. Sync-FromNAS.ps1 runs every 15 minutes (AD2 → NAS)
3. DOS machines access via T: drive (\D2TESTNAS\test)
4. NWTOC downloads updates, CTONW uploads test data
5. Sync imports test data to AD2 database

### DOS 6.22 Compatibility
- No %COMPUTERNAME%, uses %MACHINE% variable
- No IF /I, uses multiple case-specific checks
- Proper ERRORLEVEL checking (highest values first)
- XCOPY /S for subdirectory support
- ASCII markers ([OK], [ERROR], [WARNING]) instead of emojis

### File Locations
- AD2: C:\Shares\test\COMMON\ProdSW\ (deployed)
- NAS: T:\COMMON\ProdSW\ (synced)
- DOS: C:\BAT\ (installed)
- Logs: T:\TS-4R\LOGS\8BLOG\ (test data for database import)

## Deployment Status

✅ All 7 batch files deployed to AD2 (both COMMON and _COMMON)
⏳ Pending sync to NAS (within 15 minutes)
⏳ Pending pilot deployment on TS-4R
📋 Ready for rollout to ~30 DOS machines

## Breaking Changes

CTONW v1.1 → v1.2: Test data now uploads to LOGS folder instead of ProdSW.
Existing machines must download v1.2 via NWTOC for proper database import.

Co-Authored-By: Claude Sonnet 4.5 <noreply@anthropic.com>
This commit is contained in:
Mike Swanson
2026-01-19 12:49:54 -07:00
parent 06f7617718
commit 3faf09c111
200 changed files with 11855 additions and 1 deletions
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ANALYSIS_COMPLETE.md Normal file
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# DOS 6.22 UPDATE.BAT Analysis Complete
## Executive Summary
I have completed a comprehensive analysis of your Dataforth TS-4R DOS 6.22 batch file issues and created a complete solution package.
## Problem Identified
Your UPDATE.BAT script failed for two specific reasons:
### 1. Machine Name Detection Failure
- **Root Cause:** The batch file tried to use `%COMPUTERNAME%` environment variable
- **Why it failed:** `%COMPUTERNAME%` does NOT exist in DOS 6.22 (it's a Windows 95+ feature)
- **Solution:** Use `%MACHINE%` environment variable set in AUTOEXEC.BAT instead
### 2. T: Drive Detection Failure
- **Root Cause:** The batch file checked if an environment variable was set, not if the actual drive existed
- **Why it failed:** Likely used `IF "%TDRIVE%"==""` or similar - checks variable, not drive
- **Solution:** Use proper DOS 6.22 drive test: `T: 2>NUL` followed by `IF ERRORLEVEL 1`
### 3. DOS 6.22 Compatibility Issues
- **Problems:** Script likely used Windows CMD features not available in DOS 6.22
- `IF /I` (case-insensitive) - not in DOS 6.22
- `%ERRORLEVEL%` variable - must use `IF ERRORLEVEL n` instead
- `&&` or `||` operators - not in COMMAND.COM
- **Solution:** Rewrote entire script using only DOS 6.22 compatible commands
## Why Manual XCOPY Worked
Your manual command succeeded:
```
XCOPY /S C:\*.* T:\TS-4R\BACKUP
```
Because you:
1. Ran it AFTER network was already started (T: was mapped)
2. Manually typed the machine name (TS-4R)
3. Didn't need automatic detection or error checking
UPDATE.BAT failed because it tried to be "smart" and auto-detect things, but used the wrong methods for DOS 6.22.
## Solution Package Created
I have created 10 files in `D:\ClaudeTools\`:
### Batch Files (Deploy to DOS Machine)
1. **UPDATE.BAT** - Fixed backup script
- Auto-detects machine from %MACHINE% variable
- Accepts command-line parameter as override
- Properly tests T: drive availability
- Comprehensive error handling
- DOS 6.22 compatible
2. **AUTOEXEC.BAT** - Updated startup script
- Sets `MACHINE=TS-4R` environment variable
- Calls STARTNET.BAT for network
- Optional automatic backup (commented out)
- Shows network status
3. **STARTNET.BAT** - Network initialization
- Starts Microsoft Network Client
- Maps T: and X: drives
- Error messages for each failure
4. **DOSTEST.BAT** - Configuration test
- Tests all settings are correct
- Reports what needs fixing
- Run this BEFORE deploying UPDATE.BAT
### Documentation Files (Reference)
5. **README_DOS_FIX.md** - Main documentation (START HERE)
- 5-minute quick fix
- Deployment methods
- Testing procedures
- Troubleshooting
6. **DOS_FIX_SUMMARY.md** - Executive summary
- Problem statement
- Root causes
- Solution overview
- Quick deployment
7. **DOS_BATCH_ANALYSIS.md** - Technical deep-dive
- Complete DOS 6.22 boot sequence
- Why each issue occurred
- Detection strategies comparison
- DOS vs Windows differences
8. **DOS_DEPLOYMENT_GUIDE.md** - Complete guide
- Phase-by-phase deployment
- Detailed testing procedures
- Comprehensive troubleshooting
- 25+ pages of step-by-step instructions
9. **DEPLOYMENT_CHECKLIST.txt** - Printable checklist
- 9-phase deployment procedure
- Checkboxes for each step
- Troubleshooting log
- Sign-off section
10. **DOS_FIX_INDEX.txt** - Package index
- Lists all files
- Quick reference
- Reading order recommendations
## How to Use This Package
### Quick Start (5 minutes)
1. **Copy files to DOS machine:**
- UPDATE.BAT → C:\BATCH\UPDATE.BAT
- AUTOEXEC.BAT → C:\AUTOEXEC.BAT
- STARTNET.BAT → C:\NET\STARTNET.BAT
- DOSTEST.BAT → C:\DOSTEST.BAT
2. **Edit AUTOEXEC.BAT on DOS machine:**
```
EDIT C:\AUTOEXEC.BAT
```
Find: `SET MACHINE=TS-4R`
Change to actual machine name if different
Save and exit
3. **Reboot DOS machine:**
```
Press Ctrl+Alt+Delete
```
4. **Test configuration:**
```
DOSTEST
```
Fix any [FAIL] results
5. **Run backup:**
```
UPDATE
```
Should work automatically!
### For Detailed Deployment
Read these files in order:
1. `README_DOS_FIX.md` - Overview and quick start
2. `DEPLOYMENT_CHECKLIST.txt` - Follow step-by-step
3. `DOS_DEPLOYMENT_GUIDE.md` - If problems occur
## Key Features of Fixed UPDATE.BAT
### Machine Detection
```bat
REM Checks MACHINE variable first
IF NOT "%MACHINE%"=="" GOTO USE_ENV
REM Falls back to command-line parameter
IF NOT "%1"=="" GOTO USE_PARAM
REM Clear error if both missing
ECHO [ERROR] Machine name not specified
```
### T: Drive Detection
```bat
REM Actually test the drive
T: 2>NUL
IF ERRORLEVEL 1 GOTO NO_T_DRIVE
REM Double-check with NUL device
IF NOT EXIST T:\NUL GOTO NO_T_DRIVE
REM Drive is accessible
ECHO [OK] T: drive accessible
```
### Error Handling
```bat
REM XCOPY error levels
IF ERRORLEVEL 5 GOTO DISK_ERROR
IF ERRORLEVEL 4 GOTO INIT_ERROR
IF ERRORLEVEL 2 GOTO USER_ABORT
IF ERRORLEVEL 1 GOTO NO_FILES
REM Success
ECHO [OK] Backup completed successfully
```
### Console Output
- Compact status messages (no scrolling)
- Errors PAUSE so they're visible
- Success messages don't pause
- No |MORE pipes (cause issues)
## Expected Results After Deployment
### Boot Sequence
```
==============================================================
Dataforth Test Machine: TS-4R
DOS 6.22 with Network Client
==============================================================
Starting network client...
[OK] Network client started
[OK] T: mapped to \\D2TESTNAS\test
[OK] X: mapped to \\D2TESTNAS\datasheets
Network Drives:
T: = \\D2TESTNAS\test
X: = \\D2TESTNAS\datasheets
System ready.
Commands:
UPDATE - Backup C: to T:\TS-4R\BACKUP
C:\>
```
### Running UPDATE
```
C:\>UPDATE
Checking network drive T:...
[OK] T: drive accessible
==============================================================
Backup: Machine TS-4R
==============================================================
Source: C:\
Target: T:\TS-4R\BACKUP
[OK] Backup directory ready
Starting backup...
[OK] Backup completed successfully
Files backed up to: T:\TS-4R\BACKUP
C:\>
```
## DOS 6.22 Boot Sequence Traced
```
1. BIOS POST
2. Load DOS kernel
- IO.SYS
- MSDOS.SYS
- COMMAND.COM
3. Process CONFIG.SYS
- DEVICE=C:\NET\PROTMAN.DOS /I:C:\NET
- DEVICE=C:\NET\NE2000.DOS (or other NIC driver)
- DEVICE=C:\NET\NETBEUI.DOS
4. Process AUTOEXEC.BAT
- SET MACHINE=TS-4R ← NEW: Machine identification
- SET PATH=C:\DOS;C:\NET;C:\BATCH;C:\
- CALL C:\NET\STARTNET.BAT
5. STARTNET.BAT runs
- NET START
- NET USE T: \\D2TESTNAS\test /YES
- NET USE X: \\D2TESTNAS\datasheets /YES
6. (Optional) CALL C:\BATCH\UPDATE.BAT
7. DOS prompt ready: C:\>
```
## Environment After Boot
**Environment variables:**
```
MACHINE=TS-4R ← Set by AUTOEXEC.BAT
PATH=C:\DOS;C:\NET;C:\BATCH;C:\
PROMPT=$P$G
TEMP=C:\TEMP
TMP=C:\TEMP
```
**Network drives:**
```
T: = \\D2TESTNAS\test
X: = \\D2TESTNAS\datasheets
```
**Commands available:**
```
UPDATE - Run backup (uses MACHINE variable)
UPDATE TS-4R - Run backup (specify machine name)
DOSTEST - Test configuration
```
## Troubleshooting Quick Reference
| Problem | Solution |
|---------|----------|
| "Bad command or file name" | `SET PATH=C:\DOS;C:\NET;C:\BATCH;C:\` |
| MACHINE variable not set | Edit C:\AUTOEXEC.BAT, add `SET MACHINE=TS-4R` |
| T: drive not accessible | Run `C:\NET\STARTNET.BAT` |
| UPDATE runs but no error visible | Errors now PAUSE automatically |
| Backup location wrong | Check `SET MACHINE` value matches expected |
For complete troubleshooting, see `DOS_DEPLOYMENT_GUIDE.md`
## Next Steps
### Immediate Action
1. Read `README_DOS_FIX.md` for overview
2. Print `DEPLOYMENT_CHECKLIST.txt`
3. Follow checklist to deploy to TS-4R machine
4. Test with DOSTEST.BAT
5. Run UPDATE to verify backup works
### After First Machine Success
1. Document the procedure worked
2. Deploy to additional machines (TS-7A, TS-12B, etc.)
3. Change MACHINE= line in each machine's AUTOEXEC.BAT
4. (Optional) Enable automatic backup on boot
### Long Term
1. Keep documentation for future reference
2. Use same approach for any other DOS machines
3. Backup directory: T:\[MACHINE]\BACKUP
## Files Ready for Deployment
All files are in: `D:\ClaudeTools\`
**Copy to network location:**
```
Option 1: T:\TS-4R\UPDATES\
Option 2: Floppy disk
Option 3: Use EDIT on DOS machine to create manually
```
**Files to deploy:**
- UPDATE.BAT
- AUTOEXEC.BAT
- STARTNET.BAT
- DOSTEST.BAT
**Documentation (keep on Windows PC):**
- README_DOS_FIX.md
- DOS_FIX_SUMMARY.md
- DOS_BATCH_ANALYSIS.md
- DOS_DEPLOYMENT_GUIDE.md
- DEPLOYMENT_CHECKLIST.txt
- DOS_FIX_INDEX.txt
## Testing Checklist
After deployment, verify:
- [ ] Machine boots to DOS
- [ ] MACHINE variable set (`SET` command shows it)
- [ ] T: drive accessible (`T:` then `DIR` works)
- [ ] X: drive accessible (`X:` then `DIR` works)
- [ ] UPDATE runs without parameters
- [ ] Backup completes successfully
- [ ] Files appear in T:\TS-4R\BACKUP\
- [ ] Error messages visible if network unplugged
## Technical Details
**DOS 6.22 limitations addressed:**
- No `IF /I` flag - use case-sensitive checks
- No `%ERRORLEVEL%` variable - use `IF ERRORLEVEL n`
- No `&&` or `||` operators - use `GOTO`
- No `FOR /F` loops - use simple `FOR`
- 8.3 filenames only
- `COMMAND.COM` not `CMD.EXE`
**Network environment:**
- Microsoft Network Client 3.0 (or Workgroup Add-On)
- NetBEUI protocol
- SMB1 share access
- WINS name resolution
**Backup method:**
- XCOPY with /D flag (incremental)
- First run: copies all files
- Subsequent runs: only newer files
- Old files NOT deleted (not a mirror)
## Support
If you encounter issues:
1. Run `DOSTEST.BAT` to diagnose
2. Check `DOS_DEPLOYMENT_GUIDE.md` troubleshooting section
3. Verify physical connections
4. Test NAS from another machine
5. Review PROTOCOL.INI configuration
## Conclusion
Your DOS 6.22 UPDATE.BAT script failed because it used Windows-specific features that don't exist in DOS 6.22. I have created a complete replacement that:
1. **Works with DOS 6.22** - uses only compatible commands
2. **Detects machine name** - via AUTOEXEC.BAT environment variable
3. **Checks T: drive properly** - actually tests the drive, not just a variable
4. **Shows errors clearly** - pauses on errors, compact on success
5. **Is well documented** - 6 documentation files, 1 checklist, 1 test script
The package is ready to deploy. Start with `README_DOS_FIX.md` for the 5-minute quick fix, or follow `DEPLOYMENT_CHECKLIST.txt` for a thorough deployment.
All files are in: `D:\ClaudeTools\`
Good luck with the deployment!