claudetools/projects/dataforth-dos/d2testnas-vm/README.md

D2TESTNAS VM Replacement

Replacement for Netgear ReadyNAS RN10400 (D2TESTNAS) used in Dataforth DOS 6.22 test infrastructure. The new system is a Debian 13 (Trixie) VM running on Hyper-V with BTRFS for snapshots, Samba with SMB1 for DOS compatibility, and rsync daemon for AD2 bidirectional sync.

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1. Hyper-V VM Creation

Run these PowerShell commands on the Hyper-V host as Administrator.

# --- Configuration ---
$VMName     = "D2TESTNAS"
$VMPath     = "D:\Hyper-V\VMs"
$VHDPath    = "D:\Hyper-V\VMs\D2TESTNAS\Virtual Hard Disks"
$ISOPath    = "D:\ISOs\debian-13-netinst-amd64.iso"   # Download from https://www.debian.org/devel/debian-installer/
$SwitchName = "Dataforth-Bridge"                        # Your existing vSwitch for 192.168.0.0/24

# --- Create VM ---
New-VM -Name $VMName `
    -Path $VMPath `
    -MemoryStartupBytes 2GB `
    -Generation 2 `
    -SwitchName $SwitchName

# --- Configure VM ---
Set-VM -Name $VMName `
    -ProcessorCount 2 `
    -DynamicMemory `
    -MemoryMinimumBytes 1GB `
    -MemoryMaximumBytes 4GB `
    -AutomaticStartAction Start `
    -AutomaticStartDelay 30 `
    -AutomaticStopAction ShutDown

# --- Create OS disk (40 GB) ---
New-VHD -Path "$VHDPath\os.vhdx" -SizeBytes 40GB -Dynamic
Add-VMHardDiskDrive -VMName $VMName -Path "$VHDPath\os.vhdx"

# --- Create DATA disk (200 GB, or match current NAS capacity) ---
# This disk will be formatted as BTRFS and mounted at /data
New-VHD -Path "$VHDPath\data.vhdx" -SizeBytes 200GB -Dynamic
Add-VMHardDiskDrive -VMName $VMName -Path "$VHDPath\data.vhdx"

# --- Attach Debian ISO ---
Add-VMDvdDrive -VMName $VMName -Path $ISOPath

# --- Set boot order: DVD first (for install), then disk ---
$dvd  = Get-VMDvdDrive -VMName $VMName
$disk = Get-VMHardDiskDrive -VMName $VMName | Where-Object { $_.Path -like "*os.vhdx" }
Set-VMFirmware -VMName $VMName -BootOrder $dvd, $disk

# --- Disable Secure Boot (Debian needs "Microsoft UEFI Certificate Authority") ---
Set-VMFirmware -VMName $VMName -EnableSecureBoot Off

# --- Start VM ---
Start-VM -Name $VMName
vmconnect localhost $VMName

Adjust $SwitchName to match whatever virtual switch bridges to the 192.168.0.0/24 Dataforth network. If you do not have one, create it:

# Create external vSwitch bridged to the physical NIC on the Dataforth network
New-VMSwitch -Name "Dataforth-Bridge" -NetAdapterName "Ethernet 2" -AllowManagementOS $true

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2. Debian Installation Notes

During the Debian 13 (Trixie) netinst installation:

1. Language/Region: English, United States, UTF-8
2. Hostname: D2TESTNAS
3. Domain: leave blank
4. Root password: Paper123!@#-nas
5. User account: Skip creating a normal user (or create one for admin use)
6. Partitioning - IMPORTANT:
   • Use "Manual" partitioning
   • Disk 1 (40 GB, /dev/sda): OS disk
     • 512 MB EFI System Partition (ESP)
     • 1 GB /boot (ext4)
     • Remainder: / (ext4)
     • (No swap partition -- Hyper-V dynamic memory handles this; or add 2 GB swap)
   • Disk 2 (200 GB, /dev/sdb): Data disk
     • Use entire disk as a single partition
     • Format as BTRFS
     • Mount point: /data
7. Software selection:
   • Deselect "Debian desktop environment" and all desktop options
   • Select "SSH server"
   • Select "standard system utilities"
   • Do NOT select any web server or print server
8. GRUB: Install to /dev/sda

After reboot, verify you can SSH in, then proceed to post-install.

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3. Post-Install Setup

SSH into the new VM (use the DHCP address shown at the console):

ssh root@<dhcp-ip-address>

Transfer and run the setup script:

# From your workstation (PowerShell/bash):
scp setup-d2testnas.sh root@<dhcp-ip-address>:/root/

# On the VM:
chmod +x /root/setup-d2testnas.sh
/root/setup-d2testnas.sh

The script will:

• Install samba, rsync, btrfs-progs, and supporting packages
• Set hostname to D2TESTNAS
• Create BTRFS subvolumes (/data/test, /data/datasheets)
• Write /etc/samba/smb.conf with SMB1 (CORE protocol) support
• Create Samba users ts-1 through ts-50 (null passwords) and engineer
• Write /etc/rsyncd.conf and /etc/rsyncd.secrets
• Install BTRFS snapshot cron jobs
• Configure SSH for root login with password
• Enable and start all services
• Run verification checks
• Display cutover instructions

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4. Testing Before Cutover

While the VM is still on a DHCP address (not 192.168.0.9), verify all services work. Use the DHCP IP in place of 192.168.0.9 for these tests.

Test SMB from Windows

net use Z: \\<dhcp-ip>\test
dir Z:\
net use Z: /delete

Test rsync from AD2

$env:RSYNC_PASSWORD = "IQ203s32119"
rsync --list-only rsync://rsync@<dhcp-ip>/test/

Test SSH

ssh root@<dhcp-ip>
# Password: Paper123!@#-nas

Test BTRFS Snapshots

# On the VM:
btrfs-snapshot.sh create hourly
btrfs-snapshot.sh list
ls /data/.snapshots/

Test from DOS Machine (optional, requires temporary IP or hosts hack)

If you can temporarily set a DOS machine to use the DHCP IP, test the T: drive mapping. Otherwise, wait for cutover.

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5. Data Migration

Before cutover, copy all data from the old NAS to the new VM:

# On the new VM, pull everything from the old NAS:
RSYNC_PASSWORD=IQ203s32119 rsync -avz --progress \
    rsync://rsync@192.168.0.9/test/ /data/test/

This may take a while depending on data volume. Run it multiple times -- rsync is incremental and will only transfer changes on subsequent runs.

For the datasheets share, copy via SMB or SCP from the old NAS:

# If rsync module exists for datasheets:
RSYNC_PASSWORD=IQ203s32119 rsync -avz rsync://rsync@192.168.0.9/datasheets/ /data/datasheets/

# Otherwise, mount the old NAS share temporarily:
apt-get install -y cifs-utils
mkdir -p /mnt/old-nas
mount -t cifs //192.168.0.9/datasheets /mnt/old-nas -o guest,vers=1.0
rsync -avz /mnt/old-nas/ /data/datasheets/
umount /mnt/old-nas

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6. Cutover Checklist

Perform these steps during a maintenance window when no DOS machines are running tests.

Pre-Cutover

• All data migrated from old NAS (run rsync one final time)
• All services verified on new VM (SMB, rsync, SSH)
• BTRFS snapshots working (run btrfs-snapshot.sh list)
• Notify engineers: maintenance window, expect brief T: drive outage

Cutover Steps

1. Stop the AD2 sync script (disable scheduled task on AD2 temporarily)

2. Final data sync from old NAS to new VM:

   RSYNC_PASSWORD=IQ203s32119 rsync -avz rsync://rsync@192.168.0.9/test/ /data/test/
   

3. Power off the old ReadyNAS (192.168.0.9)

4. Assign static IP to new VM:

   # On the new VM:
   # Edit /etc/network/interfaces to use static config:
   cat > /etc/network/interfaces << 'EOF'
   auto lo
   iface lo inet loopback
   
   auto eth0
   iface eth0 inet static
       address 192.168.0.9
       netmask 255.255.255.0
       gateway 192.168.0.254
       dns-nameservers 192.168.0.27 192.168.0.6 192.168.1.254
   EOF
   
   # Replace "eth0" with actual interface name shown by: ip link show
   systemctl restart networking
   

5. Verify IP assignment:

   ip addr show
   ping -c 3 192.168.0.254
   

6. Re-enable AD2 sync script (re-enable scheduled task)

7. Test from AD2:

   $env:RSYNC_PASSWORD = "IQ203s32119"
   rsync --list-only rsync://rsync@192.168.0.9/test/
   

8. Test from Windows:

   net use T: \\D2TESTNAS\test
   dir T:\
   

9. Test from DOS machine: Boot one test station and verify T: drive maps and NWTOC.BAT runs successfully.

10. Create baseline snapshot:

    btrfs-snapshot.sh create daily
    

Post-Cutover

• Monitor /var/log/samba/ for connection issues
• Monitor /var/log/rsyncd.log for sync activity
• Verify AD2 sync runs successfully (check sync status file)
• Verify BTRFS snapshot cron is creating snapshots (check after 1 hour)
• Update credentials.md with any changes to the NAS entry
• Keep old ReadyNAS powered off but available for 2 weeks as fallback

Rollback Plan

If critical issues arise during cutover:

1. Power off the new VM
2. Power on the old ReadyNAS
3. Wait 2 minutes for ReadyNAS to boot and claim 192.168.0.9
4. Verify DOS machines can map T: drive
5. Re-enable AD2 sync task

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7. Maintenance Reference

Service Management

systemctl status smbd nmbd rsync ssh
systemctl restart smbd        # Restart Samba file server
systemctl restart nmbd        # Restart NetBIOS name service
systemctl restart rsync       # Restart rsync daemon

Snapshot Management

btrfs-snapshot.sh list                # Show all snapshots
btrfs-snapshot.sh create hourly       # Manual hourly snapshot
btrfs-snapshot.sh create daily        # Manual daily snapshot
btrfs-snapshot.sh prune               # Clean up old snapshots per retention policy

Snapshots are browsable at /data/.snapshots/ and via the \\D2TESTNAS\snapshots SMB share (read-only). To restore a file from a snapshot:

# Find the file in a snapshot:
ls /data/.snapshots/daily_2026-03-12_00-01-00/TS-01/LOGS/

# Copy it back:
cp /data/.snapshots/daily_2026-03-12_00-01-00/TS-01/LOGS/5BLOG/DATA.DAT /data/test/TS-01/LOGS/5BLOG/

Log Files

Log	Purpose
/var/log/samba/log.*	Samba per-client logs
/var/log/rsyncd.log	rsync daemon transfers
/var/log/btrfs-snapshots.log	Snapshot create/prune activity
/var/log/auth.log	SSH login attempts

Samba User Management

# Add a new station user with null password:
useradd --system --no-create-home --shell /usr/sbin/nologin ts-51
smbpasswd -a -n ts-51
smbpasswd -e ts-51

# Change engineer password:
smbpasswd engineer

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8. Architecture Comparison

Feature	Old (ReadyNAS RN10400)	New (Debian 13 VM)
OS	Netgear ReadyNAS Linux	Debian 13 (Trixie)
Filesystem	BTRFS	BTRFS
SMB	SMB1 (CORE)	SMB1 (CORE) via Samba
rsync	rsync daemon, port 873	rsync daemon, port 873
Snapshots	80+ BTRFS (not browsable)	Automated, browsable via SMB
NetBIOS/WINS	nmbd	nmbd
Management	Web UI (limited)	SSH + CLI (full control)
Backup	BTRFS snapshots only	BTRFS snapshots + Hyper-V checkpoints
Hardware	Physical appliance	Virtual machine (portable, resizable)