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.

---

## 1. Hyper-V VM Creation

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

```powershell
# --- 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:

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

---

## 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.

---

## 3. Post-Install Setup

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

```bash
ssh root@<dhcp-ip-address>
```

Transfer and run the setup script:

```bash
# 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

---

## 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

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

### Test rsync from AD2

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

### Test SSH

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

### Test BTRFS Snapshots

```bash
# 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.

---

## 5. Data Migration

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

```bash
# 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:

```bash
# 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
```

---

## 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:
   ```bash
   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:**
   ```bash
   # 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:**
   ```bash
   ip addr show
   ping -c 3 192.168.0.254
   ```

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

7. **Test from AD2:**
   ```powershell
   $env:RSYNC_PASSWORD = "IQ203s32119"
   rsync --list-only rsync://rsync@192.168.0.9/test/
   ```

8. **Test from Windows:**
   ```cmd
   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:**
    ```bash
    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

---

## 7. Maintenance Reference

### Service Management

```bash
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

```bash
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:

```bash
# 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

```bash
# 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
```

---

## 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) |