286 lines
17 KiB
Markdown
286 lines
17 KiB
Markdown
# Test-Datasheet Bug — End-to-End Trace & Diagnosis
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**Date:** 2026-06-17
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**Host:** AD2 (192.168.0.6) — testdatadb generator + PostgreSQL 18
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**Author:** Mike Swanson / AZ Computer Guru
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**Status:** DIAGNOSIS ONLY — no code or DB changes made
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**Reported by:** John Lehman / Peter Iliya (Dataforth) — customer Wellbore Integrity (Joseph Swinehart) cal-cert audit on 8B35 4-wire RTD certs
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---
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## 0. TL;DR
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There are **two independent defects, both in the datasheet *renderer*** (`templates/datasheet-exact.js`). Ingestion (.DAT parsing), the database contents, and the spec files are all **correct** — the raw test data in the DB holds the right values; the renderer mislabels and mis-maps them.
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| # | Defect | Symptom on cert | Scope | Severity |
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|---|--------|-----------------|-------|----------|
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| **A** | RTD input column rendered as **resistance** instead of **temperature** | Header reads `Rin (ohms)`, should read `Temp. (C)`; positive input values lost their leading `+` | ~24,000 RTD certs (8B35, DSCA34, SCM5B34/35, and any RTD variant) | **HIGH** — this is the audit finding |
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| **B** | **Entire DSCA Final-Test parameter list is wrong** | Wrong parameter names, garbage specs (`< 0 mA`, `+/- 0 %`), values aligned to the wrong rows, output column mislabeled (`Vout (V)` vs `Output (mA)`), lines missing/added | up to 78,343 DSCA certs (all DSCLOG) | **HIGH** |
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Defect A is a small, surgical fix. Defect B requires rebuilding the DSCA template against the legacy spec (`DSCFIN.DAT`) and is a larger effort.
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**Root cause is confirmed against the original ground-truth files** (the DOS-station-generated staged `.TXT`), not assumptions.
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---
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## 1. The Original File IS the Ground Truth — and We Found It
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Mike's key point was correct: **the rendered datasheet exists as a file BEFORE it ever reaches the database.** That original file is produced by the DOS test station itself and is the source of truth. Our DB-based regeneration is what introduces the error.
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### Where the original files physically live
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The DOS station's QuickBASIC ATE program writes a fully-rendered `.TXT` datasheet to `C:\STAGE\` on the station, then `CTONWTXT.BAT` uploads it to the NAS `STAGE` share. It is mirrored to AD2:
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```
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ORIGINAL (ground truth) staged datasheets:
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AD2: C:\Shares\test\STAGE\<TS-station>\<encoded-SN>.TXT
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NAS: /data/test/STAGE/<TS-station>/<encoded-SN>.TXT (\\192.168.0.9\test\STAGE)
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```
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Filenames use the 8.3 hex-prefix serial encoding (first two digits → letter, `55 + n`):
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`179553-13` → `17`→`H` → **`H9553-13.TXT`**; `180224-7` → `18`→`I` → **`I0224-7.TXT`**.
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**Confirmed files for this investigation:**
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| Module | SN | Original staged file (ground truth) | Source `.DAT` |
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|--------|----|--------------------------------------|---------------|
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| 8B35-04 (4-wire RTD) | 179553-13 | `C:\Shares\test\STAGE\TS-4L\H9553-13.TXT` | `C:\Shares\test\TS-4L\LOGS\8BLOG\35-04.DAT` |
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| DSCA38-05 (full bridge) | 180224-7 | `C:\Shares\test\STAGE\TS-11R\I0224-7.TXT` | `C:\Shares\test\TS-11R\LOGS\DSCLOG\38-05.DAT` |
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| DSCA34-05C (3-wire RTD) | 180007-8 | `C:\Shares\test\STAGE\TS-4R\I0007-8.TXT` | `C:\Shares\test\TS-4R\LOGS\DSCLOG\34-05C.DAT` |
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> Note re Peter: `179553-13` cannot be found on X: / DFWDS / For_Web because the **website copy is regenerated from the DB at upload time** — it is never written to disk. The on-disk ground truth is the **STAGE** copy above, not For_Web. (For_Web on AD2 holds only ~7,500 legacy files and does not contain this SN.)
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---
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## 2. End-to-End Pipeline (upstream emphasis)
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```
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[1] DOS Test Station (TS-xx, DOS 6.22, QuickBASIC ATE)
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- Runs the unit test, measures everything.
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- Writes TWO artifacts:
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(a) C:\ATE\...\<model>.DAT raw CSV-ish multi-line test log (-> network LOGS)
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(b) C:\STAGE\<encSN>.TXT FULLY RENDERED datasheet <-- GROUND TRUTH
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- The station ALREADY knows the sensor type, so it prints the correct
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input column ("Temp. (C)" for RTD) and the correct Final-Test parameter
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list for that exact model. This is the format we must reproduce.
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[2] Boot upload (CTONW.BAT / CTONWTXT.BAT)
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- .DAT -> \\NAS\test\<TS>\LOGS\<logtype>\<model>.DAT
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- .TXT -> \\NAS\test\STAGE\<TS>\<encSN>.TXT
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[3] NAS <-> AD2 sync (Sync-FromNAS.ps1, 15 min)
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- Mirrors to C:\Shares\test\... on AD2.
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[4] testdatadb ingest (THIS host) ----- the original .TXT is IGNORED here -----
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- import.js scans .DAT files (NOT the staged .TXT).
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- parsers/multiline.js parses the .DAT into a record:
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{ log_type, model_number, serial_number, test_date, test_station,
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overall_result, raw_data (the verbatim .DAT block), source_file }
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- INSERT ... ON CONFLICT(serial_number) into PostgreSQL test_records.
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raw_data = the exact .DAT text block (this is faithful & correct).
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[5] Render + upload (the bug lives here)
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- render-datasheet.js -> templates/datasheet-exact.js regenerates the
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datasheet text FROM raw_data + spec files, in memory.
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- upload-to-api.js POSTs {SerialNumber, Content} to Hoffman bulk API.
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- Hoffman serves it on the public product page.
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```
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**The pivotal architectural fact:** step [4] throws away the already-correct rendered `.TXT` and keeps only the raw `.DAT` block (`raw_data`). Step [5] then *re-renders* from scratch. Every rendering defect is introduced in step [5]; the upstream data is fine.
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### 2.1 What the `.DAT` / `raw_data` actually contains (8B35-04, SN 179553-13)
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```
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"8B35-04 " <- model
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-1.461694,-1.218078E-02,-.014174,-3.986431E-02,"PASS" <- accuracy pt 1: stim,calc,meas,err,status
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151.5394,1.262828,1.26273,-1.966953E-03,"PASS" <- pt 2
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303.6477,2.530397,2.531,1.204967E-02,"PASS" <- pt 3
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448.7633,3.739694,3.7414,.0341177,"PASS" <- pt 4
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598.0475,4.983729,4.9824,-2.658844E-02,"PASS" <- pt 5
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"0","0",0 <- step-response placeholder
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"PASS 28.424741","PASS","PASS 252.21681","PASS","PASS" <- final-test STATUS groups (5 per line)
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"PASS","","PASS","PASS","PASS"
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"PASS","PASS 3.478871E-023","PASS 3.986431E-023","PASS","PASS 26.328911"
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"PASS","PASS","PASS 40.429370","PASS","PASS 140.50"
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```
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The **first column of each accuracy point is the stimulus**. For SN 179553-13 it is `-1.46, 151.5, 303.6, 448.8, 598.0` — clearly **temperatures in °C** (model MAXIN = 600 °C), **not** ohms. The spec record confirms `SENTYPE = "P1RTD4W"`, `MAXIN = 600`. So the DB has the right numbers and the right sensor type. Nothing upstream is wrong.
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---
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## 3. Diffs — Original (correct) vs DB-Generated (wrong)
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### 3.1 8B35-04 RTD (SN 179553-13) — Defect A only
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ACCURACY block header + first/last rows:
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```
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ORIGINAL (H9553-13.TXT, ground truth) GENERATED (current testdatadb)
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----------------------------------- ------------------------------
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Temp. (C) Vout (V) ... Rin (ohms) Vout (V) ... <-- WRONG LABEL
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-1.46 ... -1.46 ... (same)
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+151.54 ... 151.54 ... <-- lost '+'
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+598.05 ... 598.05 ... <-- lost '+'
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```
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- **Header:** `Temp. (C)` → rendered as `Rin (ohms)`. **This is the audit discrepancy.**
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- **Values:** numerically identical (correct temperatures). Only difference: positive values lose the leading `+` because the resistance formatter omits the sign.
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- **Final Test Results: byte-for-byte IDENTICAL** to the original (7 lines: Supply Current Nom, Exc. Current #1, Linearity, Accuracy, Supply Sensitivity, Frequency Response, Output Noise). **No missing lines for 8B35.** The 8B/5B Final-Test rendering is correct.
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So for the Wellbore Integrity audit, the **only** defect on the 8B35 cert is the input column header label (and the cosmetic `+` sign). The measured data is right.
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### 3.2 DSCA38-05 full-bridge (SN 180224-7) — Defect B
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This is not a label tweak — the **whole Final Test table is wrong**:
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```
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ORIGINAL (I0224-7.TXT) GENERATED (current)
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Supply Current 23.8 mA < 30 mA Supply Current, Nom 23.8 mA < 0 mA <- spec garbage
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Supply Curr. w/ EXC Load 53.8 mA < 80 mA Supply Current @ Max Load 53.8 mA < 0 mA
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Excitation Voltage 10.000 V 10+/-.003V Linearity, 50mA Load 10.000 % +/- 0 % <- wrong name+unit
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Exc. Load Regulation -6 ppm/mA ... Accuracy, 50mA Load 6 % +/- 0 % <- wrong row
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Output Reg. w/ EXC Load 0.00 % +/- .05 % Positive Current Limit 0.0 mA < 0 mA
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Excitation Current Limit 54 mA < 65 mA Negative Current Limit 54 mA > 0 mA
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Linearity 0.002 % +/- .02 % Overrange 0.002 % > 0 %
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Accuracy -0.008 % +/- .05 % Power Supply Sensitivity 0.008 %/% +/-.0006
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Power Supply Sens. 0.0000 %/% +/-.0006 Frequency Response 0.0000 dB 25+/-5 dB <- value=0
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Frequency Response 25.0 dB 25+/-5 dB Compliance 25.0 % +/- 0 % <- 25.0 is freq!
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Output Noise 1205 uVrms <=2000 (Output Noise line dropped entirely)
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```
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Also in the ACCURACY block: original column titles are `Output (V)` and separator dashes `----------`; the generator emits `Vout (V)` and `==========`. The input header happens to read `Vin (mV)` in both (bridge module), so the bridge input label is OK, but everything below it is misaligned.
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### 3.3 DSCA34-05C 3-wire RTD (SN 180007-8) — Defect A **and** B together
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```
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ORIGINAL (I0007-8.TXT) GENERATED (current)
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Temp. (C) Output (mA) ... Rin (ohms) Vout (V) ... <-- A: label + wrong out-unit
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Supply Current 50.7 mA < 65 mA Supply Current, Nom 50.7 mA < 0 mA
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Exc. Current @ -f.s. 264.0 uA 261 uA Linearity, 0mA Load 264.0 % +/- 0 % <-- 264.0 is uA, not %
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Exc. Current @ +f.s. 281.0 uA 278 uA Accuracy, 0mA Load 281.0 % +/- 0 %
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Linearity 0.017 % +/-.03% Overrange 0.017 % > 0 %
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Accuracy -0.034 % +/-.05% Power Supply Sens. 0.034 %/% +/-.0005
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... (9 real params) ... (wrong names, garbage specs, lines dropped)
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```
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The excitation currents (264.0 uA, 281.0 uA) get printed under the labels "Linearity, 0mA Load" / "Accuracy, 0mA Load" as **percentages** — visibly nonsensical.
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---
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## 4. Root-Cause Localization
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Tested against the original files, the defect is **(c) the renderer** — `templates/datasheet-exact.js`. Ingestion/parsing (a) and the DB data (b) are correct.
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### Defect A — RTD treated as resistance
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```js
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// getSensorNum(): RTD maps to 7
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if (s.includes('RTD')) return 7; // line ~150
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// Accuracy input-column header (generateExactDatasheet):
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} else if (sensorNum === 7) {
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inputHeader = ' Rin (ohms)'; // line ~564 <-- WRONG for Dataforth RTD
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}
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// Accuracy value formatting (formatAccuracyLine):
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} else if (sensorNum === 7) {
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stimStr = point.stim.toFixed(2).padStart(8); // line ~447 <-- resistance format, no sign
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}
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```
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Dataforth RTD modules always express the input as **temperature** on the datasheet (the RTD curve converts resistance→°C; the `.DAT` already stores °C). `sensorNum === 7` is reached **only** by RTD sentypes (`P1RTD3W`, `P1RTD4W`, `NIRTD3W`, …). There is currently **no module for which `Rin (ohms)` is correct** — true resistance/potentiometer inputs are not routed to 7 (they fall through to the voltage default). So fixing the `7` branch is safe and will not over-correct.
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### Defect B — DSCA parameter list mismatch
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`DATA_LINES['DSCA']` is a **single hardcoded list** (Supply Current Nom / @ Max Load / Linearity 0mA / Accuracy 0mA / Linearity 5mA / … / Compliance / Accuracy @ 5 ohm). Real DSCA modules use **different Final-Test layouts per subtype** (bridge/excitation modules list Excitation Voltage / Exc. Load Reg. / Output Reg.; RTD/TC list Exc. Current @ ±f.s.; etc.). The hardcoded list does not match, so:
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- `raw_data` STATUS groups are mapped positionally onto the **wrong** parameter names;
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- `buildTSpecs()` for DSCA reads spec fields (`ILIMIT`, `PERCOVER`, `COMPLIANCE`, `ACCURACY1/2/3`, `LINEAR1/2/3`) that are zero/absent for these modules → specs print as `< 0`, `+/- 0`;
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- the skip rule `if (status.length <= 4) continue` drops every bare-`PASS` slot, but because the list is misaligned the *wrong* lines drop and the survivors land on wrong rows;
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- the ACCURACY block also uses the 5B/8B titles (`Vout (V)` / `==========`) instead of DSCA's (`Output (V|mA)` / `----------`).
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The "missing Final Test lines" complaint is a **symptom of Defect B** (DSCA misalignment + skip rule), **not** a separate bug. The 8B/5B skip rule is correct — the legacy station also prints only tested parameters (verified: 8B35 matches exactly).
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> Clarification for the thread: **DSCA38 is a bridge/strain-gauge module (FBRIDGE/HBRIDGE), not an RTD.** The DSCA RTD analog is **DSCA34**. So DSCA38's problem is Defect B; DSCA34's problem is A+B. If the audit specifically concerns RTD resistance-vs-temperature, the DSCA part to verify with the customer is **DSCA34**, while DSCA38 demonstrates the broader DSCA table breakage.
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---
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## 5. Correct Output & Proposed Fix
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### 5.1 Correct RTD output (Defect A)
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Per the originals, RTD modules must render:
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- **Input column header:** `Temp. (C)` (same column/format as thermocouples, `sensorNum` 3–6).
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- **Input values:** the stimulus value straight from `raw_data` (already °C — **no conversion needed**), signed format (`+598.05`, `-1.46`).
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Surgical change in `templates/datasheet-exact.js` (fold RTD into the temperature path):
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```js
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// (1) Header — replace the sensorNum===7 branch:
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if ((sensorNum >= 3 && sensorNum <= 6) || sensorNum === 7) {
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inputHeader = ' Temp. (C)';
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} else if (sensorNum === 2 || sensorNum === 9) {
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inputHeader = ' Iin (mA)';
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} else {
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inputHeader = (maxIn != null && maxIn < 1) ? ' Vin (mV)' : ' Vin (V)';
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}
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// (2) Value format — in formatAccuracyLine, treat 7 like 3–6:
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if ((sensorNum >= 3 && sensorNum <= 6) || sensorNum === 7) {
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stimStr = formatSigned(point.stim, 2, 8); // temperature, signed
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} else { ... }
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```
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Leave the existing `i===13 && sensorNum===7 → 'ohm/ohm'` unit override (Lead-R-Effect) as-is; it is a separate, correct detail. **Verify exact leading-space alignment** against a known-good thermocouple original before pushing (the header column should byte-match; this is the same polish already in progress in `generated-v2-*.TXT`).
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This fix corrects **header + values** for all RTD modules (8B35, DSCA34, SCM5B34/35, etc.) at once. **Do not** add any resistance→temperature math — the data is already temperature.
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### 5.2 DSCA template (Defect B)
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Not a one-liner. The fix is to drive the DSCA Final-Test parameter list (and ACCURACY column titles/units) **per module subtype**, matching the legacy QuickBASIC DSC writer. The legacy parameter selection lives in **`specdata\DSCFIN.DAT`** (DSC final-test definitions) alongside `DSCMAIN4.DAT`/`DSCOUT.DAT`. Recommended approach:
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1. Reverse the DSCFIN.DAT layout (or read the QB DSC datasheet source) to get the per-subtype parameter name/unit/spec list.
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2. Replace the single `DATA_LINES['DSCA']` + DSCA branch of `buildTSpecs()` with subtype-aware selection keyed on SENTYPE / output-signal type.
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3. Fix the DSCA ACCURACY block to use `Output (V|mA)` (per `OUTSIGTYPE`) and dash separators.
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4. Validate byte-for-byte against staged originals across DSCA subtypes (bridge, RTD, TC, current-out, voltage-out).
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Until B is fixed, **all DSCA (DSCLOG) website datasheets should be treated as unreliable** for Final-Test content.
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---
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## 6. Impact (records currently on the website)
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| Group | On-web count | Defect |
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|-------|-------------:|--------|
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| 8B35* | 5,476 | A |
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| DSCA34* (RTD) | 3,573 | A + B |
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| SCM5B34/35* (RTD) | 14,887 | A |
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| All DSCA (DSCLOG) | 78,343 | B (RTD subset also A) |
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| **Total on website** | 464,671 | — |
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RTD-label exposure (Defect A) ≈ **24,000 certs**; DSCA table exposure (Defect B) ≈ **78,000 certs**.
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After fixes are reviewed and deployed, affected records can be re-pushed by clearing `api_uploaded_at` for the affected models and letting the upload path re-render (RE-PUSH is idempotent; Hoffman returns `Unchanged` when content matches).
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---
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## 7. How to Reproduce / Verify (read-only)
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```powershell
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# Render current generator output for a SN and compare to the staged original:
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cd C:\Shares\testdatadb
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node -e "const db=require('./database/db');const {renderContent}=require('./database/render-datasheet');(async()=>{const r=await db.queryOne('SELECT * FROM test_records WHERE serial_number=$1',['179553-13']);if(r.test_date&&r.test_date.toISOString)r.test_date=r.test_date.toISOString().slice(0,10);console.log(renderContent(r));await db.close();})()"
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# Ground truth:
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type C:\Shares\test\STAGE\TS-4L\H9553-13.TXT
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```
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---
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## 8. Files Referenced
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- Generator: `C:\Shares\testdatadb\templates\datasheet-exact.js` (repo: `projects/dataforth-dos/datasheet-pipeline/implementation/templates/datasheet-exact.js`)
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- Render glue: `C:\Shares\testdatadb\database\render-datasheet.js`
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- Specs: `C:\Shares\testdatadb\parsers\spec-reader.js`, `C:\Shares\testdatadb\specdata\*.DAT` (incl. `DSCFIN.DAT`)
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- Ingest: `C:\Shares\testdatadb\database\import.js`, `C:\Shares\testdatadb\parsers\multiline.js`
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- Ground-truth originals: `C:\Shares\test\STAGE\<TS>\<encSN>.TXT`
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