claudetools/docs/DEPLOYMENT_GUIDE.md

DOS Update System - Test Staff Deployment Guide

Document Version: 1.0 Date: January 19, 2026 Audience: Test Staff and Technicians Prerequisites: Access to DOS test machines (TS-01 through TS-30)

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What's New?

Automatic Updates!

Good news: You no longer need to manually run update commands!

Old way:

1. Boot machine
2. Wait for network
3. Type: C:\BAT\NWTOC
4. Type: C:\BAT\CTONW
5. Start testing

New way:

1. Boot machine
2. Wait for network
3. ✅ Updates download automatically
4. ✅ Test data uploads automatically
5. Start testing

That's it! The system now handles updates during boot.

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Table of Contents

1. Quick Start
2. Daily Operations
3. Initial Deployment
4. Understanding the Boot Process
5. Manual Operations
6. Troubleshooting
7. FAQ

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Quick Start

Starting Your Day

For machines already deployed:

1. Power on DOS machine
2. Wait for boot process (watch the screen)
3. System automatically:
   • Starts network
   • Downloads updates
   • Uploads test data
4. See "System Ready" message
5. Start testing!

No commands needed!

---

First Time Setup (New Machine)

If machine has never been configured:

1. Boot machine
2. Wait for network to start
3. Type: T:\UPDATE.BAT TS-XX (replace XX with machine number)
   • Example: T:\UPDATE.BAT TS-04 for machine TS-04
4. Wait for deployment (about 2 minutes)
5. Reboot when prompted
6. After reboot, automatic updates enabled!

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Daily Operations

Normal Boot Sequence

When you power on a DOS machine, you'll see:

┌─────────────────────────────────────────────────────────────────┐
│ Microsoft(R) MS-DOS(R) Version 6.22                             │
│                                                                  │
│ ==============================================================  │
│   Dataforth Test Machine: TS-04                                 │
│   DOS 6.22 with Automatic Update System                        │
│ ==============================================================  │
│                                                                  │
│ Starting network client...                                      │
│ [OK] Network started                                            │
│                                                                  │
│ Network Drives:                                                 │
│   T: = \\D2TESTNAS\test                                         │
│   X: = \\D2TESTNAS\datasheets                                   │
│                                                                  │
│ Checking for software updates...                                │
│ [1/4] Updating batch files from T:\COMMON\ProdSW...            │
│       [OK] No new batch files in COMMON                         │
│ [2/4] Updating machine-specific files...                        │
│       [SKIP] No machine-specific directory                      │
│ [3/4] Checking for system file updates...                       │
│       [OK] No system file updates                               │
│ [4/4] Checking for network client updates...                    │
│       [OK] No network client updates                            │
│ ==============================================================  │
│ Update Complete                                                 │
│ ==============================================================  │
│                                                                  │
│ Uploading test data to network...                               │
│ [1/3] Uploading batch files from C:\BAT...                     │
│       [OK] Batch files uploaded                                 │
│ [2/3] Uploading programs and config from C:\ATE...             │
│       [OK] Programs uploaded to ProdSW                          │
│ [3/3] Uploading test data to LOGS...                            │
│       [OK] Test data uploaded to LOGS (for database import)     │
│ ==============================================================  │
│ Upload Complete                                                 │
│ ==============================================================  │
│                                                                  │
│ ==============================================================  │
│ System Ready                                                    │
│ ==============================================================  │
│                                                                  │
│ C:\>                                                            │
└─────────────────────────────────────────────────────────────────┘

![Screenshot: Normal Boot Sequence] Screenshot placeholder: DOS screen showing complete boot process with all status messages

Boot time: Approximately 2-3 minutes (depending on updates)

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What Happens During Boot

Step-by-step breakdown:

1. DOS starts (5 seconds)

   • Loads CONFIG.SYS
   • Runs AUTOEXEC.BAT

2. Network starts (30 seconds)

   • Loads Microsoft Network Client
   • Maps T: drive to \D2TESTNAS\test
   • Maps X: drive to \D2TESTNAS\datasheets

3. NWTOC downloads updates (30-60 seconds)

   • Checks T:\COMMON\ProdSW for new batch files
   • Checks T:\TS-XX\ProdSW for machine-specific files
   • Downloads only newer files (smart update)
   • Creates .BAK backups of replaced files

4. CTONW uploads test data (30-60 seconds)

   • Uploads batch files from C:\BAT to network
   • Uploads programs from C:\ATE to network
   • Uploads test data (.DAT files) to LOGS folder

5. System Ready

   • Displays command prompt
   • Ready for testing

Total time: 2-3 minutes

---

Initial Deployment

When to Run Deployment

Run deployment on:

• Brand new DOS machine
• Reformatted machine
• Machine without automatic updates

Do NOT run deployment on:

• Machines already deployed (unnecessary)
• Machines that auto-update on boot (already deployed)

---

Deployment Procedure

Follow these steps exactly:

Step 1: Boot Machine

• Power on DOS machine
• Let it fully boot to C:> prompt
• Verify network drives mapped (T: and X:)

![Screenshot: DOS Prompt Ready] Screenshot placeholder: DOS C:> prompt with machine name displayed

Step 2: Verify Network Access

Type:

DIR T:\

You should see:

COMMON     <DIR>
TS-01      <DIR>
TS-02      <DIR>
...

![Screenshot: T Drive Contents] Screenshot placeholder: DOS DIR T:\ output showing COMMON and TS-XX folders

If you see "Invalid drive" or error, see Troubleshooting: Network Not Available

Step 3: Run Deployment Command

Type (replace XX with your machine number):

T:\UPDATE.BAT TS-04

Important:

• Use your actual machine number (TS-01 through TS-30)
• Type exactly as shown (uppercase)
• Press Enter

![Screenshot: Running UPDATE.BAT] Screenshot placeholder: DOS screen showing T:\UPDATE.BAT TS-04 command being entered

Step 4: Watch Deployment Progress

You'll see:

==============================================================
DOS Update System - Deployment
==============================================================
Machine: TS-04
==============================================================

Installing automatic update system...

Files to install:
  - AUTOEXEC.BAT (startup configuration)
  - NWTOC.BAT (download updates)
  - CTONW.BAT (upload test data)
  - UPDATE.BAT (full backup)
  - CHECKUPD.BAT (check updates)
  - STAGE.BAT (system file updates)
  - REBOOT.BAT (apply staged updates)

Press any key to continue . . .

Press any key to continue

![Screenshot: Deployment Starting] Screenshot placeholder: DOS deployment screen showing file list

Step 5: Deployment Progress

Watch the screen as deployment proceeds:

[1/3] Creating C:\BAT directory...
[OK] C:\BAT directory ready

[2/3] Copying batch files to C:\BAT...
  [OK] NWTOC.BAT
  [OK] CTONW.BAT
  [OK] UPDATE.BAT
  [OK] CHECKUPD.BAT
  [OK] STAGE.BAT
  [OK] REBOOT.BAT
[OK] All batch files installed

[3/3] Installing AUTOEXEC.BAT...
[OK] AUTOEXEC.BAT installed with MACHINE=TS-04
[OK] Network backup folder created: T:\TS-04

![Screenshot: Deployment Progress] Screenshot placeholder: DOS screen showing [OK] messages as files copy

Step 6: Deployment Complete

Final screen:

==============================================================
Deployment Complete!
==============================================================

Machine: TS-04

The automatic update system is now installed.

What happens on next reboot:
  1. Network client starts (C:\NET\STARTNET.BAT)
  2. Software updates download automatically (NWTOC)
  3. Test data uploads automatically (CTONW)
  4. System ready for testing

==============================================================
REBOOT NOW
==============================================================

Press Ctrl+Alt+Del to reboot

After reboot, the system will be fully operational.

Press any key to continue . . .

![Screenshot: Deployment Complete] Screenshot placeholder: DOS screen showing "Deployment Complete!" message

Step 7: Reboot

Press Ctrl+Alt+Del to reboot

After reboot:

• Automatic updates enabled
• No manual commands needed
• Ready for testing!

---

Verifying Deployment Successful

After reboot, check for:

1. Network drives mapped:

   DIR T:\
   DIR X:\
   

   Both should work without errors

2. Batch files installed:

   DIR C:\BAT
   

   You should see: NWTOC.BAT, CTONW.BAT, UPDATE.BAT, etc.

3. Machine name set:

   ECHO %MACHINE%
   

   Should show: TS-04 (or your machine number)

4. Automatic updates ran:

   • Boot screen showed "Checking for software updates..."
   • Boot screen showed "Uploading test data to network..."
   • Both completed with [OK] messages

If all checks pass: Deployment successful! ✅

---

Understanding the Boot Process

What Each Component Does

AUTOEXEC.BAT

• Location: C:\AUTOEXEC.BAT
• Runs: Every boot (automatically)
• Purpose: Machine startup configuration
• What it does:
  1. Sets machine identity (MACHINE=TS-04)
  2. Sets DOS path and environment
  3. Starts network client
  4. Calls NWTOC (download updates)
  5. Calls CTONW (upload test data)
  6. Displays "System Ready"

You never need to edit or run this manually.

---

NWTOC.BAT (Network to Computer)

• Location: C:\BAT\NWTOC.BAT
• Runs: Automatically during boot (called by AUTOEXEC.BAT)
• Purpose: Download software updates from network
• What it downloads:
  • Batch files: T:\COMMON\ProdSW → C:\BAT
  • Programs/Config: T:\TS-XX\ProdSW → C:\ATE
  • System files: T:\COMMON\DOS → C:\ (staged for reboot)

Manual use: Only if you need updates without rebooting (see Manual Operations)

---

CTONW.BAT (Computer to Network)

• Location: C:\BAT\CTONW.BAT
• Runs: Automatically during boot (called by AUTOEXEC.BAT)
• Purpose: Upload test data and local changes to network
• What it uploads:
  • Batch files: C:\BAT → T:\TS-XX\ProdSW
  • Programs: C:\ATE → T:\TS-XX\ProdSW
  • Test data: C:\ATE*DATA → T:\TS-XX\LOGS (for database import)

Manual use: If you need to upload data without rebooting

---

UPDATE.BAT

• Location 1: T:\UPDATE.BAT (network shortcut)
• Location 2: C:\BAT\UPDATE.BAT (backup utility)
• Purpose: Two different functions depending on location

T:\UPDATE.BAT (Deployment):

• Runs DEPLOY.BAT for initial setup
• Usage: T:\UPDATE.BAT TS-04
• Use once per machine (initial deployment)

C:\BAT\UPDATE.BAT (Backup):

• Creates full system backup to T:\TS-XX\BACKUP
• Usage: C:\BAT\UPDATE.BAT
• Use before major changes

---

CHECKUPD.BAT

• Location: C:\BAT\CHECKUPD.BAT
• Purpose: Check what updates are available without downloading
• Usage: C:\BAT\CHECKUPD
• Shows:
  • Available batch file updates
  • Available system file updates (AUTOEXEC.NEW, CONFIG.NEW)
  • Available machine-specific updates

Use this to see what will download on next reboot.

---

STAGE.BAT & REBOOT.BAT

• Location: C:\BAT\STAGE.BAT, C:\BAT\REBOOT.BAT
• Purpose: Apply system file updates (AUTOEXEC.BAT, CONFIG.SYS)
• When used: Automatically when AUTOEXEC.NEW or CONFIG.NEW detected

Process:

1. NWTOC finds AUTOEXEC.NEW on network
2. NWTOC calls STAGE.BAT
3. STAGE.BAT creates REBOOT.BAT
4. Screen prompts: "Reboot required"
5. You run: C:\BAT\REBOOT.BAT
6. System reboots
7. REBOOT.BAT applies new AUTOEXEC.BAT
8. New configuration active

---

Manual Operations

When Manual Operations Needed

Normally: No manual operations required (automatic updates handle everything)

Manual operations needed when:

• Urgent update can't wait for reboot
• Testing new batch file immediately
• Checking for available updates
• Troubleshooting update issues
• Creating full system backup

---

Manual Update Check

To see what updates are available:

C:\BAT\CHECKUPD

Output shows:

==============================================================
Update Check: TS-04 from Network
==============================================================

[1/3] Checking T:\COMMON\ProdSW for updates...
      [FOUND] 2 newer batch files available:
        NWTOC.BAT (2026-01-19 vs 2026-01-15)
        CTONW.BAT (2026-01-19 vs 2026-01-15)

[2/3] Checking T:\TS-04\ProdSW for machine-specific updates...
      [SKIP] No machine-specific directory

[3/3] Checking for system file updates...
      [OK] No system file updates

==============================================================
Summary: 2 updates available
==============================================================

To download updates: C:\BAT\NWTOC
Or wait for next reboot (automatic download)

![Screenshot: CHECKUPD Output] Screenshot placeholder: DOS screen showing CHECKUPD results with 2 updates available

---

Manual Update Download

To download updates immediately (without rebooting):

C:\BAT\NWTOC

What happens:

• Downloads all available updates
• Creates .BAK backups of replaced files
• Updates ready to use immediately
• No reboot required (unless system files)

When to use:

• Engineer says "urgent update available"
• Need new feature immediately
• Troubleshooting batch file issue

![Screenshot: Manual NWTOC] Screenshot placeholder: DOS screen showing NWTOC downloading updates manually

---

Manual Data Upload

To upload test data immediately (without rebooting):

C:\BAT\CTONW

What happens:

• Uploads batch files from C:\BAT
• Uploads programs from C:\ATE
• Uploads test data (.DAT files) to LOGS

When to use:

• Just finished test run
• Need data in database immediately
• Sharing modified batch file with engineering

---

Manual Full Backup

To create complete system backup:

C:\BAT\UPDATE

What it backs up:

• C:\BAT* → T:\TS-XX\BACKUP\BAT\
• C:\ATE* → T:\TS-XX\BACKUP\ATE\
• C:\AUTOEXEC.BAT → T:\TS-XX\BACKUP\
• C:\CONFIG.SYS → T:\TS-XX\BACKUP\

When to use:

• Before major system changes
• Before deploying new AUTOEXEC.BAT
• Monthly backup routine
• Before reformatting machine

Backup location: T:\TS-04\BACKUP\ (or your machine number)

---

Applying System File Updates

If you see message: "Reboot required for system updates"

Steps:

1. Save your work (close all programs)

2. Run reboot script:

   C:\BAT\REBOOT
   

3. Watch the screen during reboot:

   • You'll see: "Applying system updates..."
   • REBOOT.BAT copies staged files
   • System reboots again automatically

4. After second reboot:

   • New AUTOEXEC.BAT or CONFIG.SYS active
   • System ready for testing

Don't worry if you see two reboots - this is normal for system file updates.

---

Troubleshooting

Network Not Available

Symptom:

• Error: "T: drive not available"
• Error: "Invalid drive specification"
• Network drives not mapped

Solution:

Step 1: Check Network Cable

• Verify Ethernet cable connected
• Check for link light on network port

Step 2: Restart Network Client

C:\NET\STARTNET

Wait 30 seconds, then try:

DIR T:\

Step 3: Check T: Drive Mapping

NET USE

Should show:

T: \\D2TESTNAS\test
X: \\D2TESTNAS\datasheets

If missing, network start failed. Contact IT.

---

Updates Not Downloading

Symptom:

• Boot shows: "[OK] No new batch files in COMMON"
• But engineer says updates were deployed

Possible Causes:

Cause 1: Updates Not Synced Yet

Solution: Wait 15-20 minutes, then reboot again

Engineers place files on AD2, which syncs to NAS every 15 minutes. If you reboot too soon, NAS doesn't have new files yet.

Cause 2: DOS Clock is Wrong

Check date/time:

DATE
TIME

If DOS clock is in the future, XCOPY thinks network files are "older" and skips them.

Solution: Set correct date/time:

DATE 01-19-2026
TIME 14:30:00

Then reboot or run:

C:\BAT\NWTOC

Cause 3: Files in Wrong Location

Verify file exists on network:

DIR T:\COMMON\ProdSW\FILENAME.BAT

If missing, contact engineering - file not synced or wrong location.

---

Boot Takes Too Long

Symptom:

• Boot process takes 5+ minutes
• Machine seems stuck

Normal boot time: 2-3 minutes

If longer:

Step 1: Check Network Status

During boot, watch for:

Starting network client...

If this hangs for minutes:

• Network issue (cable, switch, NAS down)
• Press Ctrl+C to skip network start
• Contact IT

Step 2: Check Update Status

If stuck at:

Checking for software updates...

Possible causes:

• Large files downloading (be patient)
• Network congestion (wait or reboot later)
• T: drive issue (see Network Not Available)

Step 3: Skip Automatic Updates (Emergency Only)

If you need to bypass auto-updates to start testing:

Edit AUTOEXEC.BAT temporarily:

EDIT C:\AUTOEXEC.BAT

Comment out NWTOC and CTONW lines:

REM Temporarily disabled for troubleshooting:
REM IF EXIST C:\BAT\NWTOC.BAT CALL C:\BAT\NWTOC.BAT
REM IF EXIST C:\BAT\CTONW.BAT CALL C:\BAT\CTONW.BAT

Save and reboot

Important: This is temporary only. Contact engineering to fix root cause.

---

"Invalid Path" or "File Not Found" Errors

Symptom:

• Batch file shows errors during execution
• References to "NUL" in error messages

Cause: Old batch file version (pre-DOS 6.22 compatibility fix)

Solution:

1. Ask engineering to verify latest files deployed
2. Force update:

   DEL C:\BAT\*.BAT
   C:\NET\STARTNET
   T:\COMMON\ProdSW\DEPLOY.BAT TS-XX
   

3. Reboot

---

Machine Name Not Set

Symptom:

• CTONW shows: "[ERROR] MACHINE variable not set"
• ECHO %MACHINE% shows nothing

Cause: Deployment never completed or AUTOEXEC.BAT corrupted

Solution: Run deployment again:

T:\UPDATE.BAT TS-04

This re-installs AUTOEXEC.BAT with correct machine name.

---

Disk Full

Symptom:

• Error: "Insufficient disk space"
• DIR C:\ shows 0 bytes free

Causes:

• .BAK backup files accumulating
• Test data files in C:\ATE
• Log files growing

Solution:

Clean Backup Files:

DEL C:\BAT\*.BAK

Clean Test Data:

DEL C:\ATE\8BDATA\*.DAT
DEL C:\ATE\DSCDATA\*.DAT
DEL C:\ATE\HVDATA\*.DAT

(After uploading to network!)

Check Disk Space:

DIR C:\

Should show several MB free.

---

Test Data Not Uploading

Symptom:

• CTONW completes but data not in database
• Engineers report missing test data

Check Upload Location:

Data goes to: T:\TS-XX\LOGS\ (not T:\TS-XX\ProdSW)

Verify manually:

DIR T:\TS-04\LOGS\8BLOG\

Should show your .DAT files.

If empty:

• Check source: DIR C:\ATE\8BDATA\*.DAT
• If source empty, no data to upload
• If source has data, run C:\BAT\CTONW again

---

FAQ

Q: Do I need to run any commands after booting?

A: No! The system handles everything automatically. Just wait for "System Ready" and start testing.

---

Q: How do I know if updates downloaded?

A: Watch the boot screen. You'll see:

[1/4] Updating batch files from T:\COMMON\ProdSW...
      [OK] Batch files updated from COMMON

Or run: C:\BAT\CHECKUPD to see available updates.

---

Q: Can I turn off automatic updates?

A: Not recommended. Automatic updates ensure you always have the latest software.

If you must disable temporarily (for troubleshooting), see Boot Takes Too Long - Step 3.

---

Q: What if I make a mistake during testing?

A: Reboot the machine. NWTOC will restore original files from network.

Or manually restore from backup:

COPY C:\BAT\FILENAME.BAK C:\BAT\FILENAME.BAT

---

Q: How do I get help?

A:

1. Check this guide first
2. Ask test lead
3. Contact engineering
4. Email IT support

For emergencies: Call IT hotline

---

Q: Can I modify batch files on the DOS machine?

A: You can, but changes will be lost on next reboot (NWTOC overwrites).

To make permanent changes:

1. Tell engineering what you need
2. They update file on AD2
3. File syncs to NAS
4. Next reboot downloads new version

---

Q: What's the difference between UPDATE.BAT locations?

A:

T:\UPDATE.BAT - Initial deployment command

• Usage: T:\UPDATE.BAT TS-04
• Run once per machine (first time setup)

C:\BAT\UPDATE.BAT - Full backup command

• Usage: C:\BAT\UPDATE
• Run before major changes

Same name, different purposes!

---

Q: Why does boot take longer than before?

A: Automatic updates add 30-60 seconds to boot time.

Before: ~60 seconds (just network start) Now: ~150 seconds (network + updates + upload)

Trade-off: Slower boot, but no manual commands needed.

Net result: Faster testing start (no waiting for you to run commands).

---

Q: What are .BAK files in C:\BAT?

A: Backup files created by NWTOC before overwriting.

Safe to delete: Yes (after verifying updates work)

Useful for: Rollback to previous version if needed

Cleanup:

DEL C:\BAT\*.BAK

---

Q: Do I need to deploy every machine individually?

A: Yes, but only once per machine.

After initial deployment: All machines update automatically on reboot.

Deployment checklist:

• TS-01 deployed
• TS-02 deployed
• ...
• TS-30 deployed

---

Quick Reference Card

Daily Operations

Boot machine → Wait for "System Ready" → Start testing

First Time Setup

T:\UPDATE.BAT TS-XX → Reboot → Done

Manual Commands

C:\BAT\CHECKUPD  - Check available updates
C:\BAT\NWTOC     - Download updates now
C:\BAT\CTONW     - Upload test data now
C:\BAT\UPDATE    - Full system backup

Troubleshooting

C:\NET\STARTNET  - Restart network
DATE             - Check DOS date
TIME             - Check DOS time
DIR T:\          - Verify network access
ECHO %MACHINE%   - Check machine name

Emergency Contacts

Test Lead: [Contact]
Engineering: [Contact]
IT Support: [Contact]

---

Document End

For detailed technical information, see ENGINEER_CHANGELOG.md For advanced procedures, see ENGINEER_HOWTO_GUIDE.md

Remember: When in doubt, reboot! The automatic system will restore everything.