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+
+
+
+Post-Deploy Debug Flowchart
+
+
+
+
+
Post-Deploy Debug Flowchart - PXE Imaged Machines
+
Audience: Shopfloor tech standing at a freshly imaged PC.
+Scope: UDC not collecting data, and DNC not pushing programs to the controller.
+Run-from: Logged in on the imaged PC as the ShopFloor local account. GUI only - no shell required.
+
+
The few commands shown (e.g. ping) run from a normal Command Prompt window.
UDC = Universal Data Collection desktop app on the imaged PC. Most "no data" issues post-deploy are not a service crash - they are the COM port pointing at the wrong physical serial port. Fix is a GUI procedure inside UDC, run as admin.
+
What you need before starting:
+
+
Badge scanner (the one wired to the PC).
+
Access to S:\SPC\UDC\UDC_Password.jpg (mapped S: drive must be working - if not, fix S: first via the standard mapdrive.bat runbook).
+
+
Step 1 - Unlock the admin menu
+
Open UDC. Click Tools -> Show All Menus.
+
+
UDC will prompt for a badge scan to authorise admin mode:
+
+
Step 2 - Scan the UDC admin password barcode
+
The admin "password" is a barcode stored as a JPG on the S: drive.
+
+
+
Navigate File Explorer to S:\SPC\UDC\UDC_Password.jpg.
+
+
+
+
Open the JPG in Paint (or any image viewer that shows it at full size).
+
+
+
Point the badge scanner at the on-screen barcode and pull the trigger. UDC accepts the scan and unlocks admin mode.
+
+
+
Step 3 - Open Options
+
With admin mode active, Tools now shows an extra Options item at the top of the menu. Click Tools -> Options.
+
+
Step 4 - Set the correct COM port
+
Click the Serial tab on the left. Set Port Name to match the physical serial port the machine cable is plugged into on the back of the PC.
+
+
+
COM 1 = onboard / Intel serial port (motherboard-integrated)
+
Logical:
+
+
Physical port to match:
+
+
+
+
COM 2 = PCIe add-in serial card
+
Logical:
+
+
Physical port to match:
+
+
+
+
Leave the rest at defaults: Baud 9600, Data Bits 8, Stop Bits One, Parity None.
+
Click Save.
+
Step 5 - Exit to apply
+
Click File -> Exit. UDC must restart for the new COM port to take effect.
+
+
Reopen UDC. Data lines should start populating as the machine runs.
+
If data still does not appear
+
Once the COM port is correct, rule out check these in order:
+
+
Wrong physical cable - cable is in COM1 socket but Port Name set to COM 2 (or vice versa). Re-check Step 4.
+
Cable / connector damaged - swap with a known-good cable.
+
Machine controller side not transmitting - confirm at the controller HMI.
+
+
+
Symptom 2 - DNC not pushing a program to the controller
+
Two independent root causes. Check in order: NTLARS first (cheaper), then NIC.
+
2A - NTLARS reg file never imported (blank General tab fields)
+
What it looks like:
+
Open NTLARS. General tab shows Site = WestJefferson but Machine No., CNC Type, Host Type, Interface Type are all empty.
+
+
The per-machine reg backup never imported during imaging, so NTLARS has no machine-specific config.
+
Fix:
+
+
+
Note the machine number (printed on the PC asset label, or look up by hostname).
+
+
+
Browse to the DNC reg backup folder on the SFLD share:
+
S:\DT\RegFiles\Dnc\Backup Copies\
+
+
Each file is named <MACHINE-NUMBER>.reg (e.g. 4008.reg, 4001.reg, 3209.reg).
+
+
+
+
In the NTLARS settings dialog, click Load... (top-right of the dialog, next to Save).
+
+
+
Browse to S:\DT\RegFiles\Dnc\Backup Copies\ and select the .reg matching this PC's machine number. Confirm the import.
+
+
+
The General tab fields should now be populated. Click OK to apply.
+
+
+
While in NTLARS, click the FMS Host tab. Check Primary - the backup reg usually populates the short hostname WJFMS3 only. Update it to the full FQDN:
+
+
+
+
+
Field
+
Required value
+
+
+
+
+
Primary
+
WJFMS3.AE.GE.COM (FQDN - not just WJFMS3)
+
+
+
Secondary
+
10.233.112.158
+
+
+
Socket Number
+
5003
+
+
+
Timeout
+
10
+
+
+
+
Click OK to save. The short hostname fails on GE corp DNS in some shopfloor segments; the FQDN resolves reliably. The manifest drift-catcher will also normalise this on next run, but doing it now avoids waiting for the next manifest cycle.
+
+
+
If fields are still blank after import: the reg backup file is stale or for a different machine number. Pull the correct one and re-import.
+
2B - Controller NIC has no static IP
+
The PC has two NICs. One faces the corporate / shopfloor LAN (gets internet); the other faces the controller on an isolated subnet (no internet - shown as "Unidentified network" / "No internet").
+
Standard controller-side config:
+
+
+
+
Setting
+
Value
+
+
+
+
+
IP assignment
+
Manual
+
+
+
IPv4 address
+
192.168.1.2
+
+
+
Subnet mask
+
255.255.255.0
+
+
+
Default gateway
+
leave blank
+
+
+
DNS servers
+
Automatic (DHCP) - leave as-is
+
+
+
+
Step-by-step (GUI - logged in as ShopFloor local account):
+
+
+
Right-click the network icon in the system tray. Select Network and Internet settings.
+
+
+
+
In Network & internet, identify the controller-facing adapter. On every PXE-imaged shopfloor PC the controller NIC is the Realtek PCIe GbE Family Controller. It will also show "No internet" / "Public network" (the other adapter, with internet, is the shopfloor LAN). Click into it.
+
+
Confirm at the bottom of the adapter detail page that Description = Realtek PCIe GbE Family Controller:
+
+
+
+
Scroll to IP assignment. If it shows Automatic (DHCP) or the IPv4 address is 169.254.x.x / blank: click Edit next to IP assignment, switch to Manual, enable IPv4, and enter:
+
+
IP address: 192.168.1.2
+
Subnet mask: 255.255.255.0
+
Gateway: leave blank
+
+
Save.
+
+
+
Verify. The adapter detail should now show:
+
+
IP assignment: Manual
+
IPv4 address: 192.168.1.2
+
IPv4 mask: 255.255.255.0
+
Description: Realtek PCIe GbE Family Controller
+
+
+
+
Verify connectivity to the controller:
+
The controller is always at 192.168.1.1 on this subnet. Open Command Prompt and run:
+
ping 192.168.1.1
+
+
Expected: 4/4 replies.
+
If pings fail:
+
+
Check the controller-side network cable.
+
Confirm no other adapter on the PC also has 192.168.1.2 (duplicate IP). In Network & internet, check both Ethernet adapters - only the Realtek PCIe GbE one should have it.
+
Confirm the controller itself is powered and online.
+
+
+
+
\ No newline at end of file
diff --git a/docs/post-deploy-debug-flowchart.md b/docs/post-deploy-debug-flowchart.md
new file mode 100644
index 0000000..e712464
--- /dev/null
+++ b/docs/post-deploy-debug-flowchart.md
@@ -0,0 +1,253 @@
+# Post-Deploy Debug Flowchart - PXE Imaged Machines
+
+**Audience:** Shopfloor tech standing at a freshly imaged PC.
+**Scope:** UDC not collecting data, and DNC not pushing programs to the controller.
+**Run-from:** Logged in on the imaged PC as the ShopFloor local account. GUI only - no shell required.
+
+> The few commands shown (e.g. `ping`) run from a normal Command Prompt window.
+
+---
+
+## Overview
+
+Click any boxed node to jump to its section.
+
+```mermaid
+%%{init: {'securityLevel':'loose'}}%%
+flowchart TD
+ Start([PC imaged - issue reported]) --> Sym{Which symptom?}
+
+ Sym -->|UDC not collecting data| U1[Open UDC: Tools - Show All Menus]
+ Sym -->|DNC not pushing to controller| D1{NTLARS General tab populated?}
+
+ U1 --> U2[Scan UDC_Password barcode from S:\SPC\UDC\UDC_Password.jpg]
+ U2 --> U3[Tools - Options - Serial tab]
+ U3 --> U4{Which physical COM port is the cable in?}
+ U4 -->|Intel / onboard| U5[Set Port Name = COM 1]
+ U4 -->|PCIe add-in card| U6[Set Port Name = COM 2]
+ U5 --> U7[Save - File - Exit - reopen UDC]
+ U6 --> U7
+ U7 --> U8([Verify data lines populate])
+
+ D1 -->|No - fields blank| D2[NTLARS: Load... -> S:\DT\RegFiles\Dnc\Backup Copies\machine.reg]
+ D1 -->|Yes - fields filled| FMS{FMS Host Primary = WJFMS3.AE.GE.COM?}
+
+ D2 --> D3[Confirm General tab populated - OK]
+ D3 --> FMS
+
+ FMS -->|No - shows WJFMS3 short| FMS1[Update Primary to FQDN WJFMS3.AE.GE.COM - OK]
+ FMS -->|Yes| NIC{Realtek PCIe GbE NIC = 192.168.1.2 / 24?}
+ FMS1 --> NIC
+
+ NIC -->|No| NIC1[Set Realtek PCIe GbE static IP 192.168.1.2 / 255.255.255.0]
+ NIC -->|Yes| NIC2[ping 192.168.1.1]
+ NIC1 --> NIC2
+ NIC2 --> NIC3{Ping replies?}
+ NIC3 -->|No| NIC4[Check cable / controller side / duplicate IP]
+ NIC3 -->|Yes| Done([Retest DNC push])
+
+ click U1 "#step-1-unlock-the-admin-menu" "Step 1 - Unlock admin"
+ click U2 "#step-2-scan-the-udc-admin-password-barcode" "Step 2 - Scan password"
+ click U3 "#step-3-open-options" "Step 3 - Options"
+ click U4 "#step-4-set-the-correct-com-port" "Step 4 - COM port"
+ click U5 "#step-4-set-the-correct-com-port" "Step 4 - COM 1"
+ click U6 "#step-4-set-the-correct-com-port" "Step 4 - COM 2"
+ click U7 "#step-5-exit-to-apply" "Step 5 - Exit"
+
+ click D2 "#2a-ntlars-reg-file-never-imported-blank-general-tab-fields" "2A - Load reg backup"
+ click D3 "#2a-ntlars-reg-file-never-imported-blank-general-tab-fields" "2A - Confirm populated"
+ click FMS1 "#2a-ntlars-reg-file-never-imported-blank-general-tab-fields" "2A - FMS Host FQDN"
+ click NIC1 "#2b-controller-nic-has-no-static-ip" "2B - Set static IP"
+ click NIC2 "#2b-controller-nic-has-no-static-ip" "2B - Ping check"
+ click NIC4 "#2b-controller-nic-has-no-static-ip" "2B - Troubleshoot"
+```
+
+---
+
+## Symptom 1 - UDC not collecting data
+
+UDC = Universal Data Collection desktop app on the imaged PC. Most "no data" issues post-deploy are not a service crash - they are the COM port pointing at the wrong physical serial port. Fix is a GUI procedure inside UDC, run as admin.
+
+**What you need before starting:**
+- Badge scanner (the one wired to the PC).
+- Access to `S:\SPC\UDC\UDC_Password.jpg` (mapped S: drive must be working - if not, fix S: first via the standard `mapdrive.bat` runbook).
+
+### Step 1 - Unlock the admin menu
+
+Open UDC. Click **Tools** -> **Show All Menus**.
+
+
+
+UDC will prompt for a badge scan to authorise admin mode:
+
+
+
+### Step 2 - Scan the UDC admin password barcode
+
+The admin "password" is a barcode stored as a JPG on the S: drive.
+
+1. Navigate File Explorer to `S:\SPC\UDC\UDC_Password.jpg`.
+
+ 
+
+2. Open the JPG in Paint (or any image viewer that shows it at full size).
+3. Point the badge scanner at the on-screen barcode and pull the trigger. UDC accepts the scan and unlocks admin mode.
+
+### Step 3 - Open Options
+
+With admin mode active, **Tools** now shows an extra **Options** item at the top of the menu. Click **Tools** -> **Options**.
+
+
+
+### Step 4 - Set the correct COM port
+
+Click the **Serial** tab on the left. Set **Port Name** to match the **physical** serial port the machine cable is plugged into on the back of the PC.
+
+- **COM 1** = onboard / Intel serial port (motherboard-integrated)
+
+ Logical:
+
+ 
+
+ Physical port to match:
+
+ 
+
+- **COM 2** = PCIe add-in serial card
+
+ Logical:
+
+ 
+
+ Physical port to match:
+
+ 
+
+Leave the rest at defaults: **Baud 9600, Data Bits 8, Stop Bits One, Parity None**.
+
+Click **Save**.
+
+### Step 5 - Exit to apply
+
+Click **File** -> **Exit**. UDC must restart for the new COM port to take effect.
+
+
+
+Reopen UDC. Data lines should start populating as the machine runs.
+
+### If data still does not appear
+
+Once the COM port is correct, ~~rule out~~ check these in order:
+- Wrong physical cable - cable is in COM1 socket but Port Name set to COM 2 (or vice versa). Re-check Step 4.
+- Cable / connector damaged - swap with a known-good cable.
+- Machine controller side not transmitting - confirm at the controller HMI.
+
+---
+
+## Symptom 2 - DNC not pushing a program to the controller
+
+Two independent root causes. Check in order: NTLARS first (cheaper), then NIC.
+
+### 2A - NTLARS reg file never imported (blank General tab fields)
+
+**What it looks like:**
+
+Open NTLARS. **General** tab shows **Site = WestJefferson** but **Machine No., CNC Type, Host Type, Interface Type** are all empty.
+
+
+
+The per-machine reg backup never imported during imaging, so NTLARS has no machine-specific config.
+
+**Fix:**
+
+1. Note the machine number (printed on the PC asset label, or look up by hostname).
+
+2. Browse to the DNC reg backup folder on the SFLD share:
+
+ ```
+ S:\DT\RegFiles\Dnc\Backup Copies\
+ ```
+
+ Each file is named `.reg` (e.g. `4008.reg`, `4001.reg`, `3209.reg`).
+
+ 
+
+3. In the NTLARS settings dialog, click **Load...** (top-right of the dialog, next to Save).
+
+4. Browse to `S:\DT\RegFiles\Dnc\Backup Copies\` and select the `.reg` matching this PC's machine number. Confirm the import.
+
+5. The General tab fields should now be populated. Click **OK** to apply.
+
+6. While in NTLARS, click the **FMS Host** tab. Check **Primary** - the backup reg usually populates the short hostname `WJFMS3` only. Update it to the full FQDN:
+
+ 
+
+ | Field | Required value |
+ |-------|----------------|
+ | Primary | `WJFMS3.AE.GE.COM` (FQDN - not just `WJFMS3`) |
+ | Secondary | `10.233.112.158` |
+ | Socket Number | `5003` |
+ | Timeout | `10` |
+
+ Click **OK** to save. The short hostname fails on GE corp DNS in some shopfloor segments; the FQDN resolves reliably. The manifest drift-catcher will also normalise this on next run, but doing it now avoids waiting for the next manifest cycle.
+
+If fields are still blank after import: the reg backup file is stale or for a different machine number. Pull the correct one and re-import.
+
+### 2B - Controller NIC has no static IP
+
+The PC has two NICs. One faces the corporate / shopfloor LAN (gets internet); the other faces the controller on an isolated subnet (no internet - shown as "Unidentified network" / "No internet").
+
+**Standard controller-side config:**
+
+| Setting | Value |
+|---------|-------|
+| IP assignment | Manual |
+| IPv4 address | `192.168.1.2` |
+| Subnet mask | `255.255.255.0` |
+| Default gateway | _leave blank_ |
+| DNS servers | Automatic (DHCP) - leave as-is |
+
+**Step-by-step (GUI - logged in as ShopFloor local account):**
+
+1. Right-click the network icon in the system tray. Select **Network and Internet settings**.
+
+ 
+
+2. In Network & internet, identify the controller-facing adapter. **On every PXE-imaged shopfloor PC the controller NIC is the `Realtek PCIe GbE Family Controller`.** It will also show **"No internet"** / **"Public network"** (the other adapter, with internet, is the shopfloor LAN). Click into it.
+
+ 
+
+ Confirm at the bottom of the adapter detail page that **Description = Realtek PCIe GbE Family Controller**:
+
+ 
+
+3. Scroll to **IP assignment**. If it shows `Automatic (DHCP)` or the IPv4 address is `169.254.x.x` / blank: click **Edit** next to IP assignment, switch to **Manual**, enable IPv4, and enter:
+
+ - IP address: `192.168.1.2`
+ - Subnet mask: `255.255.255.0`
+ - Gateway: _leave blank_
+
+ Save.
+
+4. Verify. The adapter detail should now show:
+
+ - IP assignment: **Manual**
+ - IPv4 address: **192.168.1.2**
+ - IPv4 mask: **255.255.255.0**
+ - Description: **Realtek PCIe GbE Family Controller**
+
+**Verify connectivity to the controller:**
+
+The controller is always at `192.168.1.1` on this subnet. Open Command Prompt and run:
+
+```cmd
+ping 192.168.1.1
+```
+
+Expected: 4/4 replies.
+
+If pings fail:
+- Check the controller-side network cable.
+- Confirm no other adapter on the PC also has `192.168.1.2` (duplicate IP). In Network & internet, check both Ethernet adapters - only the Realtek PCIe GbE one should have it.
+- Confirm the controller itself is powered and online.
+
diff --git a/docs/post-deploy-debug-flowchart.static.html b/docs/post-deploy-debug-flowchart.static.html
new file mode 100644
index 0000000..196272d
--- /dev/null
+++ b/docs/post-deploy-debug-flowchart.static.html
@@ -0,0 +1,236 @@
+
+
+
+Post-Deploy Debug Flowchart
+
+
+
Post-Deploy Debug Flowchart - PXE Imaged Machines
+
Audience: Shopfloor tech standing at a freshly imaged PC.
+Scope: UDC not collecting data, and DNC not pushing programs to the controller.
+Run-from: Logged in on the imaged PC as the ShopFloor local account. GUI only - no shell required.
+
+
The few commands shown (e.g. ping) run from a normal Command Prompt window.
+
+
+
Overview
+
Click any boxed node to jump to its section.
+
+
+
+
+
Symptom 1 - UDC not collecting data
+
UDC = Universal Data Collection desktop app on the imaged PC. Most "no data" issues post-deploy are not a service crash - they are the COM port pointing at the wrong physical serial port. Fix is a GUI procedure inside UDC, run as admin.
+
What you need before starting:
+
+
Badge scanner (the one wired to the PC).
+
Access to S:\SPC\UDC\UDC_Password.jpg (mapped S: drive must be working - if not, fix S: first via the standard mapdrive.bat runbook).
+
+
Step 1 - Unlock the admin menu
+
Open UDC. Click Tools -> Show All Menus.
+
+
UDC will prompt for a badge scan to authorise admin mode:
+
+
Step 2 - Scan the UDC admin password barcode
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The admin "password" is a barcode stored as a JPG on the S: drive.
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+
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Navigate File Explorer to S:\SPC\UDC\UDC_Password.jpg.
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+
+
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Open the JPG in Paint (or any image viewer that shows it at full size).
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+
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Point the badge scanner at the on-screen barcode and pull the trigger. UDC accepts the scan and unlocks admin mode.
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+
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Step 3 - Open Options
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With admin mode active, Tools now shows an extra Options item at the top of the menu. Click Tools -> Options.
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+
Step 4 - Set the correct COM port
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Click the Serial tab on the left. Set Port Name to match the physical serial port the machine cable is plugged into on the back of the PC.
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+
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COM 1 = onboard / Intel serial port (motherboard-integrated)
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Logical:
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+
Physical port to match:
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+
+
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COM 2 = PCIe add-in serial card
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Logical:
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Physical port to match:
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+
+
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Leave the rest at defaults: Baud 9600, Data Bits 8, Stop Bits One, Parity None.
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Click Save.
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Step 5 - Exit to apply
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Click File -> Exit. UDC must restart for the new COM port to take effect.
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+
Reopen UDC. Data lines should start populating as the machine runs.
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If data still does not appear
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Once the COM port is correct, rule out check these in order:
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Wrong physical cable - cable is in COM1 socket but Port Name set to COM 2 (or vice versa). Re-check Step 4.
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Cable / connector damaged - swap with a known-good cable.
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Machine controller side not transmitting - confirm at the controller HMI.
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+
+
Symptom 2 - DNC not pushing a program to the controller
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Two independent root causes. Check in order: NTLARS first (cheaper), then NIC.
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2A - NTLARS reg file never imported (blank General tab fields)
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What it looks like:
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Open NTLARS. General tab shows Site = WestJefferson but Machine No., CNC Type, Host Type, Interface Type are all empty.
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The per-machine reg backup never imported during imaging, so NTLARS has no machine-specific config.
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Fix:
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+
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Note the machine number (printed on the PC asset label, or look up by hostname).
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+
+
Browse to the DNC reg backup folder on the SFLD share:
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S:\DT\RegFiles\Dnc\Backup Copies\
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+
Each file is named <MACHINE-NUMBER>.reg (e.g. 4008.reg, 4001.reg, 3209.reg).
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+
+
+
In the NTLARS settings dialog, click Load... (top-right of the dialog, next to Save).
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+
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Browse to S:\DT\RegFiles\Dnc\Backup Copies\ and select the .reg matching this PC's machine number. Confirm the import.
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+
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The General tab fields should now be populated. Click OK to apply.
+
+
+
While in NTLARS, click the FMS Host tab. Check Primary - the backup reg usually populates the short hostname WJFMS3 only. Update it to the full FQDN:
+
+
+
+
+
Field
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Required value
+
+
+
+
+
Primary
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WJFMS3.AE.GE.COM (FQDN - not just WJFMS3)
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+
+
Secondary
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10.233.112.158
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+
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Socket Number
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5003
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+
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Timeout
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10
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+
+
+
Click OK to save. The short hostname fails on GE corp DNS in some shopfloor segments; the FQDN resolves reliably. The manifest drift-catcher will also normalise this on next run, but doing it now avoids waiting for the next manifest cycle.
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+
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If fields are still blank after import: the reg backup file is stale or for a different machine number. Pull the correct one and re-import.
+
2B - Controller NIC has no static IP
+
The PC has two NICs. One faces the corporate / shopfloor LAN (gets internet); the other faces the controller on an isolated subnet (no internet - shown as "Unidentified network" / "No internet").
+
Standard controller-side config:
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+
+
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Setting
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Value
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+
+
+
+
IP assignment
+
Manual
+
+
+
IPv4 address
+
192.168.1.2
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+
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Subnet mask
+
255.255.255.0
+
+
+
Default gateway
+
leave blank
+
+
+
DNS servers
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Automatic (DHCP) - leave as-is
+
+
+
+
Step-by-step (GUI - logged in as ShopFloor local account):
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+
+
Right-click the network icon in the system tray. Select Network and Internet settings.
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+
+
+
In Network & internet, identify the controller-facing adapter. On every PXE-imaged shopfloor PC the controller NIC is the Realtek PCIe GbE Family Controller. It will also show "No internet" / "Public network" (the other adapter, with internet, is the shopfloor LAN). Click into it.
+
+
Confirm at the bottom of the adapter detail page that Description = Realtek PCIe GbE Family Controller:
+
+
+
+
Scroll to IP assignment. If it shows Automatic (DHCP) or the IPv4 address is 169.254.x.x / blank: click Edit next to IP assignment, switch to Manual, enable IPv4, and enter:
+
+
IP address: 192.168.1.2
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Subnet mask: 255.255.255.0
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Gateway: leave blank
+
+
Save.
+
+
+
Verify. The adapter detail should now show:
+
+
IP assignment: Manual
+
IPv4 address: 192.168.1.2
+
IPv4 mask: 255.255.255.0
+
Description: Realtek PCIe GbE Family Controller
+
+
+
+
Verify connectivity to the controller:
+
The controller is always at 192.168.1.1 on this subnet. Open Command Prompt and run:
+
ping 192.168.1.1
+
+
Expected: 4/4 replies.
+
If pings fail:
+
+
Check the controller-side network cable.
+
Confirm no other adapter on the PC also has 192.168.1.2 (duplicate IP). In Network & internet, check both Ethernet adapters - only the Realtek PCIe GbE one should have it.
+
Confirm the controller itself is powered and online.
