c8a0f98be1
Step-by-step runbook for techs at the imaged PC. Two symptoms covered: UDC not collecting data (admin-unlock + COM port walkthrough) and DNC not pushing to controller (NTLARS reg restore + FMS Host FQDN + Realtek PCIe GbE static IP). Mermaid overview links to each section. Live HTML uses CDN; static HTML pre-renders SVG for offline / printable use. Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
254 lines
10 KiB
Markdown
254 lines
10 KiB
Markdown
# Post-Deploy Debug Flowchart - PXE Imaged Machines
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**Audience:** Shopfloor tech standing at a freshly imaged PC.
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**Scope:** UDC not collecting data, and DNC not pushing programs to the controller.
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**Run-from:** Logged in on the imaged PC as the ShopFloor local account. GUI only - no shell required.
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> The few commands shown (e.g. `ping`) run from a normal Command Prompt window.
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---
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## Overview
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Click any boxed node to jump to its section.
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```mermaid
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%%{init: {'securityLevel':'loose'}}%%
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flowchart TD
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Start([PC imaged - issue reported]) --> Sym{Which symptom?}
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Sym -->|UDC not collecting data| U1[Open UDC: Tools - Show All Menus]
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Sym -->|DNC not pushing to controller| D1{NTLARS General tab populated?}
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U1 --> U2[Scan UDC_Password barcode from S:\SPC\UDC\UDC_Password.jpg]
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U2 --> U3[Tools - Options - Serial tab]
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U3 --> U4{Which physical COM port is the cable in?}
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U4 -->|Intel / onboard| U5[Set Port Name = COM 1]
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U4 -->|PCIe add-in card| U6[Set Port Name = COM 2]
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U5 --> U7[Save - File - Exit - reopen UDC]
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U6 --> U7
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U7 --> U8([Verify data lines populate])
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D1 -->|No - fields blank| D2[NTLARS: Load... -> S:\DT\RegFiles\Dnc\Backup Copies\machine.reg]
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D1 -->|Yes - fields filled| FMS{FMS Host Primary = WJFMS3.AE.GE.COM?}
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D2 --> D3[Confirm General tab populated - OK]
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D3 --> FMS
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FMS -->|No - shows WJFMS3 short| FMS1[Update Primary to FQDN WJFMS3.AE.GE.COM - OK]
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FMS -->|Yes| NIC{Realtek PCIe GbE NIC = 192.168.1.2 / 24?}
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FMS1 --> NIC
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NIC -->|No| NIC1[Set Realtek PCIe GbE static IP 192.168.1.2 / 255.255.255.0]
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NIC -->|Yes| NIC2[ping 192.168.1.1]
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NIC1 --> NIC2
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NIC2 --> NIC3{Ping replies?}
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NIC3 -->|No| NIC4[Check cable / controller side / duplicate IP]
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NIC3 -->|Yes| Done([Retest DNC push])
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click U1 "#step-1-unlock-the-admin-menu" "Step 1 - Unlock admin"
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click U2 "#step-2-scan-the-udc-admin-password-barcode" "Step 2 - Scan password"
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click U3 "#step-3-open-options" "Step 3 - Options"
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click U4 "#step-4-set-the-correct-com-port" "Step 4 - COM port"
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click U5 "#step-4-set-the-correct-com-port" "Step 4 - COM 1"
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click U6 "#step-4-set-the-correct-com-port" "Step 4 - COM 2"
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click U7 "#step-5-exit-to-apply" "Step 5 - Exit"
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click D2 "#2a-ntlars-reg-file-never-imported-blank-general-tab-fields" "2A - Load reg backup"
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click D3 "#2a-ntlars-reg-file-never-imported-blank-general-tab-fields" "2A - Confirm populated"
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click FMS1 "#2a-ntlars-reg-file-never-imported-blank-general-tab-fields" "2A - FMS Host FQDN"
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click NIC1 "#2b-controller-nic-has-no-static-ip" "2B - Set static IP"
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click NIC2 "#2b-controller-nic-has-no-static-ip" "2B - Ping check"
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click NIC4 "#2b-controller-nic-has-no-static-ip" "2B - Troubleshoot"
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```
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---
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## Symptom 1 - UDC not collecting data
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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.
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**What you need before starting:**
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- Badge scanner (the one wired to the PC).
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- 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).
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### Step 1 - Unlock the admin menu
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Open UDC. Click **Tools** -> **Show All Menus**.
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UDC will prompt for a badge scan to authorise admin mode:
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### 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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1. Navigate File Explorer to `S:\SPC\UDC\UDC_Password.jpg`.
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2. Open the JPG in Paint (or any image viewer that shows it at full size).
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3. 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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### 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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- **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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- **COM 2** = PCIe add-in serial card
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Logical:
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Physical port to match:
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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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---
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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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1. Note the machine number (printed on the PC asset label, or look up by hostname).
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2. Browse to the DNC reg backup folder on the SFLD share:
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```
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S:\DT\RegFiles\Dnc\Backup Copies\
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```
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Each file is named `<MACHINE-NUMBER>.reg` (e.g. `4008.reg`, `4001.reg`, `3209.reg`).
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3. In the NTLARS settings dialog, click **Load...** (top-right of the dialog, next to Save).
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4. 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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5. The General tab fields should now be populated. Click **OK** to apply.
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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:
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| Field | Required value |
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|-------|----------------|
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| Primary | `WJFMS3.AE.GE.COM` (FQDN - not just `WJFMS3`) |
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| Secondary | `10.233.112.158` |
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| Socket Number | `5003` |
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| Timeout | `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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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.
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### 2B - Controller NIC has no static IP
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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").
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**Standard controller-side config:**
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| Setting | Value |
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|---------|-------|
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| IP assignment | Manual |
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| IPv4 address | `192.168.1.2` |
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| Subnet mask | `255.255.255.0` |
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| Default gateway | _leave blank_ |
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| DNS servers | Automatic (DHCP) - leave as-is |
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**Step-by-step (GUI - logged in as ShopFloor local account):**
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1. Right-click the network icon in the system tray. Select **Network and Internet settings**.
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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.
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Confirm at the bottom of the adapter detail page that **Description = Realtek PCIe GbE Family Controller**:
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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:
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- IP address: `192.168.1.2`
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- Subnet mask: `255.255.255.0`
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- Gateway: _leave blank_
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Save.
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4. Verify. The adapter detail should now show:
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- IP assignment: **Manual**
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- IPv4 address: **192.168.1.2**
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- IPv4 mask: **255.255.255.0**
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- Description: **Realtek PCIe GbE Family Controller**
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**Verify connectivity to the controller:**
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The controller is always at `192.168.1.1` on this subnet. Open Command Prompt and run:
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```cmd
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ping 192.168.1.1
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```
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Expected: 4/4 replies.
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If pings fail:
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- Check the controller-side network cable.
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- 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.
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- Confirm the controller itself is powered and online.
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