docs: add four planning runbooks for Phase 6.3 interop, v2 GA gates, live-hardware validation, and alarms worker wiring
Produces docs/plans/ entries for tasks #13, #15, #16, and #17-#20: - phase-6-3-redundancy-interop-plan.md: automation boundary analysis, concrete test matrix (A/B/C blocks), and a step-by-step cutover runbook for the deferred Stream F client interop work - v2-ga-lab-gates-plan.md: exact gate list with command, pass criterion, and owner for each of the nine v2 GA exit criteria - live-hardware-validation-runbooks.md: one runbook per driver (FOCAS CNC smoke #54, AB CIP live-boot, TwinCAT wire-live) with preconditions, procedure, expected results, and recording template - alarms-worker-wiring-plan.md: focused plan for A.2/A.3-A.4/C.1/D.1 worker wiring in the mxaccessgw sibling repo, documenting the discovered AVEVA API surface, the architectural decision that blocks A.2, the dependency order, and what each item needs to unblock Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
This commit is contained in:
Joseph Doherty
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docs/plans/live-hardware-validation-runbooks.md
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docs/plans/live-hardware-validation-runbooks.md
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# Live-Hardware Driver Validation Runbooks
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> **Scope**: These runbooks cover the three driver validation tasks that
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> require physical hardware or a hardware-equivalent live environment and
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> cannot be satisfied by the Docker-based simulator fixtures or unit tests
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> alone.
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>
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> Driver implementation is complete. The runbooks document the preconditions,
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> step-by-step procedure, expected results, and how to record the outcome for
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> each driver that has an open live-hardware gap.
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---
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## 1. FANUC FOCAS — Live CNC Smoke (task #54)
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### Background
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The FOCAS driver (`src/Drivers/ZB.MOM.WW.OtOpcUa.Driver.FOCAS/`) uses the
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pure-managed `WireFocasClient` that speaks FOCAS2 over TCP directly (no
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`Fwlib64.dll`, no P/Invoke). The integration test suite at
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`tests/Drivers/ZB.MOM.WW.OtOpcUa.Driver.FOCAS.IntegrationTests/` runs against
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the `focas-mock` Python server (PDU-verified against `fwlibe64.dll` upstream)
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and covers all call-shapes the driver issues. What the mock cannot cover:
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- Series-specific firmware quirks (e.g. 0i-F vs 30i-B parameter range limits)
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- Real CNC Ethernet stack behaviour (TCP keep-alive, session-close edge cases)
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- Series gating: some driver nodes are conditionally emitted based on
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`CncSeries` — only a physical CNC can confirm the suppression works
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### Preconditions
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| Item | Requirement |
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|------|-------------|
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| CNC hardware | FANUC CNC with Ethernet option enabled; TCP port 8193 reachable from the dev box or from the host running OtOpcUa |
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| CNC series | Any of: 0i-D, 0i-F, 0i-MF, 0i-TF, 16i, 30i-B, 31i, 32i, Power Motion i |
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| CNC state | Running state (not E-stop, not alarm) for live axis-data reads |
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| Network | TCP reachability from OtOpcUa server host to CNC port 8193 |
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| OtOpcUa | Server built and deployed (`dotnet publish` or running via `dotnet run`) |
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| Config | DriverInstance row for FOCAS in Config DB (`Type="FOCAS"`, `Backend="wire"`, `Devices[0].HostAddress="focas://<cnc-ip>:8193"`, `Devices[0].Series="<series>"`) |
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### Procedure
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**Step 1 — Verify TCP reachability**
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```powershell
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Test-NetConnection -ComputerName <cnc-ip> -Port 8193
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```
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Pass: `TcpTestSucceeded: True`.
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**Step 2 — Start OtOpcUa with FOCAS driver configured**
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Ensure the Config DB has the DriverInstance row. Start the server:
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```powershell
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sc start OtOpcUa
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# or for a dev run:
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dotnet run --project src/Server/ZB.MOM.WW.OtOpcUa.Server
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```
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Watch the Serilog log for:
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```
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[INF] FocasDriver initializing device focas://<cnc-ip>:8193 series=<series>
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[INF] FocasDriver device <cnc-ip>:8193 Connected
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```
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If `EW_SOCKET (-1)` appears, the TCP endpoint is unreachable or the CNC
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Ethernet option is not active.
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**Step 3 — Browse the address space**
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```powershell
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dotnet run --project src/Client/ZB.MOM.WW.OtOpcUa.Client.CLI -- `
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browse -u opc.tcp://localhost:4840 -r -d 3
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```
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Expected: a node tree containing at minimum:
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```
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FOCAS/
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<device>/
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Identity/
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SeriesNumber
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Version
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MaxAxes
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Status/
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RunState
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Mode
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EmergencyStop
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Axes/
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<X|Y|Z>/
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AbsolutePosition
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MachinePosition
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```
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Nodes suppressed by the `Series` capability gate will be absent — this is
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correct behaviour.
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**Step 4 — Read identity nodes**
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```powershell
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dotnet run --project src/Client/ZB.MOM.WW.OtOpcUa.Client.CLI -- `
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read -u opc.tcp://localhost:4840 -n "ns=2;s=FOCAS/<device>/Identity/SeriesNumber"
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dotnet run --project src/Client/ZB.MOM.WW.OtOpcUa.Client.CLI -- `
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read -u opc.tcp://localhost:4840 -n "ns=2;s=FOCAS/<device>/Identity/MaxAxes"
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```
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Pass: `Good` quality; `SeriesNumber` matches the string printed on the CNC
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control panel (e.g. `"0i-F"`); `MaxAxes` is a non-zero integer.
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**Step 5 — Read live status and axis data**
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```powershell
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dotnet run --project src/Client/ZB.MOM.WW.OtOpcUa.Client.CLI -- `
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read -u opc.tcp://localhost:4840 -n "ns=2;s=FOCAS/<device>/Status/RunState"
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dotnet run --project src/Client/ZB.MOM.WW.OtOpcUa.Client.CLI -- `
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read -u opc.tcp://localhost:4840 -n "ns=2;s=FOCAS/<device>/Axes/X/AbsolutePosition"
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```
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Pass: both return `Good` quality. `AbsolutePosition` is a `Double` (e.g.
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`-12.3456` mm). Manually compare against the machine's position display.
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**Step 6 — Subscribe and observe polling**
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```powershell
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dotnet run --project src/Client/ZB.MOM.WW.OtOpcUa.Client.CLI -- `
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subscribe -u opc.tcp://localhost:4840 `
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-n "ns=2;s=FOCAS/<device>/Status/RunState" -i 500
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```
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Let run for 30 s while jogging an axis or changing mode on the CNC operator
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panel. Pass: at least one data-change event received within 5 s; events
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continue arriving every ~500 ms.
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**Step 7 — 2-minute soak**
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Let the server run for 2 minutes with the subscription active. Pass: no
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`EW_SOCKET`, `EW_HANDLE`, `EW_BUSY` errors in the Serilog output; subscribed
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node continues delivering updates.
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**Step 8 — Run the FOCAS e2e script**
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```powershell
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pwsh scripts/e2e/test-focas.ps1 -ServerUrl opc.tcp://localhost:4840 `
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-DriverInstance "<device>" -Series "<series>"
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```
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Pass: script exits 0.
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### Expected results
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| Check | Expected |
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|-------|----------|
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| TCP connect to CNC port 8193 | Success |
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| FOCAS session open (`cnc_allclibhndl3`) | EW_OK (0) in driver log |
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| `Identity/SeriesNumber` | Matches CNC panel, `Good` quality |
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| `Identity/MaxAxes` | Non-zero integer, `Good` quality |
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| `Status/RunState` | Integer 0–3, `Good` quality |
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| `Axes/X/AbsolutePosition` | Double, `Good` quality, matches display |
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| Subscribe: events delivered | >= 3 events in 5 s soak |
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| 2-minute soak: no FOCAS errors | Clean Serilog log |
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### Recording the outcome
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```
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FOCAS live-CNC smoke — task #54
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Date: YYYY-MM-DD
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CNC: <manufacturer> <model> series=<series> firmware=<version>
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IP: <cnc-ip>:8193
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OtOpcUa SHA: <git sha>
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TCP connect: PASS
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Session open: PASS
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Identity reads: PASS SeriesNumber="<>" MaxAxes=<n>
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Status read: PASS RunState=<n>
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Axis read: PASS X/AbsolutePosition=<value>
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Subscribe: PASS <n> events in 30s
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2-min soak: PASS no errors
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e2e script: PASS
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```
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---
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## 2. Allen-Bradley CIP — Live Boot (ControlLogix)
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### Background
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The AB CIP driver (`src/Drivers/ZB.MOM.WW.OtOpcUa.Driver.AbCip/`) uses
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`libplctag` 1.6.x. The Docker `ab_server` simulator covers connectivity and
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atomic type reads (7 integration tests). Live-boot validation is needed to
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confirm UDT shape-reading, array tag access, and the CIP packing behaviour on
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a real ControlLogix backplane — all gaps acknowledged in
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`docs/drivers/AbServer-Test-Fixture.md`.
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AB CIP live-boot was first verified against a ControlLogix rig at PR #222.
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Continue running before each release.
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### Preconditions
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| Item | Requirement |
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|------|-------------|
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| PLC hardware | ControlLogix (preferred) or CompactLogix; firmware 20+ for request packing |
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| Network | TCP port 44818 reachable from OtOpcUa server host |
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| PLC state | Running; at least one DINT / REAL / BOOL / STRING controller-scoped tag defined |
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| OtOpcUa | Server built and deployed |
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| Config | DriverInstance row: `Type="AbCip"`, `Host="<plc-ip>"`, `Path="1,0"`, `PlcType="ControlLogix"` |
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### Procedure
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**Step 1 — Verify TCP reachability**
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```powershell
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Test-NetConnection -ComputerName <plc-ip> -Port 44818
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```
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Pass: `TcpTestSucceeded: True`.
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**Step 2 — Start OtOpcUa and watch driver log**
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```powershell
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sc start OtOpcUa
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```
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Look for:
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```
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[INF] AbCipDriver device <plc-ip> Connected path=1,0 plcType=ControlLogix
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```
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**Step 3 — Browse the address space**
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```powershell
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dotnet run --project src/Client/ZB.MOM.WW.OtOpcUa.Client.CLI -- `
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browse -u opc.tcp://localhost:4840 -r -d 3
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```
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Pass: node tree shows the tags defined in the ControlLogix project (controller-
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and program-scoped). UDT members appear as child nodes.
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**Step 4 — Read atomic tags**
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```powershell
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# Read a DINT tag
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dotnet run --project src/Client/ZB.MOM.WW.OtOpcUa.Client.CLI -- `
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read -u opc.tcp://localhost:4840 -n "ns=2;s=AbCip/<device>/<TagName>"
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```
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Pass: `Good` quality; value type matches the PLC tag type.
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**Step 5 — Read a UDT member**
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```powershell
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dotnet run --project src/Client/ZB.MOM.WW.OtOpcUa.Client.CLI -- `
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read -u opc.tcp://localhost:4840 -n "ns=2;s=AbCip/<device>/<UDT>/<MemberName>"
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```
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Pass: `Good` quality; value matches the live PLC value.
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**Step 6 — Write a DINT tag (if in ReadWrite mode)**
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```powershell
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dotnet run --project src/Client/ZB.MOM.WW.OtOpcUa.Client.CLI -- `
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write -u opc.tcp://localhost:4840 `
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-n "ns=2;s=AbCip/<device>/<TagName>" -v 42 -t Int32
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```
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Verify the new value via a subsequent read or on the PLC HMI.
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Pass: read back returns 42 with `Good` quality.
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**Step 7 — Subscribe to a tag that changes**
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```powershell
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dotnet run --project src/Client/ZB.MOM.WW.OtOpcUa.Client.CLI -- `
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subscribe -u opc.tcp://localhost:4840 `
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-n "ns=2;s=AbCip/<device>/<ChangingTag>" -i 500
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```
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Jog or trigger a value change on the PLC. Pass: events received within 2 s.
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**Step 8 — Override endpoint to docker sim and confirm parity**
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```powershell
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$env:AB_SERVER_ENDPOINT = "<plc-ip>:44818"
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dotnet test tests/Drivers/ZB.MOM.WW.OtOpcUa.Driver.AbCip.IntegrationTests `
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--filter "AbServerFact"
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```
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Pass: all 7 integration tests pass against the live PLC.
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### Expected results
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| Check | Expected |
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|-------|----------|
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| TCP connect | Success |
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| Driver log `Connected` | Present, no error |
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| Browse | Node tree mirrors PLC tag list |
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| Atomic read | `Good` quality, correct type |
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| UDT member read | `Good` quality, correct value |
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| Write round-trip | Written value reads back |
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| Subscribe | Events delivered on value change |
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| Integration tests with live PLC | 7/7 pass |
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### Recording the outcome
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```
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AB CIP live-boot
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Date: YYYY-MM-DD
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PLC: Allen-Bradley <model> firmware=<version>
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IP: <plc-ip>:44818 path=1,0
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OtOpcUa SHA: <git sha>
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TCP connect: PASS
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Driver connected: PASS
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Browse: PASS <n> tags visible
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Atomic read: PASS
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UDT read: PASS
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Write round-trip: PASS
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Subscribe: PASS
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Integration tests: 7/7 PASS
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```
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---
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## 3. Beckhoff TwinCAT — Wire-Live Validation
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### Background
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The TwinCAT driver (`src/Drivers/ZB.MOM.WW.OtOpcUa.Driver.TwinCAT/`) uses the
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Beckhoff `TwinCAT.Ads` .NET SDK v6. The integration test suite at
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`tests/Drivers/ZB.MOM.WW.OtOpcUa.Driver.TwinCAT.IntegrationTests/`
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(`TwinCAT3SmokeTests.cs`) covers 14 `[TwinCATFact]` methods + one 16-case
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`[TwinCATTheory]` (30 cases total) against a live ADS runtime. The TCBSD ESXi
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VM at `10.100.0.128` (AmsNetId `41.169.163.43.1.1`) is the primary fixture
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runtime (project memory `project_tcbsd_fixture.md`) and bypasses the
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TwinCAT/Hyper-V conflict on the dev box.
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Live-hardware validation extends beyond the TCBSD VM to confirm the driver
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works against a production PLC (not just the ESXi test VM) and that the three
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defects found during original integration testing do not regress on newer
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firmware:
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1. Notification cycle time unit (250 ms was being set to ~41 min — fixed).
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2. `STRING(N)` / `WSTRING(N)` type mapper (fixed).
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3. Bit-indexed BOOL path (fixed).
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### Preconditions
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**TCBSD ESXi fixture (primary — no physical hardware needed)**
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| Item | Requirement |
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|------|-------------|
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| TCBSD VM | Running on ESXi at `10.100.0.128` |
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| AMS Net ID | `41.169.163.43.1.1` |
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| ADS port | `851` (TwinCAT 3 PLC runtime 1) |
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| PLC project | TwinCAT project from `tests/.../TwinCatProject/` loaded and in Run state |
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| Network | TCP port 48898 reachable from dev box to `10.100.0.128` |
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**Production PLC (for true wire-live validation)**
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| Item | Requirement |
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|------|-------------|
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| TwinCAT hardware | Beckhoff IPC or CX series, TwinCAT 3 (TC3); TC2 is a known gap per fixture doc |
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| AMS route | Route configured on TwinCAT device back to the OtOpcUa host |
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| PLC state | Run state |
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| GVL | At least a `GVL_Fixture.nCounter` DINT and `GVL_Fixture.rSetpoint` REAL present |
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### Procedure — TCBSD ESXi fixture
|
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||||
**Step 1 — Verify TCBSD VM is reachable**
|
||||
|
||||
```powershell
|
||||
Test-NetConnection -ComputerName 10.100.0.128 -Port 48898
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||||
```
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||||
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||||
Pass: `TcpTestSucceeded: True`.
|
||||
|
||||
**Step 2 — Run the integration test suite**
|
||||
|
||||
```powershell
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||||
$env:TWINCAT_TARGET_HOST = "10.100.0.128"
|
||||
$env:TWINCAT_TARGET_NETID = "41.169.163.43.1.1"
|
||||
|
||||
dotnet test tests/Drivers/ZB.MOM.WW.OtOpcUa.Driver.TwinCAT.IntegrationTests `
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||||
--logger "console;verbosity=normal"
|
||||
```
|
||||
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||||
Pass: all 30 test cases pass (14 `[TwinCATFact]` + 16-case `[TwinCATTheory]`).
|
||||
No `[TwinCATFact]` / `[TwinCATTheory]` skips — the env var is set, so the
|
||||
runtime probe is expected to succeed.
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||||
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||||
Key tests to watch:
|
||||
|
||||
| Test | Validates |
|
||||
|------|-----------|
|
||||
| `Driver_subscribe_receives_native_ADS_notifications_on_counter_changes` | Native ADS notification path (the cycle-time-unit bug regression) |
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||||
| `Driver_reads_every_primitive_type_with_correct_mapping` | 16-type theory incl. `STRING(N)` |
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||||
| `Driver_reads_bit_indexed_BOOL_from_word` | Bit-indexed BOOL fix regression |
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||||
| `Driver_auto_reconnects_after_underlying_client_is_disposed` | Reconnect on ADS client dispose |
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||||
| `Driver_routes_reads_per_device_and_isolates_unreachable_peers` | Multi-device isolation |
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||||
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||||
**Step 3 — OtOpcUa server browse/read via Client CLI**
|
||||
|
||||
Start OtOpcUa with a TwinCAT DriverInstance pointing at the TCBSD VM:
|
||||
|
||||
```powershell
|
||||
# appsettings.json DriverInstance: Type=TwinCAT, AmsNetId=41.169.163.43.1.1, AmsPort=851
|
||||
sc start OtOpcUa
|
||||
# or dev run
|
||||
dotnet run --project src/Server/ZB.MOM.WW.OtOpcUa.Server
|
||||
```
|
||||
|
||||
```powershell
|
||||
dotnet run --project src/Client/ZB.MOM.WW.OtOpcUa.Client.CLI -- `
|
||||
browse -u opc.tcp://localhost:4840 -r -d 4
|
||||
|
||||
dotnet run --project src/Client/ZB.MOM.WW.OtOpcUa.Client.CLI -- `
|
||||
read -u opc.tcp://localhost:4840 -n "ns=2;s=TwinCAT/<device>/GVL_Fixture/nCounter"
|
||||
```
|
||||
|
||||
Pass: browse shows the PLC symbol tree; read returns `Good` quality with an
|
||||
integer value.
|
||||
|
||||
### Procedure — Production PLC (optional, for full wire-live signoff)
|
||||
|
||||
If a Beckhoff production IPC is available in the lab:
|
||||
|
||||
**Step 1** — Configure the AMS route on the TwinCAT device (TwinCAT System
|
||||
Manager → Routes → Add static route from the TwinCAT device back to the
|
||||
OtOpcUa server machine).
|
||||
|
||||
**Step 2** — Set env vars and run the integration suite against the production
|
||||
target:
|
||||
|
||||
```powershell
|
||||
$env:TWINCAT_TARGET_HOST = "<production-plc-ip>"
|
||||
$env:TWINCAT_TARGET_NETID = "<production-ams-net-id>"
|
||||
$env:TWINCAT_TARGET_PORT = "851"
|
||||
|
||||
dotnet test tests/Drivers/ZB.MOM.WW.OtOpcUa.Driver.TwinCAT.IntegrationTests
|
||||
```
|
||||
|
||||
**Step 3** — Subscribe to a counter tag for 30 s to confirm native
|
||||
notifications arrive:
|
||||
|
||||
```powershell
|
||||
dotnet run --project src/Client/ZB.MOM.WW.OtOpcUa.Client.CLI -- `
|
||||
subscribe -u opc.tcp://localhost:4840 `
|
||||
-n "ns=2;s=TwinCAT/<device>/GVL_Fixture/nCounter" -i 100
|
||||
```
|
||||
|
||||
Pass: events arrive every ~100 ms driven by the PLC's ADS notification, not
|
||||
by polling.
|
||||
|
||||
### Expected results
|
||||
|
||||
| Check | TCBSD VM | Production PLC |
|
||||
|-------|----------|----------------|
|
||||
| ADS port 48898 reachable | Required | Required |
|
||||
| Integration tests: all 30 pass | Required | Optional (same 30) |
|
||||
| Notification cycle-time test passes | Required | Required |
|
||||
| Server browse shows symbol tree | Required | Optional |
|
||||
| Read `Good` quality | Required | Optional |
|
||||
| Native ADS notifications deliver in subscribe | Required | Recommended |
|
||||
|
||||
### Known gaps (documented — not blockers for v2 GA)
|
||||
|
||||
Per `docs/drivers/TwinCAT-Test-Fixture.md` §"What it does NOT cover":
|
||||
|
||||
- Multi-hop AMS routing — single-hop only.
|
||||
- TC2 (ADS v1) compatibility — TC3 only.
|
||||
- Notification coalescing under sustained CPU load.
|
||||
- `Symbol version changed (0x0702)` storm handling under rapid PLC re-downloads.
|
||||
|
||||
These are deferred to v3 per `docs/v3/twincat-backlog.md`.
|
||||
|
||||
### Recording the outcome
|
||||
|
||||
```
|
||||
TwinCAT wire-live validation
|
||||
Date: YYYY-MM-DD
|
||||
Target: TCBSD VM 10.100.0.128 AmsNetId=41.169.163.43.1.1 (and/or production PLC details)
|
||||
TwinCAT version: <version>
|
||||
OtOpcUa SHA: <git sha>
|
||||
|
||||
ADS port reachable: PASS
|
||||
Integration tests: 30/30 PASS
|
||||
notification-cycle-time test: PASS (regression check)
|
||||
STRING(N) type test: PASS (regression check)
|
||||
bit-indexed BOOL test: PASS (regression check)
|
||||
Server browse: PASS
|
||||
Read Good quality: PASS
|
||||
Native subscription delivery: PASS <n> events in 30s
|
||||
```
|
||||
Reference in New Issue
Block a user