Hi Woody!

You probably mean a HP t510 thin client, with VIA Eden X2 U4200 CPU,
VIA VX900 Chipset, 2 GB RAM, some flash storage, VIA ChromotionHD
graphics (DVI/VGA), audio, GB-LAN, Atheros WiFi, 6x USB2, 1x RS232,
1x LPT, 2x PS/2, 65W 19V power brick:

https://support.hp.com/us-en/document/c03260067

According to this site, you can connect IDE storage, so a compact
flash card with a suitable adapter indeed sounds like a great idea.
CF usually support IDE I/O, which means that a simple mechanical
adapter with a power regulator is sufficient, no extra controller
or card reader necessary:

https://www.parkytowers.me.uk/thin/hp/t510/

Depending on the model, the flash may also be SATA instead of IDE
DOM (Disk On Module), which is even easier, but the mechanics can
be problematic given the small housing of the whole computer. Also,
the website says that using SATA SSD may somehow interfere with
and damage the network interface (LAN, Broadcom NIC). There also
is a tiny Mini-PCIe 1x slot, for WiFi extensions etc.

The app itself was first on a 256Mb CompactFlash Card, which
was attached with a USB cardreader to that PC.

Why the extra step with the USB cardreader?

The software booted from that Flashcards with a regular MSDOS6,
no USB drivers etc necessary, seems all is handled by BIOS.

When a BIOS can boot from USB, it will often be able to present
USB storage as harddisk (or sometimes floppy or CD-ROM), yes.
But it will usually not support changing "disks" on the fly.

I then changed those Flashcards to real USBSticks and formatted
them with RUFUS and FreeDOS (Kernel 2043), recompiled their App
and now some "funny" things happen

Using USB adds an extra layer of complexity and a BIOS with USB
boot support at that time may have been very minimalistic, so
for example you may only get USB 1 speed or writes would not
be supported or only in slow and convoluted ways. I remember I
once managed to boot DOS with Windows 3 from an USB stick on
an old PC , but it was no fun to use and not really stable.

Also note that certain brands of USB sticks seem allergic
to power glitches or getting unplugged at the wrong moment,
which can lead to data loss or even bricked USB sticks.
Likely a problem with the extra complexity of the firmware
running on the stick itself which prefers a clean shutdown.

... when they restart the engine, the 12V will get powered off
for a short time, thus the PC just crashes and reboots.

Nobody likes that, not even DOS. And USB sticks like it less
than compact flash cards.

Would it be possible to use a compact flash card connected
directly to the IDE port of the thin client? Or some SATA
device, assuming that LAN damage would not be a problem?

there seems to be some caching involved.

I am not aware of any free open source delayed write cache
for FreeDOS, but I am not sure whether BUFFERS can pool
writes to some small extent?

You already call FDAPM FLUSH when the app ends, but you
probably want to modify your app itself, so it can call
the flush things itself (no need to use FDAPM then) each
time when you close your files after using them.

Would it be an option to improve power supply stability?

If you boot DOS from USB, you are stuck with the BIOS USB
drivers, so you cannot update DOS drivers to solve things.

You should probably avoid USB storage completely, given
that the thin client supports internal IDE or SATA disks.

Even if you need some adapters and even if the - probably
not used in the trucks - LAN or WiFi interface breaks,
internal disks (CF, SSD, DOM etc.) are protected from
the rough street life and are probably more rugged in
terms of unplanned power loss or reboot than USB sticks.

You could for example use USB just to install one of
the computers (I also assume our USB images are meant
more as installers than as live images for everyday
use) and then clone the internal disk of that PC to
create more internal disks for more thin clients :-)

That also gives you full flexibility regarding whether
to use FAT16 or FAT32 and whether to use only a part
of the available disk space etc. With boot images, you
could always get unwanted complexity such as embedded
boot floppy or CD-ROM images, which you will not suffer
from when installing to an internal medium.

That said, you can probably just "dd" one of our USB
images to a stick in Linux, keeping extra space empty.

There must be Windows tools which allow you to just
do a dumb 1:1 transfer of our boot stick image to USB.

Other people on this list will know other boot stick
creator tools for the Windows version you are bound to.

Using DOSBOX as a tool for installation feels like at
least three extra layers of unwanted complexity.

Another recommendation: If you only need XMS and UMB
space is no problem, avoid JEMMEX, JEMM386 etc. and
consider using only one simple HIMEM or XMGR style
driver. Yet another way to reduce complexities.

As you have already found out, when you load DOS USB
drivers (for USB printers) you will compete with the
BIOS USB drivers and lose connection to the USB stick.

One workaround is to tell the DOS driver to only take
over ANOTHER controller than the one where your USB
stick is plugged in. Which ports are connected to
which controllers (I assume you do have more than one,
as you have 6 ports) is something for trial and error.
Also check the documentation of the DOS driver.

But again, I recommend to not use USB sticks at all.

Is there any way to suppress that whole bunch of
startup output, especially that "Press F8 to trace"

You can disable that by using SYS CONFIG to patch
some boot flags in the kernel, as far as I remember.

device = \freedos\jemmEx.exe PGE maxext=4096 noems

Why does the XMS get artificially limited to 4 MB?

Do you use NOEMS to get more UMB space? Note that
it does not actually disable EMS, it just disables
EMS 3.2 compatibility. EMS 4.0 stays available.

What are the pros and cons of PGE or NOPGE for you?

country = 049,850 \freedos\country.sys

The syntax seems a bit off?

files = 100

That seems to be a relatively high number.

buffers = 20

You may want to consider fewer buffers, not sure?

http://home.mnet-online.de/willybilly/fdhelp-dos/de/hhstndrd/cnfigsys/buffers.htm

set FoxProSWX=+x -t

What do those switches mean? Any other switches
that might be interesting to use?

fdapm apmdos

I hope that reduces energy consumption and heat :-)

display con=(ega,437,1)
mode con codepage prepare=((437) %DosDir%\ega.cpx)
mode con codepage select=437
keyb gr,437,%DosDir%\keyboard.sys

If you need more free RAM, you may want to give
MKEYB a try instead of KEYB. I guess you do want
to load those CP437 fonts, though?

Regards, Eric




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