Wax/Trace: per-bay FormTracePak version via bay-config.csv

Bays span 7 FormTracePak versions (5.510 - 6.213) and 3 sub-versions
(AVANT / CV-4500 / CV-3200), each with a unique licensing USER ID. Previously
all bays got v6.213 with no model/USER hint to the tech.

- bay-config.csv: 15 rows mapping asset_tag to ftpak_version + model + user_id.
- resolve-bay-config.ps1: WinPE-runnable resolver. Looks up the asset and
  writes version.txt / model.txt / userid.txt / bay-info.txt under
  W:\Enrollment\waxtrace\.
- startnet.cmd: xcopy WaxTrace bundle minus formtracepak\, invoke the
  resolver with %MACHINENUM%, then cherry-pick only the matching
  FORMTRACEPAK-V<ver>.iso (~2 GB local vs ~12 GB if all were staged).
- 09-Setup-WaxAndTrace.ps1: read the per-bay files, mount the right ISO,
  drop <asset>-FTPak-install-info.txt on SupportUser's desktop, and print
  a banner with MODEL + USER ID so the tech has them top-of-mind when
  Setup.exe dialogs come up.
- sync-waxtrace.sh: loop over all FORMTRACEPAK-V*.iso instead of hard-coding
  v6.213; also push bay-config.csv + resolve-bay-config.ps1 to the share.

playbook/shopfloor-setup/gea-shopfloor-waxtrace/09-Setup-WaxAndTrace.ps1

@@ -91,17 +91,90 @@ if (-not (Test-Path $manifestPath)) {
 }
 
 # ============================================================================
-# Step 2: FormTracePak v6.213 vendor install (Mount-DiskImage + Setup.exe)
+# Step 2: FormTracePak vendor install - per-bay version + sub-version
 # ============================================================================
 # Detection: skip if Formtracepak already present (re-run safe).
 $ftpakExe = 'C:\Program Files (x86)\MitutoyoApp\Formtracepak\Formtracepak.exe'
 if (Test-Path -LiteralPath $ftpakExe) {
     Write-WTLog "Formtracepak.exe already present - skipping vendor install"
 } else {
-    $ftpakIso = Join-Path $stagingRoot 'formtracepak\FORMTRACEPAK-V6.213.iso'
+    # Per-bay config resolved by resolve-bay-config.ps1 at WinPE time + written
-    if (-not (Test-Path -LiteralPath $ftpakIso)) {
+    # to C:\Enrollment\waxtrace\. Drives BOTH which FTPak ISO to mount AND what
-        Write-WTLog "FormTracePak ISO not found at $ftpakIso" 'ERROR'
+    # to relay to the tech in the pre-install banner + desktop reference file.
+    $waxCfgDir   = 'C:\Enrollment\waxtrace'
+    $bayAsset    = $null
+    $bayVersion  = $null
+    $bayModel    = $null
+    $bayUserId   = $null
+    foreach ($pair in @(
+        @{ Var='bayAsset';   File='C:\Enrollment\machine-number.txt' },
+        @{ Var='bayVersion'; File=(Join-Path $waxCfgDir 'version.txt') },
+        @{ Var='bayModel';   File=(Join-Path $waxCfgDir 'model.txt') },
+        @{ Var='bayUserId';  File=(Join-Path $waxCfgDir 'userid.txt') }
+    )) {
+        if (Test-Path -LiteralPath $pair.File) {
+            $val = (Get-Content -LiteralPath $pair.File -First 1 -ErrorAction SilentlyContinue)
+            if ($val) { Set-Variable -Name $pair.Var -Value $val.Trim() }
+        }
+    }
+    Write-WTLog "Bay config: asset=$bayAsset version=$bayVersion model=$bayModel userid=$bayUserId"
+
+    if (-not $bayVersion) {
+        Write-WTLog "No FormTracePak version in $waxCfgDir\version.txt - bay-config did not resolve (asset_tag not in bay-config.csv?). Manual install required." 'ERROR'
     } else {
+        $ftpakIso = Join-Path $stagingRoot ("formtracepak\FORMTRACEPAK-V$bayVersion.iso")
+        if (-not (Test-Path -LiteralPath $ftpakIso)) {
+            Write-WTLog "FormTracePak ISO missing: $ftpakIso" 'ERROR'
+            Write-WTLog "  Bay needs V$bayVersion but no matching ISO at the expected path. Either bay-config.csv has the wrong version, or sync-waxtrace.sh did not push the right ISO. Manual install required." 'ERROR'
+        } else {
+            # Drop a reference text file on the SupportUser Desktop so the tech
+            # always has the model + USER ID in front of them when the Setup.exe
+            # dialogs come up. File persists post-imaging.
+            try {
+                $desktop = 'C:\Users\SupportUser\Desktop'
+                if (-not (Test-Path -LiteralPath $desktop)) { $desktop = 'C:\Users\Public\Desktop' }
+                $deskFile = Join-Path $desktop ("$bayAsset-FTPak-install-info.txt")
+                $deskContent = @(
+                    '========================================',
+                    'FormTracePak install info for this bay',
+                    '========================================',
+                    '',
+                    "Bay:            $bayAsset",
+                    "FormTracePak:   V$bayVersion",
+                    "Sub-version:    $bayModel       <- SELECT THIS IN THE Setup.exe DIALOG",
+                    "USER ID:        $bayUserId       <- ENTER THIS AT THE LICENSING PROMPT",
+                    '',
+                    'Reference file. Open this whenever you need to recall the USER ID',
+                    'during the install dialogs.',
+                    '',
+                    "Generated at imaging time by 09-Setup-WaxAndTrace.ps1 ($(Get-Date -Format 'yyyy-MM-dd HH:mm:ss'))"
+                ) -join "`r`n"
+                Set-Content -LiteralPath $deskFile -Value $deskContent -Force
+                Write-WTLog "Wrote reference file to $deskFile"
+            } catch {
+                Write-WTLog "Failed to write desktop reference file: $_" 'WARN'
+            }
+
+            # Big banner in the PS host window. Operator sees this BEFORE Setup.exe
+            # opens so the model + USER ID are top-of-mind when the dialogs come up.
+            $bannerLines = @(
+                '',
+                '================================================================',
+                "  BAY:           $bayAsset",
+                "  FORMTRACEPAK:  V$bayVersion",
+                "  SELECT MODEL:  $bayModel",
+                "  USER ID:       $bayUserId",
+                '================================================================',
+                '  Setup.exe is about to launch. In its dialogs:',
+                "   - Pick the MODEL '$bayModel' on the language / model page.",
+                "   - Enter USER ID '$bayUserId' at the licensing prompt.",
+                "   - A reference text file with these values has been placed on",
+                "     SupportUser's desktop ($bayAsset-FTPak-install-info.txt).",
+                '================================================================',
+                ''
+            )
+            foreach ($l in $bannerLines) { Write-WTLog $l }
+
             Write-WTLog "Mounting FormTracePak ISO: $ftpakIso"
             try {
                 $img = Mount-DiskImage -ImagePath $ftpakIso -PassThru -ErrorAction Stop
@@ -117,12 +190,6 @@ if (Test-Path -LiteralPath $ftpakExe) {
                         Write-WTLog "  Setup.exe not found at $setupExe" 'ERROR'
                     } else {
                         Write-WTLog "  running $setupExe (VB6 wrapper - requires DRIVE_CDROM)"
-                    # Setup.exe is the VB6 wrapper. /silent + /qn flags often
-                    # ignored - the wrapper drives appSetup.exe + msiexec from
-                    # its own UI. If the wrapper insists on interactive, a tech
-                    # at the bay clicks through. Acceptable today; quieter
-                    # path is a future improvement (drive msiexec direct on
-                    # the wrapper's bundled MSIs).
                         try {
                             $p = Start-Process -FilePath $setupExe `
                                                -WorkingDirectory "${ftpakDrive}:\" `
@@ -141,6 +208,7 @@ if (Test-Path -LiteralPath $ftpakExe) {
             }
         }
     }
+}
 
 # ============================================================================
 # Step 3: Per-machine calibration ISO (mount + apply via cal Setup.exe)

playbook/shopfloor-setup/gea-shopfloor-waxtrace/bay-config.csv

@@ -0,0 +1,16 @@
+asset_tag,ftpak_version,model,user_id
+WJF00159,6.103,AVANT,3974839712
+WJRP3689,5.510,CV-4500,3744284509
+WJRP2660,6.0,CV-4500,2365986521
+WJRP2659,6.0,CV-4500,2709054503
+WJF00545,6.213,AVANT,3878777362
+WJRP3638,5.602,CV-4500,0720778210
+WJF00052,6.103,AVANT,3270314998
+WJF00084,6.103,AVANT,1476212857
+WJF00083,6.103,AVANT,2934506987
+WJRP3025,6.0,CV-3200,2292822471
+WJF00197,6.104,AVANT,1191612605
+WJRP4802,6.002,AVANT,0920866935
+WJRP2347,6.0,CV-4500,3585172946
+WJRP2035,6.0,CV-4500,2292822471
+WJRP2335,6.0,CV-4500,1780916688

playbook/shopfloor-setup/gea-shopfloor-waxtrace/resolve-bay-config.ps1

@@ -0,0 +1,90 @@
+# resolve-bay-config.ps1 - WinPE-runnable bay-config resolver.
+#
+# Reads bay-config.csv (per-asset ftpak_version + model + user_id) and
+# writes the matched row into per-field text files under $OutDir, so the
+# rest of startnet.cmd + the post-imaging 09-Setup-WaxAndTrace.ps1 can
+# read them as single-line files (cheaper than re-parsing CSV in batch).
+#
+# Outputs (under $OutDir, default W:\Enrollment\waxtrace\):
+#   version.txt   - exact FormTracePak version (matches an installer ISO label)
+#   model.txt     - sub-version (AVANT / CV-4500 / CV-3200)
+#   userid.txt    - per-bay license USER ID
+#   bay-info.txt  - human-readable audit dump (timestamped)
+#
+# Exit codes:
+#   0 - row found + files written
+#   1 - asset_tag not in bay-config.csv (Wax/Trace install will abort cleanly)
+#   2 - bay-config.csv missing or unparseable
+
+[CmdletBinding()]
+param(
+    [Parameter(Mandatory=$true)][string]$Asset,
+    [string]$ConfigCsv = '',
+    [string]$OutDir    = 'W:\Enrollment\waxtrace'
+)
+
+# Default ConfigCsv: bay-config.csv next to this script on the share OR
+# under the script's own directory in the local C:\WaxTrace-Install\ tree
+# (depending on where the caller invokes us from).
+if (-not $ConfigCsv) {
+    $cands = @(
+        (Join-Path $PSScriptRoot 'bay-config.csv'),
+        (Join-Path $PSScriptRoot '..\bay-config.csv'),
+        'Y:\installers-post\waxtrace\bay-config.csv',
+        'C:\WaxTrace-Install\bay-config.csv'
+    )
+    foreach ($c in $cands) {
+        if (Test-Path -LiteralPath $c) { $ConfigCsv = $c; break }
+    }
+}
+
+if (-not (Test-Path -LiteralPath $ConfigCsv)) {
+    Write-Warning "bay-config.csv not found (looked under $PSScriptRoot, ..\, Y:\installers-post\waxtrace\, C:\WaxTrace-Install\)"
+    exit 2
+}
+
+Write-Host "resolve-bay-config.ps1: looking up '$Asset' in $ConfigCsv"
+
+try {
+    $rows = @(Import-Csv -LiteralPath $ConfigCsv)
+} catch {
+    Write-Warning "Failed to parse ${ConfigCsv}: $_"
+    exit 2
+}
+
+$row = $rows | Where-Object { $_.asset_tag -ieq $Asset } | Select-Object -First 1
+if (-not $row) {
+    Write-Warning "Asset '$Asset' not in $ConfigCsv. Available asset_tags: $(($rows.asset_tag | Sort-Object) -join ', ')"
+    exit 1
+}
+
+if (-not (Test-Path -LiteralPath $OutDir)) {
+    New-Item -ItemType Directory -Path $OutDir -Force | Out-Null
+}
+
+function Write-Line {
+    param([string]$Name, [string]$Value)
+    $p = Join-Path $OutDir $Name
+    Set-Content -LiteralPath $p -Value $Value -NoNewline -Force
+    Write-Host "  wrote $p = '$Value'"
+}
+
+Write-Line 'version.txt' $row.ftpak_version
+Write-Line 'model.txt'   $row.model
+Write-Line 'userid.txt'  $row.user_id
+
+$infoLines = @(
+    "Bay-config resolved at $(Get-Date -Format 'yyyy-MM-dd HH:mm:ss')",
+    "  Asset:           $($row.asset_tag)",
+    "  FormTracePak:    V$($row.ftpak_version)",
+    "  Sub-version:     $($row.model)",
+    "  USER ID:         $($row.user_id)",
+    "",
+    "Source: $ConfigCsv"
+)
+$infoPath = Join-Path $OutDir 'bay-info.txt'
+Set-Content -LiteralPath $infoPath -Value ($infoLines -join "`r`n") -Force
+Write-Host "  wrote $infoPath"
+
+Write-Host "resolve-bay-config.ps1: OK"
+exit 0

playbook/startnet.cmd

@@ -482,18 +482,48 @@ if exist "Y:\installers-post\keyence\%KEYENCEMODEL%\manifest.json" (
 :skip_keyence_stage
 
 REM --- Stage WaxTrace bootstrap bundle (wax/trace gea-shopfloor-waxtrace only) ---
-REM Copies the FormTracePak master capture (~110 MB compressed) + HASP +
+REM Three-step process:
-REM VC++ redists + per-machine cal ISOs from the enrollment share onto the
+REM   1. xcopy installers-post\waxtrace -> W:\WaxTrace-Install  (everything
-REM target disk so 09-Setup-WaxAndTrace.ps1 can install FormTracePak via
+REM      EXCEPT the formtracepak\ subdir which carries all 7 version ISOs)
-REM xcopy + reg-import (bypassing Mitutoyo's CD-ROM-bound VB6 wrapper).
+REM   2. resolve-bay-config.ps1: reads bay-config.csv + asset_tag, writes
+REM      W:\Enrollment\waxtrace\{version,model,userid}.txt for 09-Setup to read
+REM   3. xcopy ONLY the bay's matching FORMTRACEPAK-V<ver>.iso from
+REM      Y:\installers-post\waxtrace\formtracepak\ onto the target disk
+REM      (so 09-Setup-WaxAndTrace.ps1 mounts the right version per bay)
 if /i not "%PCTYPE%"=="gea-shopfloor-waxtrace" goto skip_waxtrace_stage
-if exist "Y:\installers-post\waxtrace\waxtrace-manifest.json" (
+if not exist "Y:\installers-post\waxtrace\waxtrace-manifest.json" goto skip_waxtrace_missing
 mkdir W:\WaxTrace-Install 2>NUL
-    xcopy /E /Y /I "Y:\installers-post\waxtrace" "W:\WaxTrace-Install\"
+REM xcopy everything except the formtracepak\ dir (we cherry-pick one ISO below).
-    echo Staged WaxTrace bootstrap to W:\WaxTrace-Install.
+xcopy /E /Y /I /EXCLUDE:NUL "Y:\installers-post\waxtrace" "W:\WaxTrace-Install\" >NUL 2>NUL
+REM (Exclude file via /EXCLUDE expects a file; simpler to xcopy the whole tree
+REM then delete the formtracepak\ subdir + re-create with just the matched ISO.)
+if exist "W:\WaxTrace-Install\formtracepak" rmdir /S /Q "W:\WaxTrace-Install\formtracepak"
+mkdir W:\WaxTrace-Install\formtracepak 2>NUL
+echo Staged WaxTrace bootstrap minus formtracepak\ to W:\WaxTrace-Install.
+REM Resolve bay-config: writes W:\Enrollment\waxtrace\{version,model,userid}.txt
+mkdir W:\Enrollment\waxtrace 2>NUL
+if not "%MACHINENUM%"=="" (
+    powershell.exe -NoProfile -ExecutionPolicy Bypass -File "Y:\installers-post\waxtrace\resolve-bay-config.ps1" -Asset "%MACHINENUM%" -OutDir "W:\Enrollment\waxtrace"
 ) else (
-    echo WARNING: Y:\installers-post\waxtrace not found - WaxTrace PC cannot install FormTracePak at imaging time.
+    echo WARNING: no MACHINENUM set - skipping bay-config resolve. 09-Setup-WaxAndTrace will abort cleanly with no version.
 )
+REM Read the resolved version + xcopy ONLY that FTPak ISO (avoids dumping 12 GB
+REM of ISOs on the bay disk; only the matched ~2 GB ISO lands locally).
+set WTVER=
+if exist W:\Enrollment\waxtrace\version.txt set /p WTVER=<W:\Enrollment\waxtrace\version.txt
+if not "%WTVER%"=="" (
+    if exist "Y:\installers-post\waxtrace\formtracepak\FORMTRACEPAK-V%WTVER%.iso" (
+        xcopy /Y "Y:\installers-post\waxtrace\formtracepak\FORMTRACEPAK-V%WTVER%.iso" "W:\WaxTrace-Install\formtracepak\"
+        echo Staged FormTracePak V%WTVER%.iso for %MACHINENUM%.
+    ) else (
+        echo WARNING: No FORMTRACEPAK-V%WTVER%.iso on share for %MACHINENUM% - 09-Setup-WaxAndTrace will abort cleanly with the version-mismatch error.
+    )
+) else (
+    echo WARNING: bay-config did not resolve a FTPak version for %MACHINENUM%.
+)
+goto skip_waxtrace_stage
+:skip_waxtrace_missing
+echo WARNING: Y:\installers-post\waxtrace not found - WaxTrace PC cannot install FormTracePak at imaging time.
 :skip_waxtrace_stage
 :pctype_done
 

playbook/sync-waxtrace.sh

@@ -64,17 +64,33 @@ cp "$WAXTRACE_DIR/09-Setup-WaxAndTrace.ps1" "$STAGE/"
 if [ -f "$WAXTRACE_DIR/select-waxtrace-asset.ps1" ]; then
     cp "$WAXTRACE_DIR/select-waxtrace-asset.ps1" "$STAGE/"
 fi
+# Bay-config CSV + resolver. startnet.cmd invokes resolve-bay-config.ps1 in
+# WinPE to pick the right FTPak version per bay. resolver reads bay-config.csv
+# from this share (or W:\WaxTrace-Install\) and writes
+# W:\Enrollment\waxtrace\{version,model,userid}.txt.
+if [ -f "$WAXTRACE_DIR/bay-config.csv" ]; then
+    cp "$WAXTRACE_DIR/bay-config.csv" "$STAGE/"
+fi
+if [ -f "$WAXTRACE_DIR/resolve-bay-config.ps1" ]; then
+    cp "$WAXTRACE_DIR/resolve-bay-config.ps1" "$STAGE/"
+fi
 cp "$WAXTRACE_DIR/captured-binary/prereqs/"*.exe "$STAGE/prereqs/"
 
-# FormTracePak v6.213 vendor installer ISO (2 GB). Pulled from
+# FormTracePak vendor installer ISOs - all available versions get pushed.
-# /home/camp/pxe-images/iso/. Bay xcopies + Mount-DiskImage's at imaging
+# startnet.cmd cherry-picks the matching FORMTRACEPAK-V<ver>.iso based on
-# time. Replaces the legacy captured/ replay path; the old captured-binary/
+# bay-config.csv lookup, xcopies just that one to the local disk (~2 GB).
-# dir remains in the repo as a manual fallback but is no longer pushed.
+# Total on PXE share: ~12 GB; per-bay xcopy: ~2 GB.
-FTPAK_ISO="${FTPAK_ISO:-/home/camp/pxe-images/iso/FORMTRACEPAK-V6.213.iso}"
+FTPAK_ISO_DIR="${FTPAK_ISO_DIR:-/home/camp/pxe-images/iso}"
-if [ -f "$FTPAK_ISO" ]; then
+FTPAK_COUNT=0
-    cp "$FTPAK_ISO" "$STAGE/formtracepak/"
+for iso in "$FTPAK_ISO_DIR"/FORMTRACEPAK-V*.iso; do
+    [ -f "$iso" ] || continue
+    cp "$iso" "$STAGE/formtracepak/"
+    FTPAK_COUNT=$((FTPAK_COUNT+1))
+done
+if [ "$FTPAK_COUNT" -eq 0 ]; then
+    echo "WARNING: no FORMTRACEPAK-V*.iso in $FTPAK_ISO_DIR - bays cannot install at imaging time."
 else
-    echo "WARNING: FormTracePak ISO not found at $FTPAK_ISO - bays cannot install at imaging time."
+    echo "Staged $FTPAK_COUNT FormTracePak version ISO(s) from $FTPAK_ISO_DIR"
 fi
 
 # Cal ISOs - one per wax/trace bay