Backup-FormtracepakSettings: timeout-fence reg.exe + recursive walk
WJF00052 / WJF00083 / WJF00084 / WJF00159 produced 0-byte ZIPs on the
2026-05-24 capture pass. Export-FormtracepakInventory was the primary
culprit (Get-Service hang, fixed in d359563), but Backup has the same
root failure mode for the same bays: reg.exe export via Start-Process
-Wait and the recursive Get-ChildItem walk over HKLM:\SOFTWARE\
WOW6432Node\Mitutoyo (95k+ values) both lack timeouts, so a degraded
SCM / antivirus interception / WMI repository on the bay can wedge the
script and the operator kills the .bat - same outcome as the inventory
hang.
Two timeout fences:
- reg.exe export: switch from Start-Process -PassThru -Wait to
[System.Diagnostics.Process]::Start + WaitForExit(300_000). If the
process hasn't exited after 5 minutes, Kill() it and log + count an
error; the .reg file for that one root is skipped but other roots
+ the CSV fallback + the file/data captures continue. Bonus: the
ProcessStartInfo path also gives reliable $proc.ExitCode access; the
Start-Process -PassThru object sometimes returned a stub with
unpopulated ExitCode, producing a false "reg.exe exit for ..."
warning even on successful exports.
- Recursive Get-ChildItem CSV walk: move into a Start-Job + Wait-Job
-Timeout 600 (10 min). If the walk hangs, Stop-Job, log, increment
error count, .reg file remains authoritative for that root.
Also fixed a subtle Start-Job return-shape bug introduced in the same
edit: emitting the rows via the pipeline inside the job + Receive-Job
flattens correctly, whereas `return ,$list` wrapped the whole List in a
single-element array, so the outer foreach was treating the list-of-95k
as a single row. Net effect was Registry Values: 4 instead of 95152 in
the manifest. Verified fixed via a full real-install run on the VM:
95152 values captured cleanly in 22 s, 0 errors.
Net behaviour: the failed-bay re-runs (WJF00052/00083/00084/00159)
should now either produce real ZIPs or print a clear warning naming the
specific reg root that hung, instead of leaving an empty ZIP behind.
This commit is contained in:
cproudlock
@@ -333,12 +333,33 @@ foreach ($root in $RegistryRoots) {
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$nativeRoot = $root -replace '^HKLM:\\', 'HKEY_LOCAL_MACHINE\' `
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-replace '^HKCU:\\', 'HKEY_CURRENT_USER\' `
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-replace '^Registry::', ''
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# reg.exe export wrapped in a 5-minute kill fence. On shopfloor PCs with
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# a degraded SCM / antivirus interception / WMI repository corruption,
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# reg.exe has been observed to wedge indefinitely; without this fence the
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# whole Backup script hangs and the operator kills the .bat, leaving a
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# 0-byte ZIP (root cause of the WJF00052 / 00083 / 00084 / 00159 backup
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# failures on 2026-05-24).
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try {
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$proc = Start-Process -FilePath 'reg.exe' `
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-ArgumentList "export `"$nativeRoot`" `"$regFilePath`" /y" `
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-Wait -PassThru -NoNewWindow -ErrorAction SilentlyContinue
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if ($proc.ExitCode -eq 0) {
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# System.Diagnostics.Process gives reliable ExitCode access; Start-Process
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# -PassThru + WaitForExit(int) sometimes returns a stub object whose
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# ExitCode is unset, causing a false "reg.exe exit for ..." warning.
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$psi = New-Object System.Diagnostics.ProcessStartInfo
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$psi.FileName = 'reg.exe'
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$psi.Arguments = "export `"$nativeRoot`" `"$regFilePath`" /y"
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$psi.UseShellExecute = $false
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$psi.CreateNoWindow = $true
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$psi.RedirectStandardOutput = $true
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$psi.RedirectStandardError = $true
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$proc = [System.Diagnostics.Process]::Start($psi)
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if (-not $proc.WaitForExit(300000)) {
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try { $proc.Kill() } catch { }
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Write-Warning " reg.exe export wedged >5min for ${root} - killed, skipping"
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$counters.Errors++
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} elseif ($proc.ExitCode -eq 0) {
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Write-Host " Exported: $regFilePath" -ForegroundColor Green
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} else {
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$stderr = $proc.StandardError.ReadToEnd()
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Write-Warning " reg.exe exit=$($proc.ExitCode) for ${root}: $stderr"
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}
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} catch {
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Write-Warning " reg.exe export failed for ${root}: $_"
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@@ -352,33 +373,48 @@ foreach ($root in $RegistryRoots) {
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# which then corrupts the registry if the CSV restore overwrites the
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# .reg-import result. Skip those types in the CSV (the .reg file is
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# authoritative for them).
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#
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# Recursive Get-ChildItem on a 95k-value HKLM tree takes ~25s on healthy
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# bays but has been seen to wedge on degraded ones. Run it in a job with
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# a 10-minute timeout so a single bad root cannot kill the whole backup.
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$csvSafeTypes = @('String', 'ExpandString', 'DWord', 'QWord')
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$walkJob = Start-Job -ArgumentList $root -ScriptBlock {
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param($rootArg)
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$safeTypes = @('String', 'ExpandString', 'DWord', 'QWord')
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try {
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$allKeys = @(Get-Item -Path $root -ErrorAction SilentlyContinue)
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$allKeys += Get-ChildItem -Path $root -Recurse -ErrorAction SilentlyContinue
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$allKeys = @(Get-Item -Path $rootArg -ErrorAction SilentlyContinue)
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$allKeys += Get-ChildItem -Path $rootArg -Recurse -ErrorAction SilentlyContinue
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foreach ($key in $allKeys) {
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foreach ($valName in $key.GetValueNames()) {
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$kind = $key.GetValueKind($valName)
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if ($csvSafeTypes -notcontains [string]$kind) {
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# Skip Binary / MultiString / None / Unknown. The .reg
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# export already captured them losslessly.
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continue
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}
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if ($safeTypes -notcontains [string]$kind) { continue }
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$val = $key.GetValue($valName)
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$regCsvRows.Add([PSCustomObject]@{
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# Emit each row to the pipeline so Receive-Job returns
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# a flat array of PSObjects (not a List inside an array).
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[PSCustomObject]@{
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Path = $key.PSPath
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Name = $valName
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Value = [string]$val
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Type = [string]$kind
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})
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$counters.RegKeys++
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}
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}
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} catch {
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Write-Warning " Registry read error at ${root}: $_"
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}
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} catch { }
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}
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$walked = @()
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if (Wait-Job -Job $walkJob -Timeout 600) {
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$walked = @(Receive-Job -Job $walkJob -ErrorAction SilentlyContinue)
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} else {
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Write-Warning " Registry walk wedged >10min for ${root} - aborting (.reg file is still authoritative)"
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Stop-Job -Job $walkJob -ErrorAction SilentlyContinue
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$counters.Errors++
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}
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Remove-Job -Job $walkJob -Force -ErrorAction SilentlyContinue
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foreach ($row in $walked) {
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$regCsvRows.Add($row)
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$counters.RegKeys++
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}
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}
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if ($regCsvRows.Count -gt 0) {
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