# 09-Setup-WaxAndTrace.ps1 - Wax and Trace pc-type setup (Mitutoyo FormTracePak v6.213) # # Imaging-time install. Installs prereqs from manifest, then runs the # Mitutoyo FormTracePak v6.213 vendor installer from a mounted ISO. The # VB6 Setup.exe wrapper checks GetDriveType() == DRIVE_CDROM; Mount-DiskImage # satisfies that (a real CD drive isn't required). Per-asset calibration ISO # applies last. # # Layout at C:\WaxTrace-Install\ (xcopied by startnet.cmd): # waxtrace-manifest.json # 09-Setup-WaxAndTrace.ps1 (this file) # prereqs\vcredist_x86.exe (VC++ 2008 x86) # prereqs\vcredist_x64.exe (VC++ 2008 x64) # prereqs\vc_redist.x86.exe (VC++ 2017 x86) # prereqs\vc_redist.x64.exe (VC++ 2017 x64) # prereqs\HASPUserSetup.exe (Sentinel Runtime / HASP dongle driver) # formtracepak\FORMTRACEPAK-V6.213.iso (vendor installer ISO, ~2 GB) # calibrations\CAL-_serial-_probe-.iso (per-machine) # # Per-machine calibration is applied separately (mount cal ISO + run its # Setup.exe), keyed by C:\Enrollment\machine-number.txt. # # Legacy captured/ replay path (V6.0 zip + reg) retired 2026-05-21. The # captured-binary/ payload is still in the repo as a fallback - if the # v6.213 vendor install fails on a bay, fall back to the captured path # manually. See git history for the prior shape. # # Log: C:\Logs\WaxTrace\09-Setup-WaxAndTrace.log # C:\Logs\WaxTrace\install.log (written by Install-FromManifest) $ErrorActionPreference = 'Continue' # Mirror the CMM pattern (09-Setup-CMM.ps1): the script itself lives in the # shopfloor-setup tree (xcopied during WinPE), but the bulky bootstrap bundle # (prereqs + captured master + cal ISOs) lives at C:\WaxTrace-Install\, put # there by startnet.cmd from Y:\installers-post\waxtrace\ at imaging time. $stagingRoot = 'C:\WaxTrace-Install' $manifestPath = Join-Path $stagingRoot 'waxtrace-manifest.json' $libSource = Join-Path $PSScriptRoot '..\common\lib\Install-FromManifest.ps1' $logDir = 'C:\Logs\WaxTrace' $installLog = Join-Path $logDir 'install.log' $transcriptLog = Join-Path $logDir '09-Setup-WaxAndTrace.log' if (-not (Test-Path $logDir)) { New-Item -Path $logDir -ItemType Directory -Force | Out-Null } try { Start-Transcript -Path $transcriptLog -Append -Force | Out-Null } catch {} function Write-WTLog { param([string]$Message, [string]$Level = 'INFO') $stamp = Get-Date -Format "yyyy-MM-dd HH:mm:ss" Write-Host "[$stamp] [$Level] $Message" } Write-WTLog "================================================================" Write-WTLog "=== WaxTrace Setup (imaging-time) session start (PID $PID) ===" Write-WTLog "Running as: $([System.Security.Principal.WindowsIdentity]::GetCurrent().Name)" Write-WTLog "Script root: $PSScriptRoot" Write-WTLog "================================================================" # Status push - best-effort. $pxeStatusLib = Join-Path $PSScriptRoot '..\Shopfloor\lib\Send-PxeStatus.ps1' if (Test-Path $pxeStatusLib) { try { . $pxeStatusLib; Send-PxeStatus -Stage '09-Setup-WaxAndTrace: starting' -StageIndex 3 -StageTotal 8 } catch { } } foreach ($file in @('pc-type.txt','machine-number.txt')) { $path = "C:\Enrollment\$file" if (Test-Path -LiteralPath $path) { $content = (Get-Content -LiteralPath $path -First 1 -ErrorAction SilentlyContinue).Trim() Write-WTLog " $file = $content" } else { Write-WTLog " $file = (not present)" } } # ============================================================================ # Step 1: Prereqs via manifest (VC++ 2008 + 2017, HASP/Sentinel) # ============================================================================ if (-not (Test-Path $manifestPath)) { Write-WTLog "waxtrace-manifest.json not found at $manifestPath" 'ERROR' } elseif (-not (Test-Path $libSource)) { Write-WTLog "Install-FromManifest.ps1 not found at $libSource" 'ERROR' } else { Write-WTLog "Running Install-FromManifest (InstallerRoot=$PSScriptRoot)" & $libSource -ManifestPath $manifestPath -InstallerRoot $stagingRoot -LogFile $installLog $rc = $LASTEXITCODE Write-WTLog "Install-FromManifest returned $rc" } # ============================================================================ # 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 { # Per-bay config resolved by resolve-bay-config.ps1 at WinPE time + written # to C:\Enrollment\waxtrace\. Drives BOTH which FTPak ISO to mount AND what # 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 Start-Sleep -Seconds 8 $vol = Get-DiskImage -ImagePath $ftpakIso | Get-Volume $ftpakDrive = $vol.DriveLetter if (-not $ftpakDrive) { Write-WTLog " Mount succeeded but no drive letter assigned" 'ERROR' } else { Write-WTLog " mounted at ${ftpakDrive}: (volume label=$($vol.FileSystemLabel))" $setupExe = "${ftpakDrive}:\Setup.exe" if (-not [System.IO.File]::Exists($setupExe)) { Write-WTLog " Setup.exe not found at $setupExe" 'ERROR' } else { Write-WTLog " running $setupExe (VB6 wrapper - requires DRIVE_CDROM)" try { $p = Start-Process -FilePath $setupExe ` -WorkingDirectory "${ftpakDrive}:\" ` -ArgumentList '/silent' ` -Wait -PassThru Write-WTLog " Setup.exe exit $($p.ExitCode)" } catch { Write-WTLog " Setup.exe failed: $_" 'ERROR' } } } Dismount-DiskImage -ImagePath $ftpakIso -ErrorAction SilentlyContinue | Out-Null Write-WTLog " FormTracePak ISO dismounted" } catch { Write-WTLog " Mount-DiskImage failed: $_" 'ERROR' } } } } # ============================================================================ # Step 3: Per-machine calibration ISO (mount + apply via cal Setup.exe) # ============================================================================ # Cal ISOs are keyed by asset_tag. Read machine-number.txt to pick the right # ISO. Each cal ISO is ~1.7MB and contains a tiny Mitutoyo wrapper Setup.exe # plus data/*.txt compensation tables for the bay's specific probe + serial. $mnPath = 'C:\Enrollment\machine-number.txt' $asset = $null if (Test-Path -LiteralPath $mnPath) { $asset = (Get-Content -LiteralPath $mnPath -First 1 -ErrorAction SilentlyContinue).Trim() } if (-not $asset) { Write-WTLog "machine-number.txt missing or empty - skipping calibration apply" 'WARN' } else { $calDir = Join-Path $stagingRoot 'calibrations' $candidate = Get-ChildItem $calDir -Filter "CAL-${asset}_*.iso" -ErrorAction SilentlyContinue | Select-Object -First 1 if (-not $candidate) { Write-WTLog "No cal ISO matched CAL-${asset}_*.iso in $calDir - skipping" 'WARN' } else { Write-WTLog "Mounting cal ISO: $($candidate.FullName)" try { $img = Mount-DiskImage -ImagePath $candidate.FullName -PassThru -ErrorAction Stop Start-Sleep -Seconds 5 $calDrive = (Get-DiskImage -ImagePath $candidate.FullName | Get-Volume).DriveLetter $calRoot = "${calDrive}:\" Write-WTLog " mounted at $calRoot" # Disc layout differs by probe series. We have observed two: # # Older 218-458A: E:\App.ini, E:\Setup.exe, E:\data\CVIFDLL.ini, # E:\data\Cvif_Correction.exe, E:\data\.txt. # Vendor Setup.exe works (VB6, may prompt). # # Newer 218-378-13: E:\setup.bat, E:\setup.exe (.NET 4.0), # E:\iniStatus\, E:\data\cvifdll.ini, # E:\data\.txt - BUT the filenames have a # bug: probe ID ends with a TRAILING SPACE # ("218-378-13 _100072210.txt"). The vendor's # .NET Setup.exe calls FileSystemInfo.set_Attributes # on the source path and throws System.ArgumentException # because the path contains an embedded space # component, crashing every time # (exit -532462766 = 0xE0434352, .NET unhandled # exception). See diag-cal.log, WER Event 1026. # # We bypass the vendor wrapper entirely when the disc carries # the buggy filenames and do a direct file copy into FormTracePak's # data dir, renaming each file to strip the trailing space. $srcDataDir = Join-Path $calRoot 'data' $dstDataDir = 'C:\Program Files (x86)\MitutoyoApp\Formtracepak\data' $hasBrokenFilenames = $false if (Test-Path -LiteralPath $srcDataDir) { # Get-ChildItem -Filter uses Win32 filtering and does NOT # honor PowerShell wildcards / character classes - '[0-9]' # would match literal bracketed text. Use -Include + # Where-Object regex instead. The bug signature is # ' _' (space-underscore) inside the filename, e.g. # 'Linear_X_218-378-13 _100072210.txt'. $hasBrokenFilenames = [bool](Get-ChildItem -LiteralPath $srcDataDir -File -ErrorAction SilentlyContinue | Where-Object { $_.Name -match ' _\d+\.txt$' } | Select-Object -First 1) } if ($hasBrokenFilenames) { Write-WTLog " disc has trailing-space probe-ID filenames (218-378-13 series) - bypassing buggy vendor Setup.exe, doing direct copy" if (-not (Test-Path -LiteralPath $dstDataDir)) { Write-WTLog " destination data dir does not exist: $dstDataDir" 'ERROR' Write-WTLog " (FormTracePak install may not be complete; cal apply aborted)" 'ERROR' } else { $copied = 0 Get-ChildItem -LiteralPath $srcDataDir -File -ErrorAction SilentlyContinue | ForEach-Object { # Strip ' _' (space-underscore) -> '_' inside the filename to # heal the Mitutoyo burn-time typo. cvifdll.ini etc unaffected. $cleanName = $_.Name -replace ' _', '_' $dst = Join-Path $dstDataDir $cleanName try { Copy-Item -LiteralPath $_.FullName -Destination $dst -Force -ErrorAction Stop # Clear read-only on the destination so future overwrites work. try { (Get-Item -LiteralPath $dst).Attributes = 'Normal' } catch {} Write-WTLog " copied $($_.Name) -> $cleanName" $copied++ } catch { Write-WTLog " copy failed for $($_.Name): $_" 'ERROR' } } Write-WTLog " direct copy complete: $copied file(s) into $dstDataDir" } } else { # Older-style disc (clean filenames). Vendor Setup.exe is reliable. $calSetup = "${calDrive}:\Setup.exe" if (Test-Path -LiteralPath $calSetup) { Write-WTLog " running cal Setup.exe (may prompt - VB6 wrapper, same vintage as main installer)" $p = Start-Process -FilePath $calSetup -WorkingDirectory $calRoot -Wait -PassThru Write-WTLog " cal Setup.exe exit $($p.ExitCode)" } else { Write-WTLog " cal Setup.exe not found at $calSetup" 'WARN' } } Dismount-DiskImage -ImagePath $candidate.FullName -ErrorAction SilentlyContinue | Out-Null Write-WTLog " cal ISO dismounted" } catch { Write-WTLog " Mount-DiskImage failed: $_" 'ERROR' } } } # ============================================================================ # Step 3b: Restore captured layouts / prefs / data from per-asset backup ZIP # ============================================================================ # startnet.cmd stages C:\WaxTrace-Install\backup\.zip iff the PXE # share has a backup ZIP for this asset. The ZIP is the output of # Backup-FormtracepakSettings.ps1 captured on the LIVE bay BEFORE re-imaging. # Restore is data + config only - skip -RestoreRegistry until the HKEY_USERS # SID rewriting is built (captured .reg carries source bay's user SID which # does not exist on the freshly imaged bay). HKLM controller config / model # device-map / etc. came from the vendor MSI install in Step 2 already. $backupZip = $null # startnet.cmd robocopy's the whole installers-post\waxtrace\backups\ dir # to C:\WaxTrace-Install\backups\ (plural). Try plural first, then singular # for backward-compat with any older boot.wim that used the cherry-pick path. $backupDirCandidates = @( 'C:\WaxTrace-Install\backups', 'C:\WaxTrace-Install\backup' ) foreach ($bd in $backupDirCandidates) { if (-not (Test-Path -LiteralPath $bd) -or -not $bayAsset) { continue } $candidate = Join-Path $bd ("$bayAsset.zip") if (Test-Path -LiteralPath $candidate) { $backupZip = $candidate break } $newest = Get-ChildItem -LiteralPath $bd -Filter "${bayAsset}*.zip" -File -ErrorAction SilentlyContinue | Sort-Object LastWriteTime -Descending | Select-Object -First 1 if ($newest) { $backupZip = $newest.FullName break } } if ($backupZip) { $installPs1 = Join-Path $stagingRoot 'Install-FormtracepakSettings.ps1' if (Test-Path -LiteralPath $installPs1) { Write-WTLog "Restoring per-asset backup from $backupZip (HKLM + files; HKEY_USERS deferred to first ShopFloor logon)" try { # In-line restore: HKLM (controller config, device-map) + files # (layouts, prefs in install dir). HKEY_USERS per-user prefs would # need ShopFloor's hive loaded, which it isn't at imaging time - # deferred to a scheduled SYSTEM task that fires on first ShopFloor # logon (see Schedule-WaxTracePerUserRestore call below). & $installPs1 -BackupPath $backupZip -RestoreRegistry -RestoreData -RestoreConfig -Force Write-WTLog " Restore call returned (see restore log + Install-FormtracepakSettings output above)" } catch { Write-WTLog " Restore call threw: $_" 'WARN' } # Schedule the per-user prefs restore as a SYSTEM task that fires on # first ShopFloor logon. The task self-removes after one successful # run via flag file at C:\WaxTrace-Install\per-user-restore-ShopFloor.flag. $schedScript = Join-Path $stagingRoot 'Schedule-WaxTracePerUserRestore.ps1' if (-not (Test-Path -LiteralPath $schedScript)) { # Fall back: pull from shopfloor-setup scripts/ sibling tree $alt = Join-Path $PSScriptRoot 'scripts\Schedule-WaxTracePerUserRestore.ps1' if (Test-Path -LiteralPath $alt) { $schedScript = $alt } } if (Test-Path -LiteralPath $schedScript) { Write-WTLog "Registering deferred ShopFloor per-user restore task ($schedScript)" try { & $schedScript -BackupPath $backupZip -InstallScript $installPs1 -TargetUser 'ShopFloor' -AssetNumber $bayAsset Write-WTLog " Scheduled task 'WaxTrace-PerUser-Restore' registered" } catch { Write-WTLog " Schedule task call threw: $_" 'WARN' } } else { Write-WTLog "Schedule-WaxTracePerUserRestore.ps1 not found - per-user prefs will NOT auto-restore at first ShopFloor logon" 'WARN' } } else { Write-WTLog "Install-FormtracepakSettings.ps1 not found at $installPs1 - skipping restore" 'WARN' } } else { Write-WTLog "No per-asset backup ZIP at $backupDir\$bayAsset.zip - skipping restore (clean vendor install only)" } # ============================================================================ # Step 4: OpenText auto-start at login (HostExplorer "WJ Shopfloor" session) # ============================================================================ $autoStartLib = Join-Path $PSScriptRoot '..\Shopfloor\lib\Set-OpenTextAutoStart.ps1' if (Test-Path -LiteralPath $autoStartLib) { Write-WTLog "Calling $autoStartLib" & $autoStartLib } else { Write-WTLog "Set-OpenTextAutoStart.ps1 not found at $autoStartLib - OpenText auto-start NOT configured" 'WARN' } if (Get-Command Send-PxeStatus -ErrorAction SilentlyContinue) { $finalStatus = if ($rc -eq 0) { 'in_progress' } else { 'failed' } $finalErr = if ($rc -ne 0) { "Install-FromManifest exit $rc" } else { '' } Send-PxeStatus -Stage '09-Setup-WaxAndTrace: complete' -StageIndex 4 -StageTotal 8 -Status $finalStatus -Error_ $finalErr } Write-WTLog "================================================================" Write-WTLog "=== WaxTrace Setup session end ===" Write-WTLog "================================================================" try { Stop-Transcript | Out-Null } catch {}