1860a92afa
The .NET cal Setup.exe crashes (0xE0434352) on 218-378-13 series ISOs even when filenames are clean (no trailing-space bug). Previously only bypassed when the ' _' trailing-space signature was detected. Now detects by probe series ID in the data filenames too and always does direct file copy for 218-378-13. Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
418 lines
22 KiB
PowerShell
418 lines
22 KiB
PowerShell
# 09-Setup-WaxAndTrace.ps1 - Wax and Trace pc-type setup (Mitutoyo FormTracePak v6.213)
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#
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# Imaging-time install. Installs prereqs from manifest, then runs the
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# Mitutoyo FormTracePak v6.213 vendor installer from a mounted ISO. The
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# VB6 Setup.exe wrapper checks GetDriveType() == DRIVE_CDROM; Mount-DiskImage
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# satisfies that (a real CD drive isn't required). Per-asset calibration ISO
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# applies last.
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#
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# Layout at C:\WaxTrace-Install\ (xcopied by startnet.cmd):
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# waxtrace-manifest.json
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# 09-Setup-WaxAndTrace.ps1 (this file)
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# prereqs\vcredist_x86.exe (VC++ 2008 x86)
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# prereqs\vcredist_x64.exe (VC++ 2008 x64)
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# prereqs\vc_redist.x86.exe (VC++ 2017 x86)
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# prereqs\vc_redist.x64.exe (VC++ 2017 x64)
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# prereqs\HASPUserSetup.exe (Sentinel Runtime / HASP dongle driver)
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# formtracepak\FORMTRACEPAK-V6.213.iso (vendor installer ISO, ~2 GB)
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# calibrations\CAL-<asset>_serial-<sn>_probe-<probe>.iso (per-machine)
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#
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# Per-machine calibration is applied separately (mount cal ISO + run its
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# Setup.exe), keyed by C:\Enrollment\machine-number.txt.
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#
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# Legacy captured/ replay path (V6.0 zip + reg) retired 2026-05-21. The
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# captured-binary/ payload is still in the repo as a fallback - if the
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# v6.213 vendor install fails on a bay, fall back to the captured path
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# manually. See git history for the prior shape.
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#
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# Log: C:\Logs\WaxTrace\09-Setup-WaxAndTrace.log
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# C:\Logs\WaxTrace\install.log (written by Install-FromManifest)
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$ErrorActionPreference = 'Continue'
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# Mirror the CMM pattern (09-Setup-CMM.ps1): the script itself lives in the
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# shopfloor-setup tree (xcopied during WinPE), but the bulky bootstrap bundle
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# (prereqs + captured master + cal ISOs) lives at C:\WaxTrace-Install\, put
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# there by startnet.cmd from Y:\installers-post\waxtrace\ at imaging time.
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$stagingRoot = 'C:\WaxTrace-Install'
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$manifestPath = Join-Path $stagingRoot 'waxtrace-manifest.json'
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$libSource = Join-Path $PSScriptRoot '..\common\lib\Install-FromManifest.ps1'
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$logDir = 'C:\Logs\WaxTrace'
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$installLog = Join-Path $logDir 'install.log'
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$transcriptLog = Join-Path $logDir '09-Setup-WaxAndTrace.log'
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if (-not (Test-Path $logDir)) {
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New-Item -Path $logDir -ItemType Directory -Force | Out-Null
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}
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try { Start-Transcript -Path $transcriptLog -Append -Force | Out-Null } catch {}
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function Write-WTLog {
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param([string]$Message, [string]$Level = 'INFO')
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$stamp = Get-Date -Format "yyyy-MM-dd HH:mm:ss"
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Write-Host "[$stamp] [$Level] $Message"
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}
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Write-WTLog "================================================================"
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Write-WTLog "=== WaxTrace Setup (imaging-time) session start (PID $PID) ==="
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Write-WTLog "Running as: $([System.Security.Principal.WindowsIdentity]::GetCurrent().Name)"
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Write-WTLog "Script root: $PSScriptRoot"
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Write-WTLog "================================================================"
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# Status push - best-effort.
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$pxeStatusLib = Join-Path $PSScriptRoot '..\Shopfloor\lib\Send-PxeStatus.ps1'
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if (Test-Path $pxeStatusLib) {
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try { . $pxeStatusLib; Send-PxeStatus -Stage '09-Setup-WaxAndTrace: starting' -StageIndex 3 -StageTotal 8 } catch { }
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}
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foreach ($file in @('pc-type.txt','machine-number.txt')) {
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$path = "C:\Enrollment\$file"
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if (Test-Path -LiteralPath $path) {
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$content = (Get-Content -LiteralPath $path -First 1 -ErrorAction SilentlyContinue).Trim()
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Write-WTLog " $file = $content"
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} else {
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Write-WTLog " $file = (not present)"
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}
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}
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# ============================================================================
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# Step 1: Prereqs via manifest (VC++ 2008 + 2017, HASP/Sentinel)
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# ============================================================================
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if (-not (Test-Path $manifestPath)) {
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Write-WTLog "waxtrace-manifest.json not found at $manifestPath" 'ERROR'
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} elseif (-not (Test-Path $libSource)) {
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Write-WTLog "Install-FromManifest.ps1 not found at $libSource" 'ERROR'
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} else {
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Write-WTLog "Running Install-FromManifest (InstallerRoot=$PSScriptRoot)"
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& $libSource -ManifestPath $manifestPath -InstallerRoot $stagingRoot -LogFile $installLog
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$rc = $LASTEXITCODE
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Write-WTLog "Install-FromManifest returned $rc"
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}
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# ============================================================================
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# Step 2: FormTracePak vendor install - per-bay version + sub-version
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# ============================================================================
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# Detection: skip if Formtracepak already present (re-run safe).
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$ftpakExe = 'C:\Program Files (x86)\MitutoyoApp\Formtracepak\Formtracepak.exe'
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if (Test-Path -LiteralPath $ftpakExe) {
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Write-WTLog "Formtracepak.exe already present - skipping vendor install"
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} else {
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# Per-bay config resolved by resolve-bay-config.ps1 at WinPE time + written
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# to C:\Enrollment\waxtrace\. Drives BOTH which FTPak ISO to mount AND what
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# to relay to the tech in the pre-install banner + desktop reference file.
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$waxCfgDir = 'C:\Enrollment\waxtrace'
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$bayAsset = $null
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$bayVersion = $null
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$bayModel = $null
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$bayUserId = $null
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foreach ($pair in @(
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@{ Var='bayAsset'; File='C:\Enrollment\machine-number.txt' },
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@{ Var='bayVersion'; File=(Join-Path $waxCfgDir 'version.txt') },
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@{ Var='bayModel'; File=(Join-Path $waxCfgDir 'model.txt') },
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@{ Var='bayUserId'; File=(Join-Path $waxCfgDir 'userid.txt') }
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)) {
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if (Test-Path -LiteralPath $pair.File) {
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$val = (Get-Content -LiteralPath $pair.File -First 1 -ErrorAction SilentlyContinue)
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if ($val) { Set-Variable -Name $pair.Var -Value $val.Trim() }
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}
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}
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Write-WTLog "Bay config: asset=$bayAsset version=$bayVersion model=$bayModel userid=$bayUserId"
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if (-not $bayVersion) {
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Write-WTLog "No FormTracePak version in $waxCfgDir\version.txt - bay-config did not resolve (asset_tag not in bay-config.csv?). Manual install required." 'ERROR'
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} else {
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$ftpakIso = Join-Path $stagingRoot ("formtracepak\FORMTRACEPAK-V$bayVersion.iso")
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if (-not (Test-Path -LiteralPath $ftpakIso)) {
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Write-WTLog "FormTracePak ISO missing: $ftpakIso" 'ERROR'
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Write-WTLog " Bay needs V$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'
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} else {
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# Drop a reference text file on the SupportUser Desktop so the tech
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# always has the model + USER ID in front of them when the Setup.exe
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# dialogs come up. File persists post-imaging.
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try {
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$desktop = 'C:\Users\SupportUser\Desktop'
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if (-not (Test-Path -LiteralPath $desktop)) { $desktop = 'C:\Users\Public\Desktop' }
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$deskFile = Join-Path $desktop ("$bayAsset-FTPak-install-info.txt")
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$deskContent = @(
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'========================================',
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'FormTracePak install info for this bay',
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'========================================',
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'',
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"Bay: $bayAsset",
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"FormTracePak: V$bayVersion",
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"Sub-version: $bayModel <- SELECT THIS IN THE Setup.exe DIALOG",
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"USER ID: $bayUserId <- ENTER THIS AT THE LICENSING PROMPT",
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'',
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'Reference file. Open this whenever you need to recall the USER ID',
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'during the install dialogs.',
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'',
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"Generated at imaging time by 09-Setup-WaxAndTrace.ps1 ($(Get-Date -Format 'yyyy-MM-dd HH:mm:ss'))"
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) -join "`r`n"
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Set-Content -LiteralPath $deskFile -Value $deskContent -Force
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Write-WTLog "Wrote reference file to $deskFile"
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} catch {
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Write-WTLog "Failed to write desktop reference file: $_" 'WARN'
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}
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# Big banner in the PS host window. Operator sees this BEFORE Setup.exe
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# opens so the model + USER ID are top-of-mind when the dialogs come up.
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$bannerLines = @(
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'',
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'================================================================',
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" BAY: $bayAsset",
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" FORMTRACEPAK: V$bayVersion",
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" SELECT MODEL: $bayModel",
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" USER ID: $bayUserId",
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'================================================================',
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' Setup.exe is about to launch. In its dialogs:',
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" - Pick the MODEL '$bayModel' on the language / model page.",
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" - Enter USER ID '$bayUserId' at the licensing prompt.",
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" - A reference text file with these values has been placed on",
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" SupportUser's desktop ($bayAsset-FTPak-install-info.txt).",
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'================================================================',
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''
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)
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foreach ($l in $bannerLines) { Write-WTLog $l }
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Write-WTLog "Mounting FormTracePak ISO: $ftpakIso"
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try {
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$img = Mount-DiskImage -ImagePath $ftpakIso -PassThru -ErrorAction Stop
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Start-Sleep -Seconds 8
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$vol = Get-DiskImage -ImagePath $ftpakIso | Get-Volume
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$ftpakDrive = $vol.DriveLetter
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if (-not $ftpakDrive) {
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Write-WTLog " Mount succeeded but no drive letter assigned" 'ERROR'
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} else {
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Write-WTLog " mounted at ${ftpakDrive}: (volume label=$($vol.FileSystemLabel))"
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$setupExe = "${ftpakDrive}:\Setup.exe"
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if (-not [System.IO.File]::Exists($setupExe)) {
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Write-WTLog " Setup.exe not found at $setupExe" 'ERROR'
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} else {
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Write-WTLog " running $setupExe (VB6 wrapper - requires DRIVE_CDROM)"
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try {
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$p = Start-Process -FilePath $setupExe `
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-WorkingDirectory "${ftpakDrive}:\" `
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-ArgumentList '/silent' `
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-Wait -PassThru
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Write-WTLog " Setup.exe exit $($p.ExitCode)"
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} catch {
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Write-WTLog " Setup.exe failed: $_" 'ERROR'
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}
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}
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}
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Dismount-DiskImage -ImagePath $ftpakIso -ErrorAction SilentlyContinue | Out-Null
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Write-WTLog " FormTracePak ISO dismounted"
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} catch {
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Write-WTLog " Mount-DiskImage failed: $_" 'ERROR'
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}
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}
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}
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}
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# ============================================================================
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# Step 3: Per-machine calibration ISO (mount + apply via cal Setup.exe)
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# ============================================================================
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# Cal ISOs are keyed by asset_tag. Read machine-number.txt to pick the right
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# ISO. Each cal ISO is ~1.7MB and contains a tiny Mitutoyo wrapper Setup.exe
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# plus data/*.txt compensation tables for the bay's specific probe + serial.
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$mnPath = 'C:\Enrollment\machine-number.txt'
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$asset = $null
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if (Test-Path -LiteralPath $mnPath) {
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$asset = (Get-Content -LiteralPath $mnPath -First 1 -ErrorAction SilentlyContinue).Trim()
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}
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if (-not $asset) {
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Write-WTLog "machine-number.txt missing or empty - skipping calibration apply" 'WARN'
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} else {
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$calDir = Join-Path $stagingRoot 'calibrations'
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$candidate = Get-ChildItem $calDir -Filter "CAL-${asset}_*.iso" -ErrorAction SilentlyContinue | Select-Object -First 1
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if (-not $candidate) {
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Write-WTLog "No cal ISO matched CAL-${asset}_*.iso in $calDir - skipping" 'WARN'
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} else {
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Write-WTLog "Mounting cal ISO: $($candidate.FullName)"
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try {
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$img = Mount-DiskImage -ImagePath $candidate.FullName -PassThru -ErrorAction Stop
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Start-Sleep -Seconds 5
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$calDrive = (Get-DiskImage -ImagePath $candidate.FullName | Get-Volume).DriveLetter
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$calRoot = "${calDrive}:\"
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Write-WTLog " mounted at $calRoot"
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# Disc layout differs by probe series. We have observed two:
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#
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# Older 218-458A: E:\App.ini, E:\Setup.exe, E:\data\CVIFDLL.ini,
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# E:\data\Cvif_Correction.exe, E:\data\<files>.txt.
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# Vendor Setup.exe works (VB6, may prompt).
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#
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# Newer 218-378-13: E:\setup.bat, E:\setup.exe (.NET 4.0),
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# E:\iniStatus\<png>, E:\data\cvifdll.ini,
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# E:\data\<files>.txt - BUT the filenames have a
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# bug: probe ID ends with a TRAILING SPACE
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# ("218-378-13 _100072210.txt"). The vendor's
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# .NET Setup.exe calls FileSystemInfo.set_Attributes
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# on the source path and throws System.ArgumentException
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# because the path contains an embedded space
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# component, crashing every time
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# (exit -532462766 = 0xE0434352, .NET unhandled
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# exception). See diag-cal.log, WER Event 1026.
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#
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# We bypass the vendor wrapper entirely when the disc carries
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# the buggy filenames and do a direct file copy into FormTracePak's
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# data dir, renaming each file to strip the trailing space.
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$srcDataDir = Join-Path $calRoot 'data'
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$dstDataDir = 'C:\Program Files (x86)\MitutoyoApp\Formtracepak\data'
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$bypassVendorSetup = $false
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if (Test-Path -LiteralPath $srcDataDir) {
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# The 218-378-13 probe series has a buggy .NET Setup.exe
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# that crashes (0xE0434352) even when filenames are clean.
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# Older ISOs had trailing-space filenames (' _' pattern);
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# newer ISOs fixed the filenames but the .NET wrapper
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# still crashes on some path operation. Detect by probe
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# series in filename OR the trailing-space signature.
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$bypassVendorSetup = [bool](Get-ChildItem -LiteralPath $srcDataDir -File -ErrorAction SilentlyContinue |
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Where-Object { $_.Name -match '218-378-13' -or $_.Name -match ' _\d+\.txt$' } |
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Select-Object -First 1)
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}
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if ($bypassVendorSetup) {
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Write-WTLog " 218-378-13 series detected - bypassing vendor Setup.exe, doing direct file copy"
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if (-not (Test-Path -LiteralPath $dstDataDir)) {
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Write-WTLog " destination data dir does not exist: $dstDataDir" 'ERROR'
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Write-WTLog " (FormTracePak install may not be complete; cal apply aborted)" 'ERROR'
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} else {
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$copied = 0
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Get-ChildItem -LiteralPath $srcDataDir -File -ErrorAction SilentlyContinue | ForEach-Object {
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# Strip ' _' (space-underscore) -> '_' inside the filename to
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# heal the Mitutoyo burn-time typo. cvifdll.ini etc unaffected.
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$cleanName = $_.Name -replace ' _', '_'
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$dst = Join-Path $dstDataDir $cleanName
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try {
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Copy-Item -LiteralPath $_.FullName -Destination $dst -Force -ErrorAction Stop
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# Clear read-only on the destination so future overwrites work.
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try { (Get-Item -LiteralPath $dst).Attributes = 'Normal' } catch {}
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Write-WTLog " copied $($_.Name) -> $cleanName"
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$copied++
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} catch {
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Write-WTLog " copy failed for $($_.Name): $_" 'ERROR'
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}
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}
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Write-WTLog " direct copy complete: $copied file(s) into $dstDataDir"
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}
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} else {
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# Older-style disc (clean filenames). Vendor Setup.exe is reliable.
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$calSetup = "${calDrive}:\Setup.exe"
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if (Test-Path -LiteralPath $calSetup) {
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Write-WTLog " running cal Setup.exe (may prompt - VB6 wrapper, same vintage as main installer)"
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$p = Start-Process -FilePath $calSetup -WorkingDirectory $calRoot -Wait -PassThru
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Write-WTLog " cal Setup.exe exit $($p.ExitCode)"
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} else {
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Write-WTLog " cal Setup.exe not found at $calSetup" 'WARN'
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}
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}
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Dismount-DiskImage -ImagePath $candidate.FullName -ErrorAction SilentlyContinue | Out-Null
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Write-WTLog " cal ISO dismounted"
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} catch {
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Write-WTLog " Mount-DiskImage failed: $_" 'ERROR'
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}
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}
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}
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# ============================================================================
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# Step 3b: Restore captured layouts / prefs / data from per-asset backup ZIP
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# ============================================================================
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# startnet.cmd stages C:\WaxTrace-Install\backup\<asset>.zip iff the PXE
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# share has a backup ZIP for this asset. The ZIP is the output of
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# Backup-FormtracepakSettings.ps1 captured on the LIVE bay BEFORE re-imaging.
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# Restore is data + config only - skip -RestoreRegistry until the HKEY_USERS
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# SID rewriting is built (captured .reg carries source bay's user SID which
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# does not exist on the freshly imaged bay). HKLM controller config / model
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# device-map / etc. came from the vendor MSI install in Step 2 already.
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$backupZip = $null
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# startnet.cmd robocopy's the whole installers-post\waxtrace\backups\ dir
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# to C:\WaxTrace-Install\backups\ (plural). Try plural first, then singular
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# for backward-compat with any older boot.wim that used the cherry-pick path.
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$backupDirCandidates = @(
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'C:\WaxTrace-Install\backups',
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'C:\WaxTrace-Install\backup'
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)
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foreach ($bd in $backupDirCandidates) {
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if (-not (Test-Path -LiteralPath $bd) -or -not $bayAsset) { continue }
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$candidate = Join-Path $bd ("$bayAsset.zip")
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if (Test-Path -LiteralPath $candidate) {
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$backupZip = $candidate
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break
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}
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$newest = Get-ChildItem -LiteralPath $bd -Filter "${bayAsset}*.zip" -File -ErrorAction SilentlyContinue |
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Sort-Object LastWriteTime -Descending | Select-Object -First 1
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if ($newest) {
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$backupZip = $newest.FullName
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break
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}
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}
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if ($backupZip) {
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$installPs1 = Join-Path $stagingRoot 'Install-FormtracepakSettings.ps1'
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if (Test-Path -LiteralPath $installPs1) {
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Write-WTLog "Restoring per-asset backup from $backupZip (HKLM + files; HKEY_USERS deferred to first ShopFloor logon)"
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try {
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# In-line restore: HKLM (controller config, device-map) + files
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# (layouts, prefs in install dir). HKEY_USERS per-user prefs would
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# need ShopFloor's hive loaded, which it isn't at imaging time -
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# deferred to a scheduled SYSTEM task that fires on first ShopFloor
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# logon (see Schedule-WaxTracePerUserRestore call below).
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& $installPs1 -BackupPath $backupZip -RestoreRegistry -RestoreData -RestoreConfig -Force
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Write-WTLog " Restore call returned (see restore log + Install-FormtracepakSettings output above)"
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} catch {
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Write-WTLog " Restore call threw: $_" 'WARN'
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}
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# Schedule the per-user prefs restore as a SYSTEM task that fires on
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# first ShopFloor logon. The task self-removes after one successful
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# run via flag file at C:\WaxTrace-Install\per-user-restore-ShopFloor.flag.
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$schedScript = Join-Path $stagingRoot 'Schedule-WaxTracePerUserRestore.ps1'
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if (-not (Test-Path -LiteralPath $schedScript)) {
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# Fall back: pull from shopfloor-setup scripts/ sibling tree
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$alt = Join-Path $PSScriptRoot 'scripts\Schedule-WaxTracePerUserRestore.ps1'
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if (Test-Path -LiteralPath $alt) { $schedScript = $alt }
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}
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if (Test-Path -LiteralPath $schedScript) {
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Write-WTLog "Registering deferred ShopFloor per-user restore task ($schedScript)"
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try {
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& $schedScript -BackupPath $backupZip -InstallScript $installPs1 -TargetUser 'ShopFloor' -AssetNumber $bayAsset
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Write-WTLog " Scheduled task 'WaxTrace-PerUser-Restore' registered"
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} catch {
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Write-WTLog " Schedule task call threw: $_" 'WARN'
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}
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} else {
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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 for $bayAsset in $($backupDirCandidates -join ', ') - 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 {}
|