pxe-server/playbook/utilities/waxtrace-recovery/debug-waxtrace-cal.ps1

# debug-waxtrace-cal.ps1 - Forensic walkthrough of why the wax/trace
# calibration data did not land in FormTracePak's data dir on a bay.
#
# Captures everything: FTPak install location autodetected (we DO NOT
# trust the hardcoded path), data dir contents at every candidate,
# cal ISO presence + mount + listing, the current on-disk version of
# 09-Setup-WaxAndTrace.ps1 (does it have the direct-copy fix or the old
# vendor-Setup.exe path?), the imaging-time log, and Application event
# log entries for Setup.exe crashes in the last 24 hours.
#
# Run as administrator. Output to C:\Logs\WaxTrace\debug-waxtrace-cal.log
# + console. Paste the log back to support for diagnosis.

[CmdletBinding()]
param(
    [string]$Asset
)

$logDir = 'C:\Logs\WaxTrace'
if (-not (Test-Path $logDir)) { New-Item -ItemType Directory -Path $logDir -Force | Out-Null }
$logFile = Join-Path $logDir 'debug-waxtrace-cal.log'
Remove-Item $logFile -Force -EA 0

function Log {
    param([string]$Msg, [string]$Lvl = 'INFO')
    $line = '[{0}] [{1}] {2}' -f (Get-Date -Format 'yyyy-MM-dd HH:mm:ss'), $Lvl, $Msg
    Add-Content -Path $logFile -Value $line -ErrorAction SilentlyContinue
    Write-Host $line
}

Log '=== debug-waxtrace-cal.ps1 ==='
Log "User: $([Security.Principal.WindowsIdentity]::GetCurrent().Name)"
Log "Host: $env:COMPUTERNAME"

# ---------- Section 1: Asset tag ----------
Log ''
Log '--- 1. ASSET TAG ---'
if (-not $Asset) {
    $mn = 'C:\Enrollment\machine-number.txt'
    if (Test-Path $mn) {
        $Asset = (Get-Content $mn -First 1 -EA 0).Trim()
        Log "machine-number.txt: '$Asset'"
    } else {
        Log "machine-number.txt MISSING at $mn" 'WARN'
    }
}
Log "Using asset: $Asset"

# ---------- Section 2: locate FormTracePak install ----------
Log ''
Log '--- 2. FORMTRACEPAK INSTALL LOCATION ---'
$candidatePaths = @(
    'C:\Program Files (x86)\MitutoyoApp\Formtracepak',
    'C:\Program Files\MitutoyoApp\Formtracepak',
    'C:\Program Files (x86)\Mitutoyo\Formtracepak',
    'C:\Program Files\Mitutoyo\Formtracepak',
    'C:\MitutoyoApp\Formtracepak',
    'C:\Mitutoyo\Formtracepak'
)
$ftpakRoot = $null
foreach ($p in $candidatePaths) {
    $exe = Join-Path $p 'Formtracepak.exe'
    if (Test-Path -LiteralPath $exe) {
        $ftpakRoot = $p
        Log "FOUND Formtracepak.exe at: $exe"
        break
    } else {
        Log "  miss: $p"
    }
}

if (-not $ftpakRoot) {
    Log 'No Formtracepak.exe at any expected path - searching C:\ Program Files trees...'
    $hits = @()
    foreach ($pf in @('C:\Program Files', 'C:\Program Files (x86)', 'C:\Mitutoyo', 'C:\MitutoyoApp')) {
        if (-not (Test-Path $pf)) { continue }
        $hits += Get-ChildItem -Path $pf -Filter 'Formtracepak.exe' -Recurse -File -ErrorAction SilentlyContinue
    }
    if ($hits) {
        Log "Brute-force search hits:"
        $hits | ForEach-Object { Log "  $($_.FullName)" }
        $ftpakRoot = Split-Path $hits[0].FullName -Parent
    } else {
        Log 'NO Formtracepak.exe ANYWHERE on C:\ - FormTracePak install likely never completed.' 'ERROR'
    }
}

# ---------- Section 3: data dir + contents ----------
Log ''
Log '--- 3. FORMTRACEPAK DATA DIR ---'
if ($ftpakRoot) {
    $dataDir = Join-Path $ftpakRoot 'data'
    Log "Expected data dir: $dataDir"
    if (Test-Path -LiteralPath $dataDir) {
        $files = Get-ChildItem -LiteralPath $dataDir -File -EA 0 | Sort-Object Name
        if ($files) {
            Log "Data dir contents ($($files.Count) files):"
            foreach ($f in $files) {
                Log "  $($f.Name) ($($f.Length) bytes, modified $($f.LastWriteTime))"
            }
        } else {
            Log 'Data dir EXISTS but is EMPTY' 'WARN'
        }
        # Look for any cal files matching the asset's probe ID
        $probeMatches = $files | Where-Object { $_.Name -match '218-\d{3}-\d+' }
        if ($probeMatches) {
            Log 'Files with probe-ID pattern (cal data candidates):'
            foreach ($f in $probeMatches) { Log "  hit: $($f.Name)" }
        } else {
            Log 'NO files matching the 218-XXX-XX probe-ID pattern in data dir.' 'WARN'
        }
    } else {
        Log "Data dir MISSING at $dataDir" 'ERROR'
        Log "Parent dir contents:"
        Get-ChildItem -LiteralPath $ftpakRoot -EA 0 | ForEach-Object { Log "  $($_.Name)" }
    }
} else {
    Log 'Skipping data-dir check (FTPak install not found)'
}

# ---------- Section 4: cal ISO present at C:\WaxTrace-Install\calibrations\ ----------
Log ''
Log '--- 4. CAL ISO ON LOCAL DISK ---'
$calDir = 'C:\WaxTrace-Install\calibrations'
if (Test-Path -LiteralPath $calDir) {
    $allCals = Get-ChildItem -LiteralPath $calDir -Filter 'CAL-*.iso' -File -EA 0
    Log "Cal staging dir: $calDir ($($allCals.Count) ISO files total)"
    if ($Asset) {
        $matched = $allCals | Where-Object { $_.Name -like "CAL-${Asset}_*" }
        if ($matched) {
            Log "ISO matching this asset:"
            foreach ($f in $matched) { Log "  $($f.Name) ($([math]::Round($f.Length/1KB,1)) KB)" }
        } else {
            Log "NO ISO matches CAL-${Asset}_*.iso in $calDir" 'ERROR'
            Log "Available ISOs (first 8):"
            $allCals | Select-Object -First 8 | ForEach-Object { Log "  $($_.Name)" }
        }
    }
} else {
    Log "Cal staging dir MISSING: $calDir - startnet.cmd did not xcopy installers-post\waxtrace at imaging time, OR 09-Setup-WaxAndTrace.ps1 already deleted it (Step 5 cleanup)." 'ERROR'
}

# ---------- Section 5: mount the matching cal ISO and list contents ----------
Log ''
Log '--- 5. MOUNT CAL ISO + LIST CONTENTS ---'
if ($Asset -and (Test-Path -LiteralPath $calDir)) {
    $iso = Get-ChildItem -LiteralPath $calDir -Filter "CAL-${Asset}_*.iso" -EA 0 | Select-Object -First 1
    if ($iso) {
        try {
            $img = Mount-DiskImage -ImagePath $iso.FullName -PassThru -ErrorAction Stop
            Start-Sleep -Seconds 5
            $vol = Get-DiskImage -ImagePath $iso.FullName | Get-Volume
            $drive = $vol.DriveLetter
            if ($drive) {
                Log "Mounted at ${drive}:\ (label=$($vol.FileSystemLabel))"
                $items = [System.IO.Directory]::GetFileSystemEntries("${drive}:\", '*', 'AllDirectories')
                foreach ($i in $items) {
                    try {
                        $fi = [System.IO.FileInfo]::new($i)
                        if ($fi.Attributes -band [System.IO.FileAttributes]::Directory) {
                            Log "  DIR  $i"
                        } else {
                            Log "  FILE $i  ($($fi.Length) bytes)"
                        }
                    } catch { Log "  $i" }
                }
            } else {
                Log "Mount succeeded but no drive letter assigned" 'ERROR'
            }
            Dismount-DiskImage -ImagePath $iso.FullName -EA 0 | Out-Null
            Log "Cal ISO dismounted"
        } catch {
            Log "Mount failed: $_" 'ERROR'
        }
    }
}

# ---------- Section 6: on-disk version of 09-Setup-WaxAndTrace.ps1 ----------
Log ''
Log '--- 6. 09-SETUP-WAXANDTRACE.PS1 ON DISK ---'
$setupPath = 'C:\Enrollment\shopfloor-setup\gea-shopfloor-waxtrace\09-Setup-WaxAndTrace.ps1'
if (Test-Path -LiteralPath $setupPath) {
    $fi = Get-Item $setupPath
    Log "Path: $setupPath"
    Log "  size: $($fi.Length) bytes, mtime: $($fi.LastWriteTime)"
    $content = Get-Content -LiteralPath $setupPath -Raw
    $hasDirectCopy = $content -match 'hasBrokenFilenames'
    $hasV6213       = $content -match 'V6\.213'
    $vendorOnly     = $content -match 'calSetup.*Setup\.exe' -and -not $hasDirectCopy
    Log "  Direct-copy bypass present (hasBrokenFilenames):   $hasDirectCopy"
    Log "  V6.213 baseline references:                        $hasV6213"
    if (-not $hasDirectCopy) {
        Log '  !!! This bay has the OLD 09-Setup-WaxAndTrace.ps1 without the direct-copy fix.' 'ERROR'
        Log '  !!! 218-378-13 series cal discs WILL crash setup.exe with .NET unhandled exception.' 'ERROR'
        Log '  !!! Pull the latest from the share: copy /Y \\172.16.9.1\enrollment\shopfloor-setup\gea-shopfloor-waxtrace\09-Setup-WaxAndTrace.ps1 to local.' 'ERROR'
    }
} else {
    Log "09-Setup-WaxAndTrace.ps1 NOT FOUND at expected path $setupPath" 'WARN'
}

# Also check C:\WaxTrace-Install copy (staged from share at WinPE time)
$setupStaging = 'C:\WaxTrace-Install\09-Setup-WaxAndTrace.ps1'
if (Test-Path -LiteralPath $setupStaging) {
    $fi = Get-Item $setupStaging
    $content = Get-Content -LiteralPath $setupStaging -Raw
    $hasDirectCopy = $content -match 'hasBrokenFilenames'
    Log "Staging copy at $setupStaging :"
    Log "  size: $($fi.Length), mtime: $($fi.LastWriteTime), has direct-copy: $hasDirectCopy"
}

# ---------- Section 7: imaging-time log content ----------
Log ''
Log '--- 7. 09-SETUP-WAXANDTRACE.LOG CONTENT (cal sections) ---'
$wtLog = 'C:\Logs\WaxTrace\09-Setup-WaxAndTrace.log'
if (Test-Path -LiteralPath $wtLog) {
    Log "Tail of $wtLog (last 40 lines + cal-related lines):"
    $tail = Get-Content -LiteralPath $wtLog -Tail 40 -EA 0
    foreach ($l in $tail) { Log "  $l" }
    Log ''
    Log 'cal/calibration/setup/copy/Mount-DiskImage matching lines:'
    Select-String -LiteralPath $wtLog -Pattern 'cal|calibration|copied|direct copy|Mount-DiskImage|setup\.exe exit|hasBrokenFilenames' -SimpleMatch:$false -EA 0 |
        Select-Object -Last 30 | ForEach-Object { Log "  L$($_.LineNumber): $($_.Line)" }
} else {
    Log "$wtLog MISSING - 09-Setup-WaxAndTrace.ps1 never ran (or never reached transcript start)." 'WARN'
}

# ---------- Section 8: Event log .NET Runtime crashes ----------
Log ''
Log '--- 8. EVENT LOG (.NET Runtime / Application Error / WER, last 24h) ---'
$cutoff = (Get-Date).AddHours(-24)
foreach ($lname in @('Application')) {
    try {
        $events = Get-WinEvent -FilterHashtable @{
            LogName = $lname
            StartTime = $cutoff
            ProviderName = @('.NET Runtime', 'Application Error', 'Windows Error Reporting')
        } -ErrorAction Stop | Where-Object { $_.Message -match 'setup\.exe|Setup\.exe|MitutoyoLauncher|Formtracepak|FileSystemInfo|set_Attributes' } |
            Select-Object -First 5
        if ($events) {
            foreach ($e in $events) {
                Log "Event $($e.Id) [$($e.LevelDisplayName)] from $($e.ProviderName) at $($e.TimeCreated)"
                $e.Message -split "`n" | Select-Object -First 10 | ForEach-Object { Log "    $_" }
            }
        } else {
            Log "No matching .NET/AppError events in last 24h"
        }
    } catch {}
}

# ---------- Section 9: scoped search for cal data on known dirs ----------
Log ''
Log '--- 9. SCOPED CAL FILE SEARCH (Mitutoyo / Hexagon known dirs) ---'
$searchRoots = @(
    'C:\Program Files (x86)\MitutoyoApp',
    'C:\Program Files\MitutoyoApp',
    'C:\Program Files (x86)\Mitutoyo',
    'C:\Program Files\Mitutoyo',
    'C:\MitutoyoApp',
    'C:\Mitutoyo',
    'C:\ProgramData\Mitutoyo'
)
foreach ($r in $searchRoots) {
    if (-not (Test-Path -LiteralPath $r)) { continue }
    $hits = @(Get-ChildItem -Path $r -Include 'Frc_*.txt','Linear_X_*.txt','Linear_Zl_*.txt','Str_XZ_*.txt','cvifdll.ini','CVIFDLL.ini' -Recurse -ErrorAction SilentlyContinue -Force)
    if ($hits) {
        Log "Under $r :"
        $hits | Select-Object -First 10 | ForEach-Object { Log "  $($_.FullName) ($($_.Length) bytes, $($_.LastWriteTime))" }
    }
}

Log ''
Log "=== debug-waxtrace-cal.ps1 end. Output: $logFile ==="