EMDEP KSK SYSTEM

KSK SERVER
Emdep KSK Server / User’s guide

Document history and versions

Ver. Date Author Change description
1.0 11/10/2017 Gerard Llort Initial version
1.1 25/10/2017 Gerard Llort - Added the working workflow of Orders Importer Service.
- Added the Line Assignment Rules section.
1.2 12/12/2017 Gerard Llort - Updated the QSS1 file format section.
- Added the Upgrading from old Emdep KSK QSS1 Service section.
- Added the Upgrading from old Emdep KSK SAP Service section.
1.3 10/07/2018 Gerard Llort - Added the Working modes section in External Equipment Service.
1.4 20/07/2018 Gerard Llort - Updated SAP section in Synchronization Service.
1.5 09/10/2018 Gerard Llort - Added section.
22/02/2019 Gabriel Plana - Fixed some minor found misspellings
1.6 09/01/2020 Gabriel Plana - Added explanation of Schunk working in parallel in working
modes
1.7 4/5/2020 Gabriel Plana - Added segment P7 in QSS1 and QSSE files.
1.8 19/6/2020 Gabriel Plana - Added error codes 005 (“Errors in Fuses”) and 006 (“Errors in wires
and fuses”) in QSSE files and explain relationship between fuses and
modules.
1.9 24/12/2020 Gabriel Plana -Added the possibility to specify time interval in seconds for sync
service
1.10 14/01/2021 Gabriel Plana -Added format 2 to QSS1 file specification.
-Changed settings screen for task QSS1 with the new field file
format, and added its explanation.
1.11 18/01/2021 Gabriel Plana -Changed settings screen for task External (Schunk) with the new
field file format and added its explanation.
-Corrected the name of File Format 2 for QSS1, which is “QSS1 BMW
Legacy”
1.12 25/01/2021 Gabriel Plana Adding new parameter “ksk.ws.qss1.productionSystemMode” on
settings.xml in QSS1
1.13 26/5/2021 Gabriel Plana Adding Qss1 Definition tab on Settings screen of Orders importer
task.
1.14 1/6/2021 Gabriel Plana Adding option to convert PartNumbers from QSS1 using
equivalence table.
1.15 30/8/2021 Gabriel Plana Added KSK File Orders Importer service section
1.16 04/10/2021 Gabriel Plana Added KSK Txt SAP Generator service section
1.17 03/11/2021 Gabriel Plana Added KSK Schunk Generator service section
1.18 11/11/2021 Gabriel Plana Added parameter segments to ignore on QSS1 Orders Importer
service.
1.19 12/11/2021 Gabriel Plana Adding explanation of SyncActionCodes in Synchronization service:
each type of station can have a default SyncActionCode, and also it
can be defined for each station.

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1.20 29/11/2021 Gabriel Plana Adding checkbox “Use Pooling” in database properties in settings
screen.
Adding CP segment to QSS1 file specification
Added code 499 in QSSE error table.
1.21 4/01/2022 Gabriel Plana Explanation of change in Sync Service to allow application
WarehouseToRework to get the feedback from SAP
1.22 14/01/2022 Gabriel Plana New option Send feedback to SAP in QSS1 Orders
Importer service settings screen.
New options Create empty modules when they does not
exist and For Assembly Order Generator in Orders
Importer settings screen.
Add troubleshooting in Sync service and QSS1 service: if error
connecting to SAP when sending signals to SAP, install SAPGUI client
7.4.
1.23 28/01/2022 Gabriel Plana New service PPSORD Importer.
1.24 6/7/2022 Gabriel Plana New option in KSK File Orders Importer to select the line where
harness will be enqueued.
1.25 29/07/2022 Lalit Bhangale Change the name of splices at files generated for Schunk, to accept
splice variants also Add Comment and Wire Type field in Shunk
Generator Service
1.26 28/03/2023 Gerard Pasano Added in QSS1 file P8 segment.
Modifications done in QSS1 file format and QSSE file format.
1.27 08/05/2023 Gerard Pasano Modifications done in QSS1 file format and QSSE file format.
1.28 18/05/2023 Lalit Bhangale New option in Precomplier Service to Generate the Tightening Data
files for Non-Emdep Third-Party Tightening Stations

Create new task to Accept the feedback file from Non-Emdep Third-
Party Tightening Stations and Open/close stage according to feed
back file content.
1.29 29/05/2023 Lalit Bhangale Allow the Schunk Station in first step as parallel station
1.30 18/03/2024 Arnau Clarifying file name changes for QSS1 files moved for
Montañés AssemblyOrderGenerator in QSSE file format.
1.31 02/04/2024 Gerard Pasano Add No_Welding section in P8 of QSS1.
1.32 25/07/2024 Lalit Bhangale Change the P8 010 Section it should be 030.
1.33 29/07/2024 Arnau Added Squeezing Data Service.
Montañés Added YDSP File format.
Fixed file index formatting

Disclaimer
The instructions in this document have been carefully checked for accuracy and are presumed
to be reliable. EMDEP and its writers assume no responsibility for inaccuracies and reserve the
right to modify and revise this document without notice.

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If you discover a discrepancy in this document, please e-mail your comments to our Engineering
Support department (engineering.support@emdep.com).

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Contents
Document history and versions ............................................................................................................... 0
Disclaimer................................................................................................................................................. 1
GETTING STARTED ................................................................................................................................. 1
Introduction ............................................................................................................................................. 2
Configuring a KSK server .......................................................................................................................... 2
BASIC CONCEPTS .................................................................................................................................... 3
Incoming orders lifecycle ......................................................................................................................... 4
Step 1 ................................................................................................................................................... 4
Step 2 ................................................................................................................................................... 4
Step 3 ................................................................................................................................................... 5
End of incoming process ...................................................................................................................... 5
Order’s compilation ................................................................................................................................. 5
Orders production lifecycle ...................................................................................................................... 6
Step 1 ................................................................................................................................................... 6
Step 2 ................................................................................................................................................... 7
Step 3 ................................................................................................................................................... 7
Rework lifecycle ....................................................................................................................................... 7
Step 1 ................................................................................................................................................... 8
Step 2 ................................................................................................................................................... 8
Step 3 ................................................................................................................................................... 9
Rework in the station ............................................................................................................................... 9
DATABASE SERVER............................................................................................................................... 10
Database server ..................................................................................................................................... 11
Server requirements .......................................................................................................................... 11
Database configuration .......................................................................................................................... 12
Database maintenance .......................................................................................................................... 14
Clean database .................................................................................................................................. 14
Backup ............................................................................................................................................... 14
Change database files’ location ......................................................................................................... 17
SERVICES .............................................................................................................................................. 19
Server Monitor ....................................................................................................................................... 20
Managing services ............................................................................................................................. 20
Monitoring services ........................................................................................................................... 22
Configuring KSK services .................................................................................................................... 23
Orders Importer Service ......................................................................................................................... 24
Upgrading from old Emdep KSK QSS1 Service ................................................................................... 24
Supported scenarios .......................................................................................................................... 25
Configuration ..................................................................................................................................... 26
Troubleshooting................................................................................................................................. 30
PPSORD Orders Importer Service .......................................................................................................... 31
PPSORD file format ............................................................................................................................ 31
Configuration ..................................................................................................................................... 32
KSK File Orders Importer Service .......................................................................................................... 33
Format of .ksk files ............................................................................................................................. 33
Format of .ok files .............................................................................................................................. 33

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Format of .ng files .............................................................................................................................. 34

Configuration ..................................................................................................................................... 35
Precompiler Service .............................................................................................................................. 39
Configuration ..................................................................................................................................... 39
External Equipment Service .................................................................................................................. 42
Working modes .................................................................................................................................. 42
Supported equipment........................................................................................................................ 43
Configuration ..................................................................................................................................... 48
Line assignment rules ........................................................................................................................ 53
Synchronization Service ......................................................................................................................... 55
Supported systems ............................................................................................................................ 55
Upgrading from old Emdep KSK SAP Service ..................................................................................... 56
Configuration ..................................................................................................................................... 56
Logging SAP communications ............................................................................................................ 59
Troubleshooting................................................................................................................................. 59
Txt SAP Generator Service .................................................................................................................... 60
Supported systems ............................................................................................................................ 60
Configuration ..................................................................................................................................... 60
Schunk Generator Service ..................................................................................................................... 64
Configuration ..................................................................................................................................... 64
Reports Service ..................................................................................................................................... 67
Built-in reports ................................................................................................................................... 67
Configuration ..................................................................................................................................... 67
Squeezing Data Service .......................................................................................................................... 73
YDSP File Format ................................................................................................................................ 73
Configuration ..................................................................................................................................... 73
Service LOGs ........................................................................................................................................... 74
Configuration ..................................................................................................................................... 75
Windows™ services ................................................................................................................................ 76
Service properties .............................................................................................................................. 76
Operating a service in Windows™ ..................................................................................................... 78
Manually register a service in Windows™ ......................................................................................... 79
Testing and validating a service task ...................................................................................................... 80
Service test plugin for Emdep KSK Studio .......................................................................................... 80
TROUBLESHOOTING............................................................................................................................. 82
External Equipment Service ................................................................................................................... 83
Orders are not passing through an external equipment (Schunk, etc.) ............................................ 83
System & Database ................................................................................................................................ 84
ERROR: index "TableName" contains unexpected zero page ............................................................ 84
SYSTEM FAILOVER STRATEGIES ............................................................................................................ 85
System failover configurations ............................................................................................................... 86
Primary/Backup servers ..................................................................................................................... 86
Failover Clustering ............................................................................................................................. 88
MISCELLANEOUS .................................................................................................................................. 90
HKSK file format ..................................................................................................................................... 91
QSS1 file format ..................................................................................................................................... 92

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QSSE file format ..................................................................................................................................... 94

Format 1 ............................................................................................................................................ 94
Format 2 ............................................................................................................................................ 97
Schunk synchronization file (SEQOK) ..................................................................................................... 99
Hennecke synchronization file ............................................................................................................. 100
YDSP File ............................................................................................................................................... 101

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GETTING STARTED

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Introduction
Emdep KSK System is a distributed software product and it means that the system needs an
orchestration software. Emdep KSK Server consists in a couple of Windows™ services that works
over a database server.

All services are designed in a modular architecture that allows to easily add new modules if a
project requires features not covered.

Configuring a KSK server

The following steps are a summary to install and configure a KSK server. A more detailed
description for each step can be found in the different sections on this manual.

1. Install database engine

The steps to install the database engine are described in the official PostgreSQL
instructions .

2. Select the services needed

After installing the services, it is necessary to clarify which services are needed to put
the new KSK project working.
For each needed service, study all settings that must be set and if it is necessary provide
the network infrastructure (shared folders, etc.) and permissions. Some services must
be executed using a specific profile in order to get access to some network resources
such shared folders, etc.

3. Install and configure KSK services

Install the selected services following the provided instructions and set all settings.

4. Plan the operating system actions

Finally, each KSK service must be configured to react in from to the different Windows
events (start & close the operating system, reboot, crashes, etc.) to avoid manual
interventions.

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BASIC CONCEPTS

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Incoming orders lifecycle

The following schema shows the route followed by an order since it is sent by the production
system (SAP, LEPS, etc.) until it is ready to start its assembly / test in the KSK system.

Step 1
Emdep KSK Orders Importer Service is responsible to acquire the orders from the production
system (like SAP, LEPS or any other system). Depending on the production system, the order is
caught from data files (like QSS1) or obtained directly from the production system (like LEPS).

Each received order is validated individually by checking the modules and wires included.
Depending on the result, the order will take one way or another:

• NOK
o The service sends all errors detected to the production system.
o The order is not created in the KSK project, so it cannot be found.
o The order finishes his lifecycle at this point.
• OK
o The order is created in the KSK project.
o The NeedPrecompile flag is set to TRUE.
o The order is set to IMPORTING status.

Step 2
Emdep KSK Precompiler Service is responsible to precompile all incoming orders and generate
the HKSK files (test files adapted to the modules included in the order).

The service gets all orders pending to precompile and try to generate the HKSK files. Depending
on the result, the order will take one way or another:

• NOK

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o The order is set to GENERATING ERROR status.

o The error message is stored in the order.
o The order finishes his lifecycle at this point.
• OK
o The NeedPrecompile flag is set to FALSE.

Step 3
Emdep KSK Orders Importer Service perform the following actions:

• Get all orders in status IMPORTING and with the flag NeedPrecompile set to FALSE.
• For all these orders the service send an OK signal to the production system, telling that
the order is ready to be produced.
• Set all orders to WAITING.

Manually created orders (using the Order editor in KSK Studio or the old Manual Harness
Editor) don’t send the OK signals to the production system. This method should be used only
in the start-up phase and only for system setup purposes.

End of incoming process

When an order adopts the status WAITING (after step 3) is ready to be processed in the
assembly/test lines.

Order’s compilation
To generate a test (or assembly) using Wintestem™ we need the test files used by Wintestem
plugins (each type of test has his own type of file).

For the KSK system, the standard Wintestem™ built-in compiler cannot be used because the
harnesses are modular and the information on related to the modules included in the current
order resides in the KSK system. For this reason, before to start any test the KSK compiler should
be called to generate the files filtering the board components with the included components in
the KSK order (modular compilation).

The Emdep KSK Client Station package includes the compiler libraries, so in all stations should
be installed and ready to use.

A special case is the compilation for the Electrical tests. When the test is electrical a double
compilation is needed. The first compilation (performed in the server before including the order
in the KSK system) apply the KSK rules and generate the HKSK files (one per step). The second
compilation (performed in the stations before launching the electrical test), adapt these
precompiled orders to the components in the station. The following schema is showing this
process:

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Orders production lifecycle

The order production lifecycle starts with the order in WAITING status and ends when the order
is set to TESTED after passing all steps in one of the available production lines. The following
schema shows the flow followed by an order in a single station. The same flow is followed by
the order for each step in the production line.

Step 1
The operator scans the order barcode and from Wintestem, a VBS script call the OpenStage
process using the configured KSK gateway. Depending on the step of the station, two different
operations should be done:

• Station in first step:

o The order must be in WAITING status.
o When the OpenStage process is called, the order is set to IN_PROCESS and
placed in the station.

• Station in the middle or in the last step:

o The order must be in IN_PROCESS status.
o The order must be queued in the step where the station belongs.

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o When the OpenStage process is called, the order placed in the station.

Step 2
After the assembly or test operation, the stage should be closed. Depending on the step of the
station, two different operations should be done:

• Process finish with OK

o Station in the first or in an intermediate step
▪ The assembly or test operation has been successfully performed.
▪ The CloseStage is called with OK.
▪ The order is queued in the next stage.
▪ The order status is set to IN_PROCESS.
o Station in the last step
▪ The assembly or test operation has been successfully performed.
▪ The CloseStage is called with OK.
▪ The order status is set to TESTED.
• Process finish with NOK:
o The assembly or test operation has been unsuccessfully performed.
o The CloseStage is called with NOK.
o The order still queued in the current stage (not moved).
o The order status is set to IN_PROCESS.

Step 3
After a CloseStage OK, the Emdep KSK Synchronization Service should send the signals to the
production system due to maintain all data synchronized:

• Station in the first or in an intermediate step

o A signal is sent to production system informing that the step is finished.

• Station in the last step

o A signal is sent to production system informing that the harness is finished.

When the old software Status Harness Editor is used, it is possible that the production system
doesn’t receive the correct OK signals for the stations. This method should be used only in
the start-up phase and only for system setup purposes.

Rework lifecycle
When an order comes back from the rework station to the line, it can only be processed in a
step with the flag AcceptFromReworks enabled. But the order always comes back to the line in
the same (or previous) step where it was being processeed before being sent to rework station.

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Step 1
• The order is being processed in station 5 (ST5) after passing through ST1 and ST4.
• The result of the assembly/test operation in ST5 is NOK.
• The operator chooses the option to send to rework the harness.
• KSK system select an available rework station.
• The order is queued in the selected rework station.

Step 2
The rework station with Emdep KSK Rework Terminal running is ready to start:

• The operator scans the order sent to rework.

The orders sent to rework have a special label with the order number changed adding
an R at its start (A100023I570 → RA100023I570), so all orders scanned in a rework
should start with an R, otherwise the terminal cannot recognize the order.
• The terminal shows all detected defects in the harness.
• The operator(s) start repairing all defects and checking each defect putting it in a
repaired or unrepairable state.
o All defects repaired
The harness is set to repaired and can be returned to the same line from where
it was sent to reworks.
o One or more unrepairable defects
The harness must be set to UNREPAIRABLE and sent to scrap.

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Step 3
The Emdep KSK Rework Terminal, depending on the line configuration, automatically or
manually queue the order into the appropriate step:

• No steps with AcceptFromRework

The harness is automatically queued to the first step in order to start again in the line.

• No steps with AcceptFromRework before the station of origin

The harness is automatically queued to the first step in order to start again in the line.

• The first station with AcceptFromRework is the origin station

The harness is queued in the station of origin.

• There are one or more steps with AcceptFromRework before the origin station
The operator selects the step where he wants to return the harness.

At the end of this step, the harness should be either queued in a production step or rejected
(sent to scrap).

Rework in the station

In some projects it can be interesting to allow operators to rework the harnesses in the same
assembly/test stations for certain defects.

In this case, the Emdep KSK Rework Terminal can be invoked in test mode, allowing the operator
to record the detected defects and to repair them. In case of all defects are repaired in the
station:

• Dispatch station
The stage is closed as OK and, if the station is in the last stage, the harness is set to
TESTED.
• Other stations
The stage is closed as NOK and the operator(s) should repeat the assembly/test operator
in the current station to verify that all is correct.

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DATABASE SERVER

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Database server
Emdep KSK System uses a PostgreSQL database engine . Apart from being a very robust
solution, it is open source, so, it considerably reduces the cost of ownership for our customers.

Server requirements

Hardware
• Intel Core 2 Quad 2200 MHz
• 4GB RAM ECC 1066 MHz
• 200 GB of hard disk available space (using RAID5)

Software
• Microsoft Windows Server 2008 R2
• Microsoft .Net Framework 2 (3.5) and 4
• PostgreSQL 9.3.x or above

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Database configuration
Emdep KSK System uses PostgreSQL 9.3 database engine. Its configuration parameters are
defined in file postgresql.conf, which is normally kept in the data directory (by default,
c:\Program Files\PostgreSQL\9.3\data). The following values should be adjusted.

• max_connections
Determines the maximum number of concurrent connections to the database server.

• shared buffers
Sets the amount of memory the database server uses for shared memory buffers. The
default is typically 128 megabytes (128MB). However, settings significantly higher than
the minimum are usually needed for good performance. This parameter can only be set
at server start.

• temp_buffers
Sets the maximum number of temporary buffers used by each database session. These
are session-local buffers used only for access to temporary tables. The default is eight
megabytes (8MB). The setting can be changed within individual sessions, but only before
the first use of temporary tables within the session; subsequent attempts to change the
value will have no effect on that session.

• work_mem
Specifies the amount of memory to be used by internal sort operations and hash tables
before writing to temporary disk files. The value defaults to one megabyte (1MB). Note
that for a complex query, several sort or hash operations might be running in parallel;
each operation will be allowed to use as much memory as this value specifies before it
starts to write data into temporary files. Also, several running sessions could be doing
such operations concurrently. Therefore, the total memory used could be many times
the value of work_mem; it is necessary to keep this fact in mind when choosing the value.
Sort operations are used for ORDER BY, DISTINCT, and merge joins. Hash tables are used
in hash joins, hash-based aggregation, and hash-based processing of IN subqueries.

• maintenance_work_mem
Specifies the maximum amount of memory to be used by maintenance operations, such
as VACUUM, CREATE INDEX, and ALTER TABLE ADD FOREIGN KEY. It defaults to 16
megabytes (16MB). Since only one of these operations can be executed at a time by a
database session, and an installation normally doesn't have many of them running
concurrently, it's safe to set this value significantly larger than work_mem. Larger settings
might improve performance for vacuuming and for restoring database dumps.

For a standard configuration, the following values are recommended:

max_connections = 100
shared_buffers = 512MB
temp_buffers = 32MB
work_mem = 64MB
maintenance_work_mem = 256MB

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After modifying these values, PostgreSQL server must be restarted.

In chapter Server Configuration of PostgreSQL Documentation, a full description of available

parameters can be found.

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Database maintenance

Clean database
It is important to run VACUUM and ANALYZE commands on a regular basis for several reasons:

1. to recover or reuse disk space occupied by updated or deleted rows

2. to update data statistics used by the PostgreSQL query planner
3. to update the visibility map, which speeds up index-only scans
4. to protect against loss of very old data due to transaction ID wraparound or multixact
ID wraparound

PostgreSQL has an optional but highly recommended feature called autovacuum, whose
purpose is to automate the execution of VACUUM and ANALYZE commands. When enabled,
autovacuum checks for tables that have had a large number of inserted, updated or deleted
tuples. These checks use the statistics collection facility; therefore, autovacuum cannot be used
unless track_counts is set to true. In the default configuration, auto vacuuming is enabled and
the related configuration parameters are appropriately set.

This autovacuum is controlled by the variables in file postgresql.conf:

autovacuum = on
track_counts = on

In section Routine Vacuuming of chapter Routine Database Maintenance Tasks of PostgreSQL

Documentation, more details can be found.

Backup
It is important the creation of backup copies of the data on a regular schedule. Without a recent
backup, you have no chance of recovery after a catastrophe (disk failure, fire, mistakenly
dropping a critical table, etc.).

There are three fundamentally different approaches to backing up PostgreSQL data:

• SQL dump
• File system level backup
• Continuous archiving

Each has its own strengths and weaknesses.

Please, read carefully the chapter Backup and Restore of PostgreSQL Documentation to get
full understanding of each approach and choose the one that better fits on your organization.

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Backup automation using Windows Task Scheduler

The following solution is a simple backup solution that allows performing an automated backup
using a batch script, a configuration file and programming an automated task in Windows.

The following example shows how to backup two databases (DB1 and DB2, both using the
credentials dbuser/dbpass). The same solution can be applied to backup one or more databases.
In the example the folder c:\Emdep\KSK\DB is used to store all created files and the path
c:\Emdep\KSK\DB\Backup to store the backup files.

First step is to create the batch script (for example ksk_backup.bat):

@ECHO OFF

SET PGPASSFILE=c:\Emdep\KSK\DB\pgpass.conf

for /f "tokens=1-4 delims=/ " %%i in ("%date%") do (

set dow=%%i
set month=%%j
set day=%%k
set year=%%l
)
for /f "tokens=1-2 delims=: " %%i in ("%time%") do (
set hour=%%i
set minute=%%j
)
SET datestr=%year%%month%%day%_%hour%%minute%

SET DB1_BACKUP=DB1_%datestr%.backup
SET DB2_BACKUP=DB2_%datestr%.backup

echo BMPV database backup on progress.....

"c:\Program files\DB\9.3\bin\pg_dump.exe" -U dbuser –-file
c:\Emdep\KSK\DB\BACKUP\%DB1_BACKUP% -Fc -Z9 -o DB2

echo LR database backup on progress.....

"c:\Program files\DB\9.3\bin\pg_dump.exe" -U dbuser --file
c:\Emdep\KSK\DB\BACKUP\%DB2_BACKUP% -Fc -Z9 -o DB1

echo Task DONE!

timeout 5

This script needs a second configuration file used by the pg_dump.exe to get the database(s)
connection parameters and credentials:

localhost:5432:DB1:dbuser:dbpass
localhost:5432:DB2:dbuser:dbpass

The last step is to create a Windows automated task using Task Scheduler:

1. Open the Control Panel and select System and Maintenance → Administrative Tools and
double-click in Task Scheduler.
2. Find and click the task folder in the console tree that you want to create the task in. If
you want to create the task in a new task folder, see Create a New Task Folder to
create the folder.

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3. In the Actions Pane, click Create Task.

4. On the General tab of the Create Task dialog box, enter a name for the task. Fill in or
change any of the other properties on the General tab. For more information about
these properties, see General Task Properties .
5. On the Triggers tab of the Create Task dialog box, click the New… button to create a
trigger for the task, and supply information about the trigger in the New Trigger dialog
box. For more information about triggers, see Triggers .

6. On the Actions tab of the Create Task dialog box, click the New… button to create an
action for the task, and supply information about the action in the New Action dialog
box. For more information about actions, see Actions .

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7. (Optional) On the Conditions tab of the Create Task dialog box, supply conditions for
the task. For more information about the conditions, see Task Conditions .
8. (Optional) On the Settings tab of the Create Task dialog box, change the settings for
the task. For more information about the settings, see Task Settings .
9. Click the OK button on the Create Task dialog box.

Change database files’ location

Sometimes the organization has storage servers like NAS or other devices to store and backup
automatically the relevant data. PostgreSQL server can be configured to work in one computer
having the physical data files in other location. The following steps show how to change the
database physical files to another location.

1. Go to Windows Services console and stop the PostgreSQL service on the original
computer.

2. Using Windows Explorer, copy the PostgreSQL data folder (usually in C:\Program
Files\PostgreSQL\9.3\data) to the desired location into another computer or
network location.
3. After the folder copy, rename the original data folder to data_old (or something
similar).
4. Start the Windows Registry Editor and navigate to:
HKEY_LOCAL_MACHINE\SYSTEM\CurrentControlSet\Services\pgsql-some version

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5. Double click on the entry ImagePath and change the directory after the –D option to
new location. If the path to new location contains spaces, it should be enclosed with
quotes.
6. Re-open the Windows Services console. This refreshes the path just changed in the
previous step without the need to restart the system.
7. In the re-started Windows Services console, open the Properties dialogue for the
PostgreSQL service.
8. Check the field Path to executable. The path after –D option should be pointing to new
database files location.

9. Re-start the PostgreSQL service.

After the last step, the PostgreSQL database engine must be using the files in the new location.

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SERVICES

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Server Monitor
Emdep KSK System contains a couple of a Windows services responsible for orchestrating both
the stations and the interaction with the production systems of our customers.

The Emdep KSK Server Monitor allows to control and configure all running KSK services in a
unique and easy-to-use console. This software is available as standalone application (EXE) or as
a plug-in for Emdep KSK Studio.

The Emdep KSK Server Monitor allows to monitor the KSK services and all other services
needed. For example, monitoring the PostgreSQL service and other network services can be
useful to ensure all involved services are running without problems in server.

Managing services

Add new service to monitor

1. From Emdep KSK Server Monitor, press Add new service button located in the main
toolbar. The Service properties dialogue will be shown.

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2. Select the machine where the service is running: Local computer or another network
computer. To monitor services located on a network machine, the IT team must enable
the appropriate permissions .
3. Select the service.
4. If the service has an associated Windows LOG file, select it from Windows LOG drop-
box list. It not, select the No LOG available option.
5. Press Accept button to add the service in the monitor or Cancel to cancel the command.
The new service will appear in the left bar on the monitor main window.

Editing the properties of a monitored service

1. From the left vertical bar, press the Remove service button ( ) associated to the
service. The Service properties dialogue will be opened showing the service properties.
2. Change all settings needed.
3. Press Accept button to save the service properties or Cancel to cancel the command.

Remove a service from the monitor

1. From the left vertical bar, press the Edit properties button ( ) associated to the service.
The

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2. Press Yes to remove the service monitoring or No to cancel the command.

Monitoring services

Start/Stop a service
All monitored services show its status. The icon indicates that the service is running and
is used for the stopped services.

• Press Start button ( ) to start a stopped service.

• Press Stop button ( ) to stop a running service.

Showing the LOG for a service

All services with associated Windows LOG shows the button. Pressing the button, the LOG
will be shown on the main window.

While a LOG is shown all new entries will be appended to the end of list in real time (no refresh
is needed).
Double-clicking an entry will open the entry properties dialog, that shows all related data and
allows to copy the entire message to clipboard.

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Configuring KSK services

When a KSK service is included in the monitor, a new button will be shown in the service control.
Pressing the Service settings button ( ) will open the configuration dialogue for the selected
service.

Using option Use Pooling is recommended to increase performance.

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Orders Importer Service

The Emdep KSK Orders Import Service is responsible to import production orders from a couple
of sources and insert them into Emdep KSK System. Finally, for all orders a response can be sent
to production system to confirm if the orders are inserted or not and, in case of an error, which
problem has been generated.

Thanks to its modular architecture, new order’s loaders or confirmation modules can be added
to the service according to the needs of each project.

Upgrading from old Emdep KSK QSS1 Service

Before installing the latest version of the Emdep KSK Orders Importer Service in a server with
one or more working KSK projects, the following pre-requisites should be taken in consideration:

• The KSK database schema must be 1.15 or higher due to support the Q-Level field. If the
schema is lower than version 1.15, the service will generate errors and cannot work.

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• The QSS1/SAP task uses SAP GUI library wrappers that are incompatible with other
wrappers used in some KSK products released before year 2014 (the COM/ActiveX
technology does not allow to have two different versions of a library with different
interface). The affected products by this incompatibility are:
o Emdep KSK QSS1 Service
o Emdep KSK SAP Service
To allow old versions of these services to continue working, the easiest and best solution
is to install the Emdep KSK Orders Importer Service in another server.

Supported scenarios

QSS1 / SAP orders importer module

This module works as follow:

1. Read all QSS1 files available in the specified incoming folder (see the format in section
QSS1 file format).
2. Load all orders from all files (one file can contain more than one order).
3. For each loaded order, check its contents and act as follows:
a. If the order is OK (no errors found):
i. The order is inserted in the specified KSK project with status
IMPORTING_QSS1.
ii. A QSSE file is generated (see the format in section QSSE file format) with
only K0 segment (no errors found).
iii. The QSSE file is sent to SAP.
b. If the order is NOK (errors found):
i. A QSSE file is generated with K0 segment and segments P1/P2
corresponding to the modules/wires with errors.
ii. The QSSE file is sent to SAP.
4. End the import process (until next task execution cycle).

This module uses SAP GUI version 7.10 for Windows and must be installed from the official
SAP installer (it is not contained in the setup package). SAP GUI version 7.4 is also supported,
but not 7.5, where some changes in RPC interface has been done.

This task communicates directly with SAP through the SAP GUI. Section Logging SAP
communications describes how to activate the LOGs.

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Configuration
It is possible to graphically configure the service from the Emdep KSK Server Monitor (review
the section Configuring KSK services).

1. Open the graphical configuration from Emdep KSK Server Monitor. The main dialogue
will be shown.

2. Set the connection data to KSK database which contains the KSK project.
3. Press Check connection to ensure that the connection is available and to refresh the
projects list.
4. Select the KSK project where the orders will be inserted.
5. Select the Service tasks tab page.

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6. All service-controlled tasks will be shown in the main list. To add a new pre-compilation
task, select the Standard precompiler task from New task drop-box list.

7. Bring a name to the service task. When it is possible, we recommend using a name based
on the production system name to avoid confusions.
8. From Execution properties group, choose the controller execution type. The typical
execution is Cyclically using between 1 to 5 mins, it depends on the quantity (or length)
of orders that can be processed each cycle of execution.
9. Select the Settings tab page.
10. Specify the settings required for each controller (the following sections contains the
specific settings for each controller described).
11. Press OK to enable the new orders importer task or Cancel to cancel the command.
12. In Logging tab page, configure the LOGs (review the section Configuring service LOGs).
13. Press OK to write all settings to the configuration file or Cancel to cancel the operation.

Adding a QSS1 / SAP orders importer task

1. From Service tasks tab page, select the QSS1 / SAP orders importer command from
New task drop-down menu. The QSS1 / SAP orders import task properties dialogue will
be shown.
2. Configure the execution of the task as described in the previous section.
3. Select the Settings tab page.

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4. Specify the Incoming path (where the QSS1 files will be inserted by SAP) and the Backup
path (where the processed QSS1 files will be copied for traceability reasons).
5. Since version 2.7.0 there is an option to adapt backup input file to be used in GTI
Assembly Orders Generator. If this option is checked, instead of creating a folder
hierarchy with year, month and day, just one folder will be created using format
YYYY_M. Also, generated file name will be in format YYYY_MM_DD_HH_mm_SS.txt.
Please be aware that to use this option, original input file name must follow the format
YYYYMMDD_HHmmSS_xxxxxxx (where xxxxxxx can be anything).
6. Specify the file format. Default is 1, but 2 can be selected if we need to use QSS1 BMW
Legacy format, which has no QLevels for modules and defines multiple modules in a
single P1 segment.
7. Specify whether module PartNumber should be translated using Equivalence table. This
equivalence table can be defined in KSK Studio.
8. Specify if empty modules should be created when the module in P1 segment is not found
in KSK database. This option is useful when P2 segment is not in QSS1 (or it is specified
to be ignored) and the modules must be created by this service instead of being created
from KSK Studio (either manually or by importing from a DSI, KBL or PRG file).
Additionally, specifying this option will enforce the harness to be created in Waiting
status instead of being created in Importing status, so no precompilation is required (as
it also happens when specifying file format 2).
9. Specify the segments in QSS1 that must be ignored. If more than one segment have to
be ignored, separate them by using a semicolon. Leave this field empty if all segments
must be processed.

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10. Select the Output (SAP) settings tab page.

11. Fill SAP system fields needed to connect to SAP system. The button Check connection
can be used to check if the connection can be stablished with SAP.
12. Enable the QSSE confirmations backup needed (database and/or file). The QSSE
backups are specially interesting during the startup period of a project due to have an
extra confirmation of possible errors.
13. Select the GTI settings tab page.
14. If segments P3 and P4 of QSS1 files must be used as new orders for GTI, enable the Send
assembly data to GTI system checkbox and provide a valid connection data to GTI
Manager database.
Use the Check connection button to verify if connect to GTI database is possible with
provided data.
15. Press OK to enable the new orders import task or Cancel to cancel the command.
IMPORTANT: If SAP must not be used and manual files must be used instead, add this on
settings.xml file. Since version 2.7.0, this option can be added unchecking option “Send feedback
to SAP”.

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Since version 2.3.0, there is the possibility to specify some extra parameters on QSS1 definition

Using those extra parameters is not mandatory. They will be used only if checkbox “Qss1
Validation Code Enabled” is checked.

When using those extra parameters, a file path must be specified. The extra parameters will be
stored in XML format on that file.

Both the starting position and the length in where sequence and steering are located in QSS1
file must be defined.

Additionaly, some valid codes for this sequence number and steering must be specified and
added to the list. A minimum of one entry in the list must be added. For each order that match
the Sequence number and steering, a prefix and suffix can be specified. This prefix and suffix will
be added to the order number in QSS1 file before being added to the system.

When “Qss1 Valication Code Enabled” checkbox is checked, only those orders that matches
the defined sequence number and steering will be imported. However, if checkbox is disabled,
all orders will be added (it will work as previous versions).

Troubleshooting
If connecting to SAP error appears when service tries to send signals to SAP, install SAP GUI client
7.4.

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PPSORD Orders Importer Service

The Emdep KSK PPSORD Import Service is responsible to import assignations between orders
and workcenters. This information will come from a PPSORD file and will be inserted into Emdep
KSK System.

Normally orders will be created by QSS1 Orders Importer service, which will be running in
parallel, but if when running PPSORD Importer service the order still does not exist, it will be
created. However, workcenters contained in PPSORD file must exist. If when importing a
PPSORD a non-existing workcenter is found, this service will generate an error.

Once a PPSORD file has been processed, it will be moved to the output folder OK or Error,
depending on if some errors has been found or not.

PPSORD file format

A PPSORD file is a CSV file containing a KO segment and several MO1 segments. An example of
PPSORD file can be found in the below image:

As it can be seen, KO segment contains the order with “A” prefix, e.g: 0004595085IL17. In the
second column from MO1 segments, the workcenters are defined (e.g: 3003B850)

The rest of the columns will be ignored by this importation process.

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Configuration

The process to configure this service is similar to the process of configuring other KSK services.

The incoming path, and the two output paths (one for files processed without errors, and one
for files processed with errors) can be configured in the settings tab inside the task properties:

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KSK File Orders Importer Service

The Emdep KSK File Orders Import Service is responsible to import production orders from a
.ksk file and insert them into Emdep KSK System. It works in a similar way than Emdep Orders
Importer Service, but instead of QSS1 files, .ksk files are used as input files. Once a .ksk file has
been processed, it will be moved to the backup folder.

This service generates .ok files and .ng files. Both files are intended to give feedback to the
system that generates the .ksk file (such as an SAP system). When an order has been imported
and precompiled without any error, then the .ok file is generated. When the file has some issues,
such as some of the modules does not exist in the KSK system, then a .ng file is generated.

The imported harnesses will be added in a queue. Each line contains a different queue.

Format of .ksk files

.ksk files contains a first line with the order number (order name) and next lines with the
modules. Only one harness can be in a .ksk file. The format will be like this:

H;name of order
M;module 1;revision
M;module 2;revision
M;module 3;revision

Any empty line contained in the file will be ignored.

The file will be encoded using UTF-8 with no BOM. The name of the file will be
<order>.<timestamp in format yyyyMMdd_HHmmSS>.ksk

For example, for order 1234567 generated on 30 August 2021 at 9:15:41, name will be
1234567.20210830_091541.ksk

Format of .ok files

The generated files after an order is successfully imported and precompiled, will be named as
the corresponding .ksk file (with same order and same timestamp) but using extension .ok
instead of .ksk. For example, for the file 1234567.20210830_091541.ksk the .ok file will
be 1234567.20210830_091541.ok

This file will contain just two lines:

• First line with the time when order was processed, in format yyyy/MM/dd HH:mm:SS
• Second line with the name of the order as specified in .ksk file, with the prefix H;

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The contents of the file are encoded using UTF-8 with no BOM.

An example of this file could be:

2021/08/30 10:06:15
H;7654321

Format of .ng files

The generated files after order is not correctly imported, will be named as the corresponding
.ksk file (with same order and same timestamp) but using extension .ng instead of .ksk. For
example, for the file 1234567.20210830_091541.ksk the .ok file will be
1234567.20210830_091541.ng

Contents of this file will be:

• First line with the time when order was processed, in format yyyy/MM/dd HH:mm:SS
• Second line with the name of the order as specified in .ksk file, with the prefix H;
• Next lines with each module that has problems. The format for each of these lines will
be: M;modulePN;revision;errorCode;errorDescription

The contents of the file are encoded using UTF-8 with no BOM.

An example of this file could be:

2021/08/30 10:06:15
H;7654321
M;FM00001;01;001;ERROR: Customer module not found
M;FM00002;01;001;ERROR: Customer module not found
M;FM00003;01;001;ERROR: Customer module not found
M;FM00004;01;001;ERROR: Customer module not found
M;FM00005;01;001;ERROR: Customer module not found

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Configuration
It is possible to graphically configure the service from the Emdep KSK Server Monitor (review
the section Configuring KSK services).

14. Open the graphical configuration from Emdep KSK Server Monitor. The main dialogue
will be shown.
15. Set the connection data to KSK database which contains the KSK project.

16. Press Check connection to ensure that the connection is available and to refresh the
projects list.
17. Select the KSK project where the orders will be inserted.
18. Select the Service tasks tab page.

19. All service-controlled tasks will be shown in the main list. To add a new KSK File Orders
Importer task, select the KSK File orders Importer task from New task drop-box list.

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20. Bring a name to the service task. When it is possible, we recommend using a name based
on the production system name to avoid confusions.
21. From Execution properties group, choose the controller execution type. The typical
execution is Cyclically using between 1 to 5 mins, it depends on the quantity (or length)
of orders that can be processed each cycle of execution.
22. Select the Settings tab page.
23. Specify the settings related to Input files (.ksk files):

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24. Specify the settings for Output tab (.ok and .ng files):

25. Specify the settings for the Harness Queue: select the line where the harnesses must be
enqueued. If harnesses must be enqueued in several lines, several services must be
created.

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26. Finally, press OK to enable the new Ksk File orders importer task or Cancel to cancel the
command.
27. In Logging tab page, configure the LOGs (review the section Configuring service LOGs).
28. Press OK to write all settings to the configuration file or Cancel to cancel the operation.

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Precompiler Service
The Emdep KSK Precompiler Service is responsible to pre-compile the imported production
orders. The pre-compilation action generates generic HNS files (used by electrical test boards to
perform a test) for all modules contained in the harness. Later, in the station, these files are
used to compile the harness for specific components tested in the test table.

Configuration
It is possible to graphically configure the service from the Emdep KSK Server Monitor (review
the section Configuring KSK services).

1. Open the graphical configuration from Emdep KSK Server Monitor. The main dialogue
will be shown.

2. Set the connection data to KSK database which contains the KSK project.
3. Press Check connection to ensure that the connection is available and to refresh the
projects list.
4. Select the KSK project where the station(s) to control are contained.
5. Select the Service tasks tab page.

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6. All service controlled tasks will be shown in the main list. To add a new pre-compilation
task, select the Standard precompiler task from New task drop-box list.

7. Bring a name to the service task.

8. From Execution properties group, choose the controller execution type. The typical
execution is Cyclically using between 1 to 5 mins, it depends on the quantity of orders
that can be processed each cycle of execution.
9. Select the format of the file generated by Schunk Station (sync file). Standard is 1, but
since version 2.2.0 a format 2 has been added which includes also the start time.
10. Select the Settings tab page.

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11. In field Precompiled orders folder, specify the output path where the generated HNS
files from precompiler will be placed.
12. Set a database command execution timeout. This timeout is used to avoid blocking the
service in case to a high demand on database. The value is specified in seconds and 0
means infinite waiting time (disabled timeout).
13. Set the number of precompilation trials (activated in case of an error during the
precompilation process, usually due to a database timeout or to an order without
modules).
14. Check box should check if we want to generate the files for third-party Tightening
Station.
15. In field Precompiled orders third-party stations folder, specify the output path where the
generated tightening data files(.tqe) from precompiler will be placed which is for third-
party tightening station.
16. Format of .tqe file (OrderName; WireName; From Connector Name, From Connector
Part Number; To Connector Name, To Connector Part Number) like
ORD_1;SBF35A_A;C3BF01-C;7009721802;C1B101-B;7189285830
ORD_1;SBF16_A;C3BF01-D;7009710302;C3DF02-B;7009531602
17. Press OK to enable the new precompiler task or Cancel to cancel the command.
18. In Logging tab page, configure the LOGs (review the section Configuring service LOGs).
19. Press OK to write all settings to the configuration file or Cancel to cancel the operation.

Only one precompiler task can be enabled in the same instance of a service. If two projects
need the precompiler service, it is necessary to create two instances (install two times the
service) and configure two separated tasks, one per instance.

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External Equipment Service

The Emdep KSK External Equipment Service is responsible to synchronize third party equipment
(not EMDEP) through the assembly/test lines. Using this service is possible add non Emdep
equipment maintaining the sequentially of the lines.

The Emdep KSK External Equipment Service is a replacement for the old Emdep KSK Schunk
Service, so the both versions cannot be used working together!

Working modes
The service could work in two different modes to fit the different production needs.

Normal mode
This working mode assume that the station is a single station and the goods should pass through
the external equipment in sequential order. Using this working mode, the external equipment
can be placed in first position.

Integrated mode
This working mode assume that the station is integrated with the previous station in the line. It
means that orders can be processed by the service before or after the previous station has been
processes indistinctly.

Rules to work in integrated mode:

• The external equipment always must be placed behind the station where it is integrated
• The external equipment cannot be placed in first position in the line
• The previous stage cannot be optional.

If the rules are not met, the service will generate an error during the processing of the orders.

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Parallel mode
Since version 2.1.0, when a Schunk station is in the same step of another station which is a
different type, such as tightening, then a harness can be processed on that Schunk station not
only if its planned step is current step, but also if it is a previous one.

This means that in the configuration above, where Schunk is working in parallel in step 4, it will
be able to process any harness that is in step 1, 2, 3 or 4 (and also harnesses in waiting status).

From Version 2.5.0 : Schunk station can be allow to process in step 1 in parallel with Other
station. If Order is in process it will process in same line and it is in waiting then it will follow the
assign the line as define in setting file.

Supported equipment

Schunk equipment
The equipment of Schunk company generate a unique file where
all OK orders are appended (no information about NOK orders are

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provided by equipment). See the section Schunk synchronization file (SEQOK) for more detailed
information on the file format.

When the Schunk control task is executed, the synchronization file is renamed to avoid adding
new orders during the process. The renamed file is loaded and for each order:

• Schunk station in first line step:

1. Get the appropriate assembly/test line using the line assignment rules.
2. Change the order status to INPROCESS.
3. Open/Close stage for the Schunk station.
4. Queue the order into the next step available in the line.

• Schunk station in middle step of the line:

1. Open/Close stage for the Schunk station.
2. Queue the order into the next step available in the line.

• Schunk station is at the end of the line:

1. Open/Close stage for the Schunk station.
2. Change the order status to TESTED.

Finally, the processed file is moved to the backup folder for traceability reasons.

The Schunk controller supports an optional previous stage. In the optional previous stage is the
first stage, the line assignment rules must be configured to assign the processed order in the
appropriate line.

Errors that occur during the processing of an order are reported using the activated LOGs.
Additionally, for each station a file is generated (in the installation folder) and a line is appended
with the order, a timestamp and the description of the error.

Using SCHUNK equipment with single SCHUNK OK file

In certain projects, multiple SCHUNK equipment are generating a single SEQOK file. In this case,
the layout should be configured using the following premises:

• All SCHUNK equipment should have the same name (identical for all lines).
• All SCHUNK equipment should be included in the same stage (same order in line).

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If any of these premises cannot be met, then it will be necessary to create one Schunk service
task per machine and then, process SEQOK files separately.

Hennecke equipment
The equipment of Hennecke company generate
one file for each processed order (only OK
orders). See the section Hennecke
synchronization file for more detailed information on the file format.

When the Hennecke control task is executed, all available files generated by the equipment are
renamed to be locked during the process. For each blocked file the order number is obtained,
and the order process starts:

• Hennecke station in first line step:

1. Get the appropriate assembly/test line using the line assignment rules.
2. Change the order status to INPROCESS.
3. Open/Close stage for the Schunk station.
4. Queue the order into the next step available in the line.

• Hennecke station in middle step of the line:

1. Open/Close stage for the Schunk station.
2. Queue the order into the next step available in the line.

• Hennecke station is at the end of the line:

1. Open/Close stage for the Schunk station.
2. Change the order status to TESTED.

Finally, all processed files are moved to the backup folder for traceability reasons.

Errors that occur during the processing of an order are reported using the activated LOGs.

Generic equipment
Emdep has developed a generic controller and can be used to synchronize equipment when it is
possible to configure it to cover the specifications (or develop a software capable to generate
compatible files).

This controller supports both OK and NOK signals. Each order signal corresponds to a file placed
in a folder (one for OK signals and another for NOK signals). The name for these files (excluding
the extension) must be the order number.

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When the generic control task is executed, all available files generated by the equipment are
renamed to be locked during the process. For each blocked file the order number is obtained,
and the order process starts:

• Generic external station in first line step:

1. Get the appropriate assembly/test line using the line assignment rules1.
2. Change the order status to INPROCESS.
3. Open/Close stage for the Schunk station.
4. Queue the order into the next step available in the line.

• Generic external station in middle step of the line:

1. Open/Close stage for the Schunk station.
2. Queue the order into the next step available in the line.

• Generic external station is at the end of the line:

1. Open/Close stage for the Schunk station.
2. Change the order status to TESTED.

For the NOK orders, a stage is performed with NOK result, so the order remains in the same
equipment.

POP equipment
Basically, this system is the same as the generic equipment but without using the line assignment
rules and it is designed specifically to be used in equipment that is placed at first position on the
assembly/test lines.

1
The generic control only has the order number, so the line assignment rules only can be set using that
information. If the order is not enough to determine the line where the order must be assigned, the POP
controller should be used instead.

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Each POP station will generate one file per order when its process finish (as OK), and each station
must have its own incoming folder. When a new file is generated, the controller places the
harness order in the mapped line and queue it the specified next station.

Third-Party Tightening equipment

Emdep has developed a controller and can be used to synchronize the third-party tightening
equipment using feedback files generated by those stations.

Each third-party tightening station will generate one file per order when its process finish, When
a new file is generated,

This controller supports both OK and NOK signals using Status, The name for these files
(excluding the extension) must be the order number. Like (123456.st)

the controller takes the harness order and do the transaction according to status of it is OK
controller close the stage and send to next station if Other than OK, it close the stage with NOK
and keep it in current station.

Format of the Feedback file

123456 (Order Number)

50-02_BT01 (Station)
OK (Status OK/NOK)
23.08.2022 08:05 (End time)

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Configuration
It is possible to graphically configure the service from the Emdep KSK Server Monitor (review
the section Configuring KSK services).

1. Open the graphical configuration from Emdep KSK Server Monitor. The main dialogue
will be shown.

2. Set the connection data to KSK database which contains the KSK project.
3. Press Check connection to ensure that the connection is available and to refresh the
projects list.
4. Select the KSK project where the station(s) to control are contained.
5. Select the Service tasks tab page.

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6. Each task added is to control one external station2. To add a new station, select the
station type wanted from New station drop-box list (next sections explain how to
configure specific settings for all types of external equipment).

7. Bring a name to the service task. When it is possible, we recommend using a name based
on the station name to avoid confusions.
8. From Execution properties, choose the controller execution type. The typical execution
is Cyclically using between 1 to 5 mins, it depends on the quantity of orders that can be
processed each cycle of execution.
9. Specify the settings required for each controller (see next section).
10. Press OK to enable the new station controller or Cancel to cancel the command.
11. In Line assignments tab page, configure the rules to cover all assembly/test lines (review
the Line assignment rules to learn how the service select the appropriate line for each
order).
12. In Logging tab page, configure the LOGs (review the section Configuring service LOGs).
13. Press OK to write all settings to the configuration file or Cancel to cancel the operation.

Adding a Schunk equipment control task

1. From Service tasks tab page, select the Schunk station command from New station
drop-down menu. The Schunk external station properties dialogue will be shown.
2. Configure the execution of the task as described in the previous section.
3. Select the Settings tab page.

2
Except equipment controlled by POP files. This task allows configure multiple stations per task.

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4. Specify the Station name. It must match to the station name to be controlled by the
new task.
5. If the SCHUNK station(s) should work integrated with the previous station(s) in the line,
the Integrated mode check box should be checked.
6. Select the Synchronization file. This file is generated by Schunk equipment and
containing all processed orders (only OK orders).
7. Specify the Backup path, where all processed files will be copied for traceability reasons.
8. Press OK to create the new control task or Cancel to cancel the command.

If the Schunk equipment is located at first position in the assembly/test line, the line
assignment rules must be configured so that the orders can be placed on the correct line.

Adding a Hennecke equipment control task

1. From Service tasks tab page, select the Hennecke station command from New station
drop-down menu. The Schunk external station properties dialogue will be shown.
2. Configure the execution of the task as described in the previous section.
3. Select the Settings tab page.

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4. Specify the Station name. It must match to the station name to be controlled by the
new task.
5. Select the Incoming path where the Hennecke equipment is generating the
synchronization files.
6. Specify the extension used by the generated files in field Incoming file extension
(without dot).
7. Select the Backup path where the processed files will be copied for traceability reasons.
8. Press OK to create the new control task or Cancel to cancel the command.

If the Hennecke equipment is located at first position in the assembly/test line, the line
assignment rules must be configured so that the orders can be placed on the correct line.

Adding a POP equipment control task

1. From Service tasks tab page, select the POP station command from New station drop-
down menu. The POP external station properties dialogue will be shown.
2. Configure the execution of the task as described in the previous section.
3. Select the Settings tab page.

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4. Press Add button ( ) to create a map a new POP station. The POP station mapping
properties dialogue will be shown.

5. Select the assembly/test line from Line drop-down list.

6. Select the next station from Station drop-down list. Next station is where the harness
will be placed when the OK signal is received from POP equipment.
7. Specify the Path to incoming files, where the equipment will generate the
synchronization files.
8. Press OK to create the station mapping or Cancel to cancel the command.
9. Repeat steps 4 to 8 for each POP station.
10. Press OK to create the new control task or Cancel to cancel the command.

Adding a Third-party Tightening equipment control task

1. From Service tasks tab page, select the Third-Party Tightening Station command from
New station drop-down menu. The Third-party Tightening station properties dialogue
will be shown.
2. Configure the execution of the task as described in the previous section.
3. Select the Settings tab page.

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4. Select the Path to incoming files, where the equipment will generate the
synchronization files.
5. Specify the extension of the file.(like .st)
6. Select the Path for the backup file. (After process file move to this folder)
7. Press OK to create the new control task or Cancel to cancel the command.

Line assignment rules

The line assignments must be configured if one or more station controllers are in the first step
of assembly/test line(s)3. These rules describe which line must be selected for a confirmed order
in an external equipment.

1. From the main configuration dialogue, select the Line assignments tab page.

3
POP controller doesn’t use the line assignment rules. In this case, it is not necessary to be configured.

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2. Press Add assignment button ( ) to create a new rule. The Action properties dialogue
will be shown.

3. Select the trigger type and specify the expression to be evaluated.

4. Press OK to create the rule or Cancel to cancel the command.
5. Repeat steps 2 to 4 for all rules needed to cover all lines.
6. In the main setting dialogue, press OK to save the configuration or Cancel to cancel the
command.

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Synchronization Service4
The Emdep KSK Synchronization Service is used to send feedback to production systems like
SAP, LEPS or others. The feedback can be:

• Orders successfully imported: Currently this is sent by Orders Importer service

• Orders that cannot be imported: Currently this is sent by Orders Importer service
• Harness status changes
• Harness movements in the lines/stations (including movement to Rework)
• Module validation information (using module validation stations)

All information generated by stations and harnesses is stored temporally in a queue and this
service is responsible to centralize all communications with the production system allowing to
have updated all the states of the orders sent to production.

Supported systems
As all KSK server services, the Emdep KSK Synchronization Service is designed to be a modular
container, allowing to add new control modules to cover all needs.

SAP
One of the most popular business suites is SAP and many harness manufacturers has its
production system based on this system. This module uses SAP GUI version 7.10 for Windows
and must be installed from the official SAP installer (it is not contained in the setup package).
SAP GUI version 7.4 is also supported, but not 7.5, where some changes in RPC interface has
been done.

When the SAP system is used to synchronize the KSK system actions, an OK/NOK signal will be
sent when an order finish in each step of the lines. The default action codes sent are:

Station type SAP action

Electrical YETF
Vision (fuses) YFTF
Clips YCTF
Bolt / Tightening YBTF
Welding YWEF
Rework YRFD

Those codes are configurable using DefaultSyncAction field on TypeStation table in Emdep KSK
database. Additionaly, a code can be configured for a specific station filling field SyncActionCode
field on Station table in Emdep KSK database. This is especially useful when production lines
have multiple steps of the same type, meaning that it is possible to change the SAP action code

4
This service is equivalent to Emdep KSK SAP Service.

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for certain steps to be able to differentiate the steps into SAP. For security reasons, this code is
shown in station properties in Emdep KSK Studio (Layout designer plug-in), but cannot be
edited. The only way to set this value is setting it directly in database.

Additionally, since version 2.8.0, the feedback from SAP is taken into consideration to allow
WarehouseToRework application know if SAP signal has been sent successfully by using harness
status. When WarehouseToRework generates signal YRSD, harness is put to a new status called
WarehouseToProduction. When Sync service found an YRSD signal whose harness is in
WarehouseToProduction status, it behaves like this:

1. If SAP feedback is OK, then harness status is changed to InProcess

2. If SAP feedback is NOK, then harness status is changed back to Tested and next expected
station (which was rework) is removed (so that this harness is not expected on any
station).

Upgrading from old Emdep KSK SAP Service

Before to install the latest version of the Emdep KSK Orders Importer Service in a server with
one or more working KSK projects, the following pre-requisites should be taken in consideration:

• The KSK database schema must be 1.15 or higher due to support the Q-Level field. If the
schema is lower than version 1.15, the service will generate errors and cannot work.

• The QSS1/SAP task uses SAP GUI library wrappers that are incompatible with other
wrappers used in some KSK products released before year 2014 (the COM/ActiveX
technology does not allow to have two different versions of a library with different
interface). The affected products by this incompatibility are:
o Emdep KSK QSS1 Service
o Emdep KSK SAP Service

To allow old versions of these services continue working, the easiest and best solution
is to install the Emdep KSK Orders Importer Service in another server.

Configuration
It is possible to graphically configure the service from the Emdep KSK Server Monitor (review
the section Configuring KSK services).

1. Open the graphical configuration from Emdep KSK Server Monitor. The main dialogue
will be shown.

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2. Set the connection data to KSK database which contains the KSK project.
3. Press Check connection to ensure that the connection is available and to refresh the
projects list.
4. Select the Service tasks tab page. The service tasks will be listed in the list. Each task
added is to synchronize one production system.

5. To add a new sync module, select the system type from New task drop-box list.

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6. Bring a name to the service task. When it is possible, we recommend using a name based
on the system to avoid confusions.
7. From Execution properties, choose the controller execution type. The typical execution
is Cyclically using between 1 to 5 mins, it depends on the quantity of orders that can be
processed each cycle of execution.
8. Specify the settings required for each controller (check next sections to find the settings
required for each type of module).
9. Press OK to enable the new controller or Cancel to cancel the command.
10. In Logging tab page, configure the LOGs (review the section Configuring service LOGs).
11. Press OK to write all settings to the configuration file or Cancel to cancel the operation.

Adding an SAP production system synchronization task

1. From Service tasks tab page, select the SAP system command from New task drop-
down menu. The SAP synchronization task properties dialogue will be shown.
2. Configure the execution of the task as described in the previous section.
3. Select the Settings tab page.

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4. Provide all common SAP connection parameters and check if the connection can be
stablished by clicking Check connection button.
5. Specify the maximum number of attempts for the rejected signals.
Each rejected signal is attempted to be resent after a few minutes, as many times as
specified with this parameter.
6. Press OK to create the new control task or Cancel to cancel the command.

Logging SAP communications

When SAP synchronization task is enabled, it is possible to LOG all communications between
Emdep KSK Synchronization Service and SAP through the SAP GUI. To enable the LOGs for
communications, follow these steps:

1. Go to folder where resides the Emdep.KSK.Comm.SAPGUI.dll library.

This library is included in both Emdep KSK Synchronization Service and Emdep KSK
Orders Importer Service, so if both services are installed, and both services are working
with SAP, it is necessary to know which KSKFuncSAP.dll is registered in Windows COM+
system. To know the path, a utility like RegDllView utility can be used.
2. Create an empty file called debug.txt.
3. The library starts immediately to write LOG information in the file logEmdep.txt.

Troubleshooting
If connecting to SAP error appears when service tries to send signals to SAP, install SAP GUI client
7.4.

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Txt SAP Generator Service

The Emdep Txt SAP Generator Service is used to send feedback to production systems like SAP,
LEPS or others using txt files.

The format of those files is specified in file TxtSapCommunication_SPECS_EN_vX.x.pdf (where

X.x is the version of the document).

The feedback can be:

• Production module completed

• Functional module completed
• Assembly completed
• Harness passed successfully in a station
• Harness completed

All that information generated about production modules, stations and harnesses is stored
temporally in a queue and this service is responsible to centralize all communications with the
production system allowing to have updated all the states of the orders sent to production.

Supported systems
Any system that is able to process these generated text files are suitable to be supported.

Configuration
It is possible to graphically configure the service from the Emdep KSK Server Monitor (review
the section Configuring KSK services).

1. Open the graphical configuration from Emdep KSK Server Monitor. The main dialogue
will be shown.

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2. Set the connection data to KSK database which contains the KSK project.
3. Press Check connection to ensure that the connection is available and to refresh the
projects list.
4. Select the Service tasks tab page. The service tasks will be listed in the list. Each task
added is to synchronize one production system.

5. To add a new ksk sap generator module, select the system type FO confirmation task
from New task drop-box list.

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6. Bring a name to the service task. When it is possible, we recommend using a name based
on the system to avoid confusions.
7. From Execution properties, choose the controller execution type. The typical execution
is Cyclically using between 1 to 5 mins, it depends on the quantity of orders that can be
processed each cycle of execution. It is possible to configure to be executed after a
number of seconds instead of minutes. In the example, 20 seconds has been set:

8. Specify the settings required for each controller (check next sections to find the settings
required for each type of module).
9. Press OK to enable the new controller or Cancel to cancel the command.
10. In Logging tab page, configure the LOGs (review the section Configuring service LOGs).
11. Press OK to write all settings to the configuration file or Cancel to cancel the operation.

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Select the folders where files should be generated

7. Select the Settings tab page.
8. Set the folders for each type of file that will be generated. Same folder can be configured
for more than one type.

9. Provide all common SAP connection parameters and check if the connection can be
stablished by clicking Check connection button.
10. Press OK to create the new control task or Cancel to cancel the command.

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Schunk Generator Service

The Emdep KSK Schunk Generator Service is a Windows Service used to generate input files for
Schunk, according to specification of the file in document titled Schunk Ultraschalltechnik GmbH.

This file will be read by Schunk Sequencer, which will interact with Schunk machines to weld
wires according to the data sent by files.

Files will be generated in a preconfigured folder.

Configuration
It is possible to graphically configure the service from the Emdep KSK Server Monitor (review
the section Configuring KSK services).

1. Open the graphical configuration from Emdep KSK Server Monitor. The main dialogue
will be shown.

2. Set the connection data to KSK database which contains the KSK project.
3. Press Check connection to ensure that the connection is available and to refresh the
projects list.
4. Select the Service tasks tab page. The service tasks will be listed in the list. Each task
added is to synchronize one production system.

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5. To add a new ksk Schunk generator module, select the system type Schunk Generator
task from New task drop-box list.
6. Bring a name to the service task. When it is possible, we recommend using a name based
on the system to avoid confusions.
7. From Execution properties, choose the controller execution type. The typical execution
is Cyclically using between 1 to 5 mins, it depends on the quantity of orders that can be
processed each cycle of execution. It is possible to configure to be executed after a
number of seconds instead of minutes. In the example, 20 seconds has been set:

8. Specify the settings required for this task. In this case, specification of the folder where
the Schunk input files will be generated must be specified also set the number of
characters for wire field in the generated file.

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9. Press OK to enable the new task or Cancel to cancel the command.

10. In Logging tab page, configure the LOGs (review the section Configuring service LOGs).
11. Press OK to write all settings to the configuration file or Cancel to cancel the operation.

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Reports Service
The Emdep KSK Reports Service can generate different types of reports, depending on the final
requirements. Thanks to its modular architecture, new reports can be easily developed
according to the needs of each project.

Built-in reports
As all KSK server services, the Emdep KSK Reports Service is designed to be a modular container,
allowing to add new reporting modules to cover all needs.

Daily report
This report generates a file containing all harness movements in last 24h. The report is generated
in a CSV format (using TAB instead comma).

Shift report
This report generates a file containing all harness movements per shift. The report is generated
in a CSV format (using TAB instead comma).

SQL report
This report generates a file containing the data resulting of a SQL query execution. The report is
generated in a CSV format, using a configurable separator.

It allows to create powerful reports using standard SQL or using views created using standard
SQL or pgScript which allows create extremely complicated queries and data analysis.

Configuration
It is possible to graphically configure the service from the Emdep KSK Server Monitor (review
the section Configuring KSK services).

1. Open the graphical configuration from Emdep KSK Server Monitor. The main dialogue
will be shown.

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2. Set the connection data to KSK database which contains the KSK project.
3. Press Check connection to ensure that the connection is available and to refresh the
projects list.
4. In Project field, select the KSK project from the list.
5. Select the Service tasks tab page. The service tasks will be listed in the list. Each task
added is to synchronize one production system.

6. Add a report from the New task drop-down list.

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7. Bring a name to the task. When it is possible, we recommend using a name based on
the type of report to avoid confusions.
8. From Execution properties, choose the controller execution type. The typical execution
is Cyclically depending on the required generation frequency and the type of report.
9. Specify the settings required for each controller (check next sections to find the settings
required for each type of module).
10. Press OK to enable the new controller or Cancel to cancel the command.
11. In Logging tab page, configure the LOGs (review the section Configuring service LOGs).
12. Press OK to write all settings to the configuration file or Cancel to cancel the operation.

Adding SQL report task

11. From Service tasks tab page, select the SQL report command from New task drop-down
menu. The SQL report task properties dialogue will be shown.
12. Configure the execution of the task as described in the previous section.
13. Select the Settings tab page.

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14. In field Generated reports output folder, specify the output folder for the generated
reports. The name used to generate the reports is:
<report_name>_YYYYMMDDHHMMSS
…with the appropriate file extension depending on the selected format.
15. In field Output format select the desired output format (CVS or Excel5).
16. The Database commands timeout field should contain the maximum number of second
that a query can wait for the results (zero means infinite seconds). By default, this value
is set to 30 seconds.
17. The SQL query must be typed in SQL query text area. For complex or large data queries
Emdep recommend creating a view in database due to optimize the execution inside the
database engine). Use the pgAdmin tool to create and verify SQL queries.
18. Press Check query to execute the SQL query and verify is working as expected.
19. Press OK to create the new reporting task or Cancel to cancel the command.

Adding daily report task

1. From Service tasks tab page, select the Daily report task command from New task drop-
down menu. The Daily report task properties dialogue will be shown.
2. Configure the execution of the task as described in the previous section.
3. Select the Settings tab page.

5
Is not necessary to have installed Microsoft Excel to generate reports in this format.

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4. In field Generated reports output folder, specify the output folder for the generated
reports. The name used to generate the reports is:
<report_name>_YYYYMMDDHHMMSS.rpt
5. The Database commands timeout field should contain the maximum number of second
that a query can wait for the results (zero means infinite seconds). By default, this value
is set to 30 seconds.
6. Press OK to create the new reporting task or Cancel to cancel the command.

Adding shift report task

1. From Service tasks tab page, select the Shift report task command from New task drop-
down menu. The Shift report task properties dialogue will be shown.
2. Configure the execution of the task as described in the previous section.
3. Select the Settings tab page.

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4. In field Generated reports output folder, specify the output folder for the generated
reports. The name used to generate the reports is:
<report_name>_YYYYMMDDHHMMSS.rpt
5. The Database commands timeout field should contain the maximum number of second
that a query can wait for the results (zero means infinite seconds). By default, this value
is set to 30 seconds.
6. Press OK to create the new reporting task or Cancel to cancel the command.

To configure the daily shifts, the KSK database table Shift must be used. Using pgAdmin all
shift can be set easily as shown in the following image:

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Squeezing Data Service

The Emdep KSK Squeezing Data Service is used to import the .ydsp files that contain all
information regarding the eyelets of a harness. This information then will be available in KSK
Studio for reviewing and validation.

YDSP File Format

A YDSP file is a file where each line has columns separated by the tabulation character. An
example of a YDSP file can be found in the following image:

This file contains almost all information needed to start the squeezing process. The crucial piece
of missing information is the Applicator that will be used. This must be configured in KSK Studio
in order to be able to squeeze this eyelet in a squeezing station.

Configuration
The configuration process is similar to other KSK Services. The only difference is that you must
specify the path where the service will look for YDSP files and the path where the treated files
will be stored.

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Service LOGs
The LOGs are needed in two different situations:

• To see (and log) the service activity.

• In front of service errors, technicians can enable the debug LOG to see all internal
activities for the service.

The service logging can use three different loggers (sources):

• File logger: All logged activity is appended in a plain text file. The logger will create a file
each day and store it in a folder tree organized by year and month levels.
• Windows logger: All logged activity is added into a Windows Event Log file. To view the
LOG entries, the Windows Event Viewer is needed.
• Mail logger: All logged activity is sent to one or more recipients via email.

Each logger can be configured with a LOG level. The service logging supports four levels:

• Debug level: LOG all activity for the service. This level is only used with debugging
purposes and generates a big amount of data.
• Information level: Entries only for information usually used to inform about the
successful process.
• Warning level: Entries informing about something relevant that need some attention.
• Error level: Entries informing about some error produced during a process execution.
• Critical level: Entries informing about something that does not allow the service to work.

The following table shows the entry types logged when a level is activated for a specified logger:

Activated level in settings

Log level keyword Debug Information Warning Error Critical

Debug debug     
Information info     
Warning warn     
Error error     
Critical critical     

By default, this section is pre-configured to use file LOGs in debug level and Windows LOGs
in information level and it is not necessary to change any parameter in the settings.xml file.
After a test period it is recommended to disable file LOGs (or change the level from debug to
information).

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Configuration

The LOGs configuration is shared for all graphical configurators.

1. Open the service graphical configuration using Emdep KSK Server Monitor.
2. Select the service to configure.
3. Press the Settings button ( ). The graphical configuration interface will be shown.
4. Select the Logging tab page.

5. Each logger can be set with its own tab page: File, Windows and Mail. Set the
appropriate loggers with the requested settings.
6. Press OK to store the settings and Cancel to cancel the command.

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Windows™ services

Service properties
All KSK services must be configured according the customer IT policies. In this section the most
common configuration parameters are described.

Service auto-start
Using this configuration, the service starts automatically when the operating system is started.

1. Open the Windows Services console (from Control Panel, Server Administration Panel
or another source).
2. Select the service by clicking over the row.
3. Open the contextual menu by clicking the right button on the mouse.
4. In the contextual menu, select Properties option. The Properties dialogue will appear:

5. In the Startup type combo-box list, select the Automatic or Automatic (Delayed Start).
Services set to Automatic will start during the boot process; while services set to
Automatic (Delayed Start) will start shortly after boot. For KSK services the best option
is Automatic (Delayed Start) to ensure all other services (like database engine) and drive
mappings are ready when the service starts.
6. Press OK button to store the changes in service.

Service auto-restart
Using this configuration, the service is automatically re-started when an error occurs, and the
service must be stopped.

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1. Open the Windows Services console (from Control Panel, Server Administration Panel
or another source).
2. Select the service by clicking over the row.
3. Open the contextual menu by clicking the right button on the mouse.
4. In the contextual menu, select Properties option. The Properties dialogue will appear.
5. Select the Recovery tab.

6. In the First failure combo-box list, select the Restart the service. Make the same changes
with the field Second failure and Subsequent failures (if needed).
7. The restart of the service can be delayed few minutes by setting the field Restart service
after with the number of minutes.
8. Press OK button to store the changes in service.

Service log-on options

By default, all services are configured to be executed using the Local System Windows account.
But some of the KSK services need to make IO operations (like read/write files, etc.), and the
Local System account maybe cannot perform certain operations.

In these cases, the service must be configured to be executed under another account that has
the permissions according to its requirements.

1. Open the Windows Services console (from Control Panel, Server Administration Panel
or another source).
2. Select the service by clicking over the row.
3. Open the contextual menu by clicking the right button on the mouse.

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4. In the contextual menu, select Properties option. The Properties dialogue will appear.
5. Select the Log-On tab.

6. Change the current option Local System account for This account.
7. Write the account login name or select it using the system dialogue by pressing Browse…
button.
8. Input the password (and its confirmation).
9. Press OK button to store the changes in service.
When this change is performed the service will be restarted if is running.

Operating a service in Windows™

Start the service

1. Open the Windows Services console (from Control Panel, Server Administration Panel
or another source).
2. Select the service by clicking over the row.
3. Open the contextual menu by clicking the right button on the mouse.
4. In the contextual menu, select Start option.
The button in the main toolbar can be used to start the selected service.

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Stop the service

1. Open the Windows Services console (from Control Panel, Server Explorer or another
source).
2. Select the service by clicking over the row.
3. Open the contextual menu by clicking the right button on the mouse.
4. In the contextual menu, select Stop option.
The button in the main toolbar can be used to start the selected service.

Manually register a service in Windows™

To register a Windows Service an administration account is needed.

1. Open a command window using the command Run as administrator.

2. Execute the following command:

sc create “KSK Schunk Service” binPath= c:\emdep-2\ksk\services\external\

Emdep.KSK.Service.External.exe

Be careful: a space is needed after the parameter binPath= .

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Testing and validating a service task

Sometimes it is useful to test a single KSK service task due to validate that all is working as
expected, especially in a KSK project startup. The Emdep KSK System offers a simple way to do
tests and validate tasks in a comfortable visual way.

Service test plugin for Emdep KSK Studio

The Service test utility in Emdep KSK Studio allows to test and validate a single task of any KSK
service. Additionally, this utility allows to check and edit the provided settings in a visual
environment.

How to test and validate an existing service task

1. In Emdep KSK Studio, open the plugin Service test from Validation group (in the toolbox).
The main screen of the plugin will be shown in the application workplace.

2. Select the service you want to test/validate in field Service / library file.
Usually this file is the EXE file of the service but also it can be a DLL library containing
special task implementations.
3. Select the settings.xml file you want to use in field Service settings file. The settings
will be shown in the right panel of the screen.
Usually this file is the service own settings file, but it is possible to prepare a special
settings file to create test environments (pointing to test database, for example).
4. From the Task to test drop-down list, select the task to test.

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Once the task is selected, a brief information will be shown (task type and library name
and version).
5. To test a single execution press Run single process button.
To execute cyclically the selected task, provide the number of seconds between
executions and then press Run cyclic process button.
The task will be processed under the same conditions as it would in the service.

The settings can be modified using the main toolbar commands grouped in Settings, and the
modified settings can be exported in a settings.xml pressing the Save settings as… button.

More detailed information about the plugin can be found in the Emdep KSK Studio manual.

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TROUBLESHOOTING

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External Equipment Service

Orders are not passing through an external equipment (Schunk, etc.)

1. Get some affected order numbers (3 or 4 is enough), just to use to check the flow.
2. Open the Emdep KSK Server Monitor.
3. Check if External Equipment Service is started and is working.
3.1. If the service is not started:
START THE SERVICE and wait for service LOG activity.
If the orders do not start to be processed or errors appear, follow with point 4.
4. Open the External Equipment Service log.
5. Stop the service during the checkpoints.
6. Find the order numbers in LOGs.
6.1. If the order number(s) don’t appear in LOGs: If the order number is not in the LOGs
means that the order was not processed by the service for some reason.
6.1.1.Check if there is an existing confirmation file(s) from external equipment (Schunk
SEQ OK, etc.).
6.1.1.1. If the file(s) exists, check inside if the confirmation for the order is
included.
6.1.1.1.1. If it is not included:
CHECK EXTERNAL EQUIPMENT because is not reporting the orders.
6.1.1.1.2. If it is included:
RESTART THE EXTERNAL SERVICE and wait to the configured execution
frequency (usually 1-2 minutes) to check if the orders start to be
processed.
If the service is not processing waiting orders existing in confirmation
files, contact with EMDEP SUPPORT.
6.1.1.2. If the file(s) don’t exists,
CHECK EXTERNAL EQUIPMENT because is not reporting the orders.
6.2. If the order number(s) appear in LOGs:
6.2.1. If the LOG entries correspond to a status error:
6.2.1.1. If the external equipment is in the first position of the line:
CHECK THE LINE ASSIGNEMENMT RULES in the service settings because the
root cause can be a bad line assignment.
6.2.1.2. If the external equipment is not in the first position of the line:

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Check if the orders are remain waiting for the external equipment when the
steps before are finished. If not, CHECK THE CONFIGURATION OF THE
STATIONS before the external equipment until the orders processes remain
waiting for the external equipment.
In this case, contact with EMDEP SUPPORT to find the cause.

System & Database

ERROR: index "TableName" contains unexpected zero page

If any application shows this error message means that the current KSK project database have
the indicated table index corrupted (may be a result of a recent Postgres or system failure, there
was a lack of free space on the device, etc.).

1. Open the pgAdmin.

2. Make a backup of the database.
3. Open pgAdmin and select the affected table.
4. Open the contextual menu (right click) for the selected table.
5. Select the Maintenance… menu option. The maintenance dialogue will be shown.

6.
7. Select Reindex option.
8. Press OK button.

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SYSTEM FAILOVER
STRATEGIES

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System failover configurations

Many organizations require a failover system for part (or all) of its systems. Thinking in an
industrial production system, we can imagine that a failover system is a common solution.

Primary/Backup servers
This is the easiest and economically solution but requires the human intervention to switch from
one server to another in case of failover, and the time from failover is detected to have the
backup server on-line can be too long.

This solution needs two servers and a storage system that contains the KSK database. It can be
a NAS or a server with RAID5. Of course, both storage solutions need a reliable backup system.

Network

Primary Backup

Storage
Server

How to create a Primary/Backup system

Before to create a backup server some recommendations must be followed to simplify the
installation and maintenance of both servers:

• Ensure that the primary server has the latest versions of software and all software is
tested. When the system is working, every change is software on primary server must
be performed in the backup server.

• Ensure that all drives, mapped drives and other network locations have the same letter
and are accessible with the same way in both servers.

Prepare the primary server

1. Ensure that storage server is accessible from the primary server.
2. Following the steps described in section Change database files location, make the
PostgreSQL points to a location in storage server (moving the data files folder to new
location).

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3. Ensure that the PostgreSQL is working using pgAdmin.

Prepare the backup server

1. Copy all software from primary to backup server.
2. Stop the primary server (shut down).
3. Ensure that storage server is accessible from the backup server.
4. Install the PostgreSQL.
5. Following the steps described in section Change database files location, make the
PostgreSQL points to the storage server database files (see Prepare the primary
server for more information).
6. Ensure that the PostgreSQL is working using pgAdmin.
7. Install (or copy) all Emdep KSK System software installed in the Primary Server
(copied in step 1). The easiest way is copying directly all installed software and
registering the services (see how to register a service in the user guides from services).
8. If all recommendations on how to prepare primary/backup servers are followed, all
software is properly configured.
If not, all KSK software configurations must be checked to correct drives, paths and/or
network locations.
9. To check all is working, start services and run some applications.

Caution!
Both servers are configured to use the same database files: only one PostgreSQL server engine
can use these files at same time, otherwise the database can be damaged!

In addition, KSK services are not designed to work in parallel with other instances, so
unpredictable and unwanted behaviors may occur.

Both servers cannot work at same time!

Activate the backup server in case of a system failure

In case of failover the next steps must be followed to change from one server to another (valid
for both directions).

On running (damaged) server:

1. If the operating system is responding: Stop all running KSK services.

2. If the operating system is responding: Stop PostgreSQL service.
3. If the operating system is responding: Shut down the computer.
4. Disconnect the server from network and proceed with diagnostics and reparation.

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On off (backup) server:

1. Before turning on, check all network connections.

2. Turn on the backup server.
3. When the system is completely started:
a. If all services are configured to start automatically:
Ensure that PostgreSQL and KSK services have started up normally (only visual
check using Windows Explorer and eventually the Event Viewer).
b. If services are configured to start manually:
c. Start PostgreSQL.
d. Start KSK services (no matter the boot order).
4. Using pgAdmin, make a backup of KSK database to get a copy before starting the
production over the backup server.

Options to avoid re-configure all KSK connected computers

In a primary/backup server failover solution there are two computers with different hostname
and IP address. So, if someone switches from primary to secondary server, all KSK clients (all
connected software in all computers) will stop working because they cannot connect to
database server.

To avoid re-configure all KSK clients there are two basic solutions that can be adopted:

• IP sharing
When a primary server is off-line and backup server is on-line, replace the IP address
in backup server for the primary server.

• DNS register
You can provide a unique hostname for the active server and in case to switch of
server, changing the associated IP of the hostname. This solution is less effective than
the IP sharing because changes in DNS register may take too much time to take effect
in the network.

Failover Clustering
A failover cluster is a group of independent computers that work together to increase the
availability and scalability of clustered roles (formerly called clustered applications and services).
The clustered servers (called nodes) are connected by physical cables and by software. If one or
more of the cluster nodes fail, other nodes begin to provide service (a process known as
failover). In addition, the clustered roles are proactively monitored to verify that they are
working properly. If they are not working, they are restarted or moved to another node. Failover
clusters also provide Cluster Shared Volume (CSV) functionality that provides a consistent,

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distributed namespace that clustered roles can use to access shared storage from all nodes.
With the Failover Clustering feature, users experience a minimum of disruptions in service.

You can manage failover clusters by using the Failover Cluster Manager snap-in and the Failover
Clustering Windows PowerShell cmdlets. You can also use the tools in File and Storage Services
to manage file shares on file server clusters.

More information about failover clustering in Windows eco-systems can be found here:

https://technet.microsoft.com/en-us/library/hh831579(v=ws.11).aspx

Applying a cluster technique in an organization require a study on all hardware and software
available, the network connections and many other aspects and need to involve the IT
department.

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MISCELLANEOUS

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HKSK file format

The harness precompiled file (HKSK) is a file that contains the electrical test information related
to a harness without any filtering (usually, by the components contained in a test station). The
HKSK are used by the compiler to generate a HNS file (electrical test file) for a particular station.

Value Details
Num wires Number of wires described
Name ; From ( conn alias ; conn PN ; way name or X for splice ) ; To ( conn
Wires alias ; conn PN ; way name or X for splice
) ; Color1 ; Color2 ; Color3 ; Module name ; Type
Num detections Number of detections described
Detections Name ; conn alias ; conn PN ; status ; isCreatedInRule
Num disabled
Number of disabled connectors
connectors
Disabled
conn alias ; conn PN
connectors
Num forced
Number of forced connectors
connectors
Forced
conn alias ; conn PN
connectors
Num RC
Number of RC components described
components
RC components See source code

Sample contents
5
2701;PSF1C;9673877980;9;2610A;9672943480;2;-8372160;12303291;12303291;9821191780;0
2802;2615A;9672943480;3;PSF1A;9811913080;5;-65536;12303291;12303291;9821191780;0
2702;2615A;9672943480;2;PSF1A;9811913080;27;-32640;12303291;12303291;9821191780;0
2801;PSF1C;9673877980;23;2610A;9672943480;3;-16711936;12303291;12303291;9821191780;0
9053B;E953;;X;ICK5C;9672943580;9;-1;12303291;12303291;9821193380;0
167
PRES4;MC20_4;;1;0
PRES2;MC21_2;;1;0
PRES3;MC21_3;;1;0
PRES4;MC21_4;;1;0
PRES2;MC46_2;;1;0
PRES1;MC46_1;;1;0
4
1524;9656916680
BMF FULL1;9627413080
BMF ECO1;9627413080
13C6A;7287350780
0
0

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QSS1 file format

The QSS1 files are a standard format to send orders to Emdep KSK System using the Emdep KSK
Orders Importer Service. The format for these files is described in the following table.

Segment Field Content Opt. Len. Use

Product Needed for a unique identification of the data
No 18
hierarchy (contains information such as OEM, carline, ...)
Order No. Product num. + parts group identifier No 40
Sy-Datum No 8
Drawing
Manually maintained in ECM by engineering. Yes 40
No.
K0 KSK
Drawing
Manually maintained in ECM by engineering. Yes 8
index
Placeholder for data which might be needed for
TestData Yes 100
printing the label.
JINUM SAP internal number for JIT call. Yes 10
POSID POSID No 10
Customer
Module part number No 35
module
P1 KSK
Change
Modules Revision Yes 8
index
Q-Level Yes 4
P2 Wire
Wire name No 8 KSK
Wires Identifier
Customer
Module part number No 35
P3 module
GTI
Modules Change
Revision Yes 8
index
P4 Wire
Wire name No 8 GTI
Wires Identifier
Fuse
Position of fuse No 16 KSK
P7 Address
Fuses Fuse
Part Number (value) of the fuse No 16 KSK
Parameter
There are 3 subtypes of alerts:
Segment 001: Concern
Yes 3 KSK
subtype 002: Alert assigned to concern
P8 003: Other alerts
Alerts Contains the content of the alert.
One 002 only is accepted related with a 001
Value Yes 40 KSK
concern.
A Harness may not have more than one “Concern”.

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A Harness can have all “Other alerts” as is

requiered.
Segment P8 of subtype 030:
1. If it has a value of 0, the order does not require
welding. P80300
P8 Segment
2. If it has a value other than 0, the order requires Yes 6 KSK
No_Welding subtype
welding.
If segment P8 of subtype 030 does not exist, the
order requires welding.
POSID Posid of the harness to be combined with this one No 10 KSK

CP Order number of the main harness of the

Combined combined production (can be related to POSID
Production Order No. specified in this CP segment, can be the same as Yes 40 KSK
current harness (specified in K0 segment) or can
be related to another one.

One QSS1 file can contain one or more orders.

For each order, a K0 segment is mandatory followed by a list of modules (P1 segment) and a list
of wires (P2 segment) involved in the order.

If a combined production contains more than 2 harnesses, more than one CP segment will
appear for each harness. Example:

K0 order=1, POSID=A
CP POSID=B
CP POSID=C

K0 order=2, POSID=B
CP POSID=A
CP POSID=C

K0 order=3, POSID=C
CP POSID=A
CP POSID=B

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QSSE file format

The QSSE files are a standard format used by Emdep KSK Orders Importer Service to reply to an
external production system (like SAP) when an order is received (usually from QSS1 file).

Since 2.15.0, the files generated from QSS1 have their dates changed to the date when they
were generated, instead of the original date.

Format 1
For each P1 segment, several P2 and P7 segments can appear (in that order: first all P2 segments
related to current module, and then all P7 segments related to current module). A P1 segment
with a virtual module will appear to group errors in wires and fuses that are not related to a
module,

Segment Field Content Opt. Len.

Product hierarchy No 18
Order No. Product num. + parts group identifier No 40
Sy-Datum No 8
Drawing No. Manually maintained in ECM by engineering. Yes 40
K0
Drawing index Manually maintained in ECM by engineering. Yes 8
JINUM SAP internal number for JIT call. Yes 10
Number of errors Number of errors (0 = All OK, n = n errors) No 3
POSID POSID Yes 10
Customer module Customer material number for customer module yes 35

P1 Change index No 8
Modules Code Error code No 3
Error text Description text No 80
Code Error code No 3
P2
Error text Descriptive text Yes 80
Wires
Wire identifier Name of the wire. Yes 8
Code Error code No 3
Error text Description text No 80
SAP Position Position in the box (in SAP notation) Yes 16
P7
Fuses Fuse Parameter Part Number of the fuse sent by QSS1 Yes 16
Part Number of the fuse found in KSK for given
KSK Part Number position (only for “wrong fuse” and “missing fuse” Yes 16
error types)

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The error codes used in QSSE segments P1 and P2 are the following:

Segment Code Message Comments

001 ERROR: Customer module not found Module is missing in KSK Server
ERROR: Customer module revision not Module revision is missing in KSK
002
found Server
003 UNUSED
Module has one or more wire
004 ERROR: Errors in wires
errors (and have no fuse errors)
Module has errors in fuses (but it
Customer 005 ERROR: Errors in fuses
has no wire errors).
modules (P1)
Module has errors in wires and
006 ERROR: Errors in both wires and fuses
fuses.
Optional parameter MP barcode
has been specified in CP segment,
ERROR: Mismatch in combined but it is inconsistent because all
499
production MP barcodes MP barcodes should be the same
for each harness in combined
harness.
011 ERROR: Missing wire When wire is missing in SAP
012 ERROR: Extra wire When wire is extra in SAP
Wires (P2)
When wire repeated in KSK
013 ERROR: Duplicated wire
Server
100 ERROR: Missing Fuse A fuse is missing in QSS1 order
A fuse appears in QSS1 order but
101 ERROR: Extra Fuse
not in Emdep data
The fuse value does not match
102 ERROR: Wrong Fuse
between QSS1 and Dmdep data
When merging the modules, a
Fuses (P7) ERROR: Duplicated Fuse in Emdep KSK fuse appears in Emdep data
103
data several times with different
values
The fuse appears more than once
104 ERROR: Duplicated Fuse in QSS1 file
in QSS1
Position for fuse does not exist in
105 ERROR: Undefined Position
Emdep data
ERROR: Alert related to many alerts The line before of the alert is
201 for a concern other alert. The line before of an
Alerts (P8) alert always must be a concern.

ERROR: Concert without content Concern doesn’t have definet the

203
value.

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ERROR: Concern already related The concern that is trying to

204 with Harness or module insert is already related with the
harness or module.

ERROR: Alert type not

The type of alerts only can be:
205 implemented 001, 002, 003

ERROR: Missing data The concern/alert is missing data

206
to be inserted.
ERROR: Too many concerns for
A Harness can only have one
207 Harness concern.

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Format 2
Since version 2.2.5, there is the possibility to specify format 2, which can contain K0 and P1
segments.

K0 segment can start by K0 or by KO, and has this format:

Data Len Description

KO or K0 2 Constant. It means header data

(blank)1 2 Not used

Order number 8 The order number (which is alphanumerical). Such as 00254498

Date 8 Date in format YYYYMMDD, wuch as 20130613.

Seq. number 4 Sequence number generated by XPPS, such as 0001.

Part Number 13 The part number which is a prefix + order number. Such as
1164A00254498.

(blanks) 96 Revision information. Will contain 96 blank characters.

Steering 2 Example: LL

From 1 From code for TSK

HSV_964 7

Release number 6 Release number of drawing number, such as END121

Drawing number 7 Drawing number, such as 9267358

Change index 2 Change index of order. Such as 00

* 1 Asterisk character meaning end of line.

IMPORTANT: Only field Order number is used by QSS1 service.

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P1 segment starts by P1 and has this format:

Data Len Description

P1 2 Constant. It means customer modules.

Part Number 7 Part number of the module

Index prefix 2 Normally it will be 01, which means that customer modules has
only 6 characters in XPP.

Change index 6 Change index of customer module

* 1 Asterisk character meaning end of line.

Module revision will be considered to be change index prefix + change index (8 characters).

Fields in yellow can be present several times, until the asterisk is found. That means that a P1
segment can contain several modules.

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Schunk synchronization file (SEQOK)

The equipment of Schunk company generate a unique plain text file where all OK orders are
appended. The file contains the following columns, separated by TAB character:

Column Description
ORDER Harness order
DATE Date (not used, data discarded)
TIME Time (not used, data discarded)
CONTROL_TEXT A configurable text that can contains the line name, harness family
name or other text that can be useful to obtain the production line or
other relevant information.

Sample contents
100034241934-L538CCH 28.05.2017 08:35:06 L538 Main Body
100034241343-L538EBH 28.05.2017 08:35:11 L538 Front End

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Hennecke synchronization file

The equipment of Hennecke company generate one file for each processed order (only OK
orders). These files contain information in CSV format and the following columns are present:

Column Description
START_TIMESTAMP Start process timestamp (not used, data discarded)
END_TIMESTAMP End process timestamp (not used, data discarded)
ORDER Harness order
CONTROL_TEXT A configurable text that can contains the line name, harness family
name or other text that can be useful to obtain the production line or
other relevant information.

Sample contents
start time package;end time package;Barcode;Line
[DD:MM:YYYY hh:mm:ss];[DD:MM:YYYY hh:mm:ss];[-];[-]
18.10.2017 9:15;18.10.2017 9:19;4433829I606;Line002

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YDSP File
This file for the Squeezing process is a text file with data separated with Tabulation characters.
The columns contain the following information:

Column Description
0 Order number
1 CGType. Combined with the column 0 it makes the full harness order number.
2-3 Not used
4 Grounding point. The type of eyelet to use.
5 Eyelet combination. The specific combination for this grounding point and
harness.
6 Not used
7 Eyelet terminal. The eyelet terminal to use.
8 Sequence. The display order of the wire in the list.
9 Cross section. The specific cross section of this wire.
10 Not used
11 Yazaki wire material. Currently not used, but stored for future use.
12 Customer name. Currently not used, but stored for future use.
13 YDM. We only need the first 3 characters, which indicate the wire material. Used
in combination with column 9 most of the time.

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