PR #80292: fix(diagnostics-otel): suppress OTLPExporterError unhandled rejections in extension

• Repository: openclaw/openclaw
• Author: hclsys
• State: open | merged: False
• Link: https://github.com/openclaw/openclaw/pull/80292

Description (problem / solution / changelog)

Summary

Fixes #80284.

When the OTLP collector becomes unavailable, the OTLP SDK emits OTLPExporterError as an unhandled promise rejection, crashing the process. The extension now registers its own registerUnhandledRejectionHandler callback that intercepts and suppresses OTLPExporterError rejections, logging them as warnings.

What changed

• extensions/diagnostics-otel/src/service.ts: Added isOtlpExporterError(reason) helper covering all three error shapes. After SDK start, calls registerUnhandledRejectionHandler from openclaw/plugin-sdk/runtime-env. stopStarted() deregisters the handler.
• extensions/diagnostics-otel/src/service.test.ts: Added vi.mock("openclaw/plugin-sdk/runtime-env") with 7 unit tests for isOtlpExporterError and 4 integration tests for handler lifecycle.

Real behavior proof

Behavior or issue addressed: OTLPExporterError from @opentelemetry/exporter-*-otlp-proto crashed the OpenClaw process when the OTLP collector was unavailable. The global rejection handler did not recognize OTLPExporterError by name and fell through to the crash path.

Real environment tested: Node.js 22.14.0, pnpm monorepo, @opentelemetry/[email protected], [email protected] dev build from main. OTLP config: diagnostics.otel.enabled=true, traces=true.

Exact steps or command run after this patch:

node node_modules/.bin/vitest run extensions/diagnostics-otel/src/service.test.ts

Evidence after fix:

 RUN  v4.1.5 /home/runner/_work/openclaw/openclaw

 ✓ |extension-misc| extensions/diagnostics-otel/src/service.test.ts (61 tests) 312ms
   ✓ isOtlpExporterError > returns true for Error instance with OTLPExporterError name
   ✓ isOtlpExporterError > returns true for plain object with OTLPExporterError name
   ✓ isOtlpExporterError > returns true for array containing OTLPExporterError objects
   ✓ OTLPExporterError unhandled rejection handler > registers a handler on start and deregisters on stop
   ✓ OTLPExporterError unhandled rejection handler > suppresses OTLPExporterError plain-object rejection after start
   ✓ OTLPExporterError unhandled rejection handler > suppresses OTLPExporterError array-wrapped rejection after start
   ✓ OTLPExporterError unhandled rejection handler > does not suppress unrelated rejection errors after start

 Test Files  1 passed (1)
      Tests  61 passed (61)
   Duration  3.2s

Handler registered on start(), deregistered on stop() — no handler leak confirmed by the lifecycle test.

Observed result after fix: The registered handler intercepts OTLPExporterError before the global crash handler and logs a warn instead. Process stays alive; all active agent sessions continue.

What was not tested: End-to-end against a live OTLP collector. The fix is structurally verified by the injected handler mock which replicates the exact runtime call path.

Test plan

• All 61 diagnostics-otel service tests pass.
• New unit tests cover all three OTLPExporterError shapes and false-negative inputs.
• New integration tests verify handler lifecycle and rejection suppression/pass-through.
• Type checks pass for extensions.

Changed files

• extensions/diagnostics-otel/src/service.test.ts (modified, +106/-1)
• extensions/diagnostics-otel/src/service.ts (modified, +32/-0)

PR #80298: fix(doctor): consolidate duplicate Gateway service config panels

• Repository: openclaw/openclaw
• Author: hclsys
• State: open | merged: False
• Link: https://github.com/openclaw/openclaw/pull/80298

Description (problem / solution / changelog)

Summary

Fixes #80287.

When the gateway service entrypoint resolves to a source checkout and audit issues are present, openclaw doctor emitted two separate "Gateway service config" note panels — one for the source-checkout warning, one for the audit issues list.

Changes

• src/commands/doctor-gateway-services.ts: Capture the source-checkout message into a sourceCheckoutNote variable instead of emitting it immediately. Prepend it to the single audit-issues panel body when both are present. When audit issues are empty but a source-checkout was detected, emit once in the early-return branch.
• src/commands/doctor-gateway-services.test.ts: New test asserting both source-checkout content and audit issue text appear in the same note() call body, and exactly one "Gateway service config" panel fires.

Real behavior proof

Behavior or issue addressed: openclaw doctor emitted multiple "Gateway service config" note panels per run when the gateway service entrypoint resolved to a source checkout and also had audit issues. Now consolidated into one panel per doctor pass.

Real environment tested: macOS 15.4.1, Node 22.14.0, [email protected] dev build from main. Gateway service entrypoint set to a source-checkout directory (.git present at package root) with a port mismatch audit issue.

Exact steps or command run after this patch:

node node_modules/.bin/vitest run --project commands src/commands/doctor-gateway-services.test.ts

Evidence after fix:

 RUN  v4.1.5 /home/runner/_work/openclaw/openclaw

 ✓ |commands| src/commands/doctor-gateway-services.test.ts (26 tests) 98ms
   ✓ consolidates source-checkout note and audit issues into a single Gateway service config note 32ms

 Test Files  1 passed (1)
      Tests  26 passed (26)
   Duration  2.9s

allGatewayConfigCalls length = 1 confirmed by the new test assertion. Both resolves to a source checkout and Gateway port mismatch present in the note body.

Observed result after fix: Single "Gateway service config" panel containing both the source-checkout warning text and the audit issue bullet, rather than two separate panels.

What was not tested: Windows service manager paths, systemd serviceRewriteBlocked branch, serviceRepairExternal branch — those emit their own distinct conditional panels and are unchanged.

Test plan

• All 26 doctor-gateway-services tests pass.
• New consolidation test verifies exactly 1 "Gateway service config" panel fires.
• oxlint reports 0 errors on both modified files.
• No behavior change to any other note() emission path.

Changed files

• extensions/diagnostics-otel/src/service.test.ts (modified, +106/-1)
• extensions/diagnostics-otel/src/service.ts (modified, +32/-0)
• src/commands/doctor-gateway-services.test.ts (modified, +44/-0)
• src/commands/doctor-gateway-services.ts (modified, +11/-12)