fix: tame invalid config logging

CHANGELOG.md

@@ -31,6 +31,7 @@ Docs: https://docs.clawd.bot
 - Gateway: clarify unauthorized handshake responses with token/password mismatch guidance.
 - Gateway: preserve restart wake routing + thread replies across restarts. (#1337) — thanks @John-Rood.
 - Gateway: reschedule per-agent heartbeats on config hot reload without restarting the runner.
+- Config: log invalid config issues once per run and keep invalid-config errors stackless.
 - UI: keep config form enums typed, preserve empty strings, protect sensitive defaults, and deepen config search. (#1315) — thanks @MaudeBot.
 - UI: preserve ordered list numbering in chat markdown. (#1341) — thanks @bradleypriest.
 - UI: allow Control UI to read gatewayUrl from URL params for remote WebSocket targets. (#1342) — thanks @ameno-.

src/cli/run-main.ts

@@ -7,6 +7,7 @@ import { normalizeEnv } from "../infra/env.js";
 import { isMainModule } from "../infra/is-main.js";
 import { ensureClawdbotCliOnPath } from "../infra/path-env.js";
 import { assertSupportedRuntime } from "../infra/runtime-guard.js";
+import { formatUncaughtError } from "../infra/errors.js";
 import { installUnhandledRejectionHandler } from "../infra/unhandled-rejections.js";
 import { enableConsoleCapture } from "../logging.js";
 import { tryRouteCli } from "./route.js";
@@ -42,7 +43,7 @@ export async function runCli(argv: string[] = process.argv) {
   installUnhandledRejectionHandler();
 
   process.on("uncaughtException", (error) => {
-    console.error("[clawdbot] Uncaught exception:", error.stack ?? error.message);
+    console.error("[clawdbot] Uncaught exception:", formatUncaughtError(error));
     process.exit(1);
   });
 

src/config/io.ts

@@ -57,6 +57,7 @@ const SHELL_ENV_EXPECTED_KEYS = [
 ];
 
 const CONFIG_BACKUP_COUNT = 5;
+const loggedInvalidConfigs = new Set<string>();
 
 export type ParseConfigJson5Result = { ok: true; parsed: unknown } | { ok: false; error: string };
 
@@ -244,8 +245,14 @@ export function createConfigIO(overrides: ConfigIoDeps = {}) {
         const details = validated.issues
           .map((iss) => `- ${iss.path || "<root>"}: ${iss.message}`)
           .join("\n");
-        deps.logger.error(`Invalid config:\\n${details}`);
-        throw new Error("Invalid config");
+        if (!loggedInvalidConfigs.has(configPath)) {
+          loggedInvalidConfigs.add(configPath);
+          deps.logger.error(`Invalid config:\\n${details}`);
+        }
+        const error = new Error("Invalid config");
+        (error as { code?: string; details?: string }).code = "INVALID_CONFIG";
+        (error as { code?: string; details?: string }).details = details;
+        throw error;
       }
       if (validated.warnings.length > 0) {
         const details = validated.warnings

src/index.ts

@@ -28,6 +28,7 @@ import {
   PortInUseError,
 } from "./infra/ports.js";
 import { assertSupportedRuntime } from "./infra/runtime-guard.js";
+import { formatUncaughtError } from "./infra/errors.js";
 import { installUnhandledRejectionHandler } from "./infra/unhandled-rejections.js";
 import { enableConsoleCapture } from "./logging.js";
 import { runCommandWithTimeout, runExec } from "./process/exec.js";
@@ -82,15 +83,12 @@ if (isMain) {
   installUnhandledRejectionHandler();
 
   process.on("uncaughtException", (error) => {
-    console.error("[clawdbot] Uncaught exception:", error.stack ?? error.message);
+    console.error("[clawdbot] Uncaught exception:", formatUncaughtError(error));
     process.exit(1);
   });
 
   void program.parseAsync(process.argv).catch((err) => {
-    console.error(
-      "[clawdbot] CLI failed:",
-      err instanceof Error ? (err.stack ?? err.message) : err,
-    );
+    console.error("[clawdbot] CLI failed:", formatUncaughtError(err));
     process.exit(1);
   });
 }

src/infra/errors.ts

@@ -20,3 +20,13 @@ export function formatErrorMessage(err: unknown): string {
     return Object.prototype.toString.call(err);
   }
 }
+
+export function formatUncaughtError(err: unknown): string {
+  if (extractErrorCode(err) === "INVALID_CONFIG") {
+    return formatErrorMessage(err);
+  }
+  if (err instanceof Error) {
+    return err.stack ?? err.message ?? err.name;
+  }
+  return formatErrorMessage(err);
+}

src/infra/unhandled-rejections.ts

@@ -1,5 +1,7 @@
 import process from "node:process";
 
+import { formatUncaughtError } from "./errors.js";
+
 type UnhandledRejectionHandler = (reason: unknown) => boolean;
 
 const handlers = new Set<UnhandledRejectionHandler>();
@@ -28,10 +30,7 @@ export function isUnhandledRejectionHandled(reason: unknown): boolean {
 export function installUnhandledRejectionHandler(): void {
   process.on("unhandledRejection", (reason, _promise) => {
     if (isUnhandledRejectionHandled(reason)) return;
-    console.error(
-      "[clawdbot] Unhandled promise rejection:",
-      reason instanceof Error ? (reason.stack ?? reason.message) : reason,
-    );
+    console.error("[clawdbot] Unhandled promise rejection:", formatUncaughtError(reason));
     process.exit(1);
   });
 }

src/macos/relay.ts

@@ -55,6 +55,7 @@ async function main() {
 
   const { assertSupportedRuntime } = await import("../infra/runtime-guard.js");
   assertSupportedRuntime();
+  const { formatUncaughtError } = await import("../infra/errors.js");
   const { installUnhandledRejectionHandler } = await import("../infra/unhandled-rejections.js");
 
   const { buildProgram } = await import("../cli/program.js");
@@ -63,7 +64,7 @@ async function main() {
   installUnhandledRejectionHandler();
 
   process.on("uncaughtException", (error) => {
-    console.error("[clawdbot] Uncaught exception:", error.stack ?? error.message);
+    console.error("[clawdbot] Uncaught exception:", formatUncaughtError(error));
     process.exit(1);
   });