fix(ui): show config open failure feedback (#87108)

Fixes #87020.

Summary:
- Surface config.openFile failures in the Control UI instead of silently doing nothing.
- Return actionable gateway errors for headless opener failures, including the config path.
- Add gateway and UI controller regression coverage for the failed-open path.

Verification:
- node scripts/run-vitest.mjs run --config test/vitest/vitest.gateway-methods.config.ts src/gateway/server-methods/config.test.ts --reporter=dot
- node scripts/run-vitest.mjs run --config test/vitest/vitest.ui.config.ts ui/src/ui/controllers/config.test.ts --reporter=dot
- pnpm check:changed via Blacksmith Testbox tbx_01ksktydqx6mk3n20yevcbkwtn
- autoreview --mode local

Thanks @Linux2010.

Co-authored-by: Linux2010 <35169750+Linux2010@users.noreply.github.com>

src/gateway/server-methods/config.test.ts

@@ -100,7 +100,7 @@ describe("config.openFile", () => {
     );
   });
 
-  it("returns a generic error and logs details when the opener fails", async () => {
+  it("returns a detailed error and logs details when the opener fails", async () => {
     process.env.OPENCLAW_CONFIG_PATH = "/tmp/config.json";
     execFileMock.mockImplementation((...args: unknown[]) => {
       invokeExecFileCallback(
@@ -120,7 +120,7 @@ describe("config.openFile", () => {
       {
         ok: false,
         path: "/tmp/config.json",
-        error: "failed to open config file",
+        error: "Failed to open config file: spawn xdg-open ENOENT",
       },
       undefined,
     );
@@ -128,6 +128,36 @@ describe("config.openFile", () => {
       "config.openFile failed path=/tmp/config.json: spawn xdg-open ENOENT",
     );
   });
+
+  it("returns actionable headless environment error when xdg-open reports no method available", async () => {
+    process.env.OPENCLAW_CONFIG_PATH = "/tmp/config.json";
+    execFileMock.mockImplementation((...args: unknown[]) => {
+      invokeExecFileCallback(
+        args,
+        new Error("xdg-open: no method available for opening '/tmp/config.json'"),
+      );
+      return {} as never;
+    });
+
+    const { options, respond, logGateway } = createConfigHandlerHarness({
+      method: "config.openFile",
+    });
+    await configHandlers["config.openFile"](options);
+
+    expect(respond).toHaveBeenCalledWith(
+      true,
+      {
+        ok: false,
+        path: "/tmp/config.json",
+        error:
+          "Cannot open file in headless environment. File path: /tmp/config.json. This environment appears to lack a graphical or terminal browser handler.",
+      },
+      undefined,
+    );
+    expect(logGateway.warn).toHaveBeenCalledWith(
+      "config.openFile failed path=/tmp/config.json: xdg-open: no method available for opening '/tmp/config.json'",
+    );
+  });
 });
 
 describe("config schema response cache", () => {

src/gateway/server-methods/config.ts

@@ -702,12 +702,17 @@ export const configHandlers: GatewayRequestHandlers = {
       await execConfigOpenCommand(resolveConfigOpenCommand(configPath));
       respond(true, { ok: true, path: configPath }, undefined);
     } catch (error) {
+      const errorMessage = formatConfigOpenError(error);
+      const isHeadlessError = errorMessage.includes("xdg-open") && errorMessage.includes("no method available");
+      const detailedError = isHeadlessError
+        ? `Cannot open file in headless environment. File path: ${configPath}. This environment appears to lack a graphical or terminal browser handler.`
+        : `Failed to open config file: ${errorMessage}`;
       context?.logGateway?.warn(
-        `config.openFile failed path=${sanitizeLookupPathForLog(configPath)}: ${formatConfigOpenError(error)}`,
+        `config.openFile failed path=${sanitizeLookupPathForLog(configPath)}: ${errorMessage}`,
       );
       respond(
         true,
-        { ok: false, path: configPath, error: "failed to open config file" },
+        { ok: false, path: configPath, error: detailedError },
         undefined,
       );
     }

ui/src/ui/controllers/config.test.ts

@@ -1,10 +1,11 @@
-import { describe, expect, it, vi } from "vitest";
+import { afterEach, describe, expect, it, vi } from "vitest";
 import {
   applyConfigSnapshot,
   applyConfig,
   ensureAgentConfigEntry,
   findAgentConfigEntryIndex,
   loadConfig,
+  openConfigFile,
   resetConfigPendingChanges,
   runUpdate,
   saveConfig,
@@ -64,6 +65,10 @@ function requireRequestCall(request: ReturnType<typeof vi.fn>, index = 0): unkno
   return call;
 }
 
+afterEach(() => {
+  vi.unstubAllGlobals();
+});
+
 describe("applyConfigSnapshot", () => {
   it("does not clobber form edits while dirty", () => {
     const state = createState();
@@ -271,6 +276,57 @@ describe("loadConfig", () => {
   });
 });
 
+describe("openConfigFile", () => {
+  it("surfaces failed open responses and copies the returned config path", async () => {
+    const request = vi.fn().mockResolvedValue({
+      ok: false,
+      path: "/tmp/openclaw.json",
+      error: "Cannot open file in headless environment.",
+    });
+    const writeText = vi.fn().mockResolvedValue(undefined);
+    vi.stubGlobal("navigator", { clipboard: { writeText } });
+
+    const state = createState();
+    state.connected = true;
+    state.client = { request } as unknown as ConfigState["client"];
+    state.lastError = "stale error";
+
+    await openConfigFile(state);
+
+    expect(request).toHaveBeenCalledWith("config.openFile", {});
+    expect(writeText).toHaveBeenCalledWith("/tmp/openclaw.json");
+    expect(state.lastError).toBe(
+      "Cannot open file in headless environment.\n\nFile path copied to clipboard: /tmp/openclaw.json",
+    );
+  });
+
+  it("includes the config path in the visible error when clipboard fallback fails", async () => {
+    const request = vi.fn().mockResolvedValue({
+      ok: false,
+      error: "Failed to open config file",
+    });
+    const writeText = vi.fn().mockRejectedValue(new Error("clipboard denied"));
+    vi.stubGlobal("navigator", { clipboard: { writeText } });
+
+    const state = createState();
+    state.connected = true;
+    state.client = { request } as unknown as ConfigState["client"];
+    state.configSnapshot = {
+      config: {},
+      path: "/tmp/from-snapshot.json",
+      valid: true,
+      issues: [],
+    };
+
+    await openConfigFile(state);
+
+    expect(writeText).toHaveBeenCalledWith("/tmp/from-snapshot.json");
+    expect(state.lastError).toBe(
+      "Failed to open config file\n\nFile path: /tmp/from-snapshot.json",
+    );
+  });
+});
+
 describe("updateConfigFormValue", () => {
   it("seeds from snapshot when form is null", () => {
     const state = createState();

ui/src/ui/controllers/config.ts

@@ -501,9 +501,26 @@ export async function openConfigFile(state: ConfigState): Promise<void> {
   if (!state.client || !state.connected) {
     return;
   }
+  state.lastError = null;
   try {
-    await state.client.request("config.openFile", {});
-  } catch {
+    const res = await state.client.request<{ ok: boolean; path?: string; error?: string }>(
+      "config.openFile",
+      {},
+    );
+    if (!res.ok) {
+      const errorMessage = res.error || "Failed to open config file";
+      state.lastError = errorMessage;
+      const path = res.path || state.configSnapshot?.path;
+      if (path) {
+        try {
+          await navigator.clipboard.writeText(path);
+          state.lastError += `\n\nFile path copied to clipboard: ${path}`;
+        } catch {
+          state.lastError += `\n\nFile path: ${path}`;
+        }
+      }
+    }
+  } catch (err) {
     const path = state.configSnapshot?.path;
     if (path) {
       try {
@@ -512,5 +529,6 @@ export async function openConfigFile(state: ConfigState): Promise<void> {
         // ignore
       }
     }
+    state.lastError = String(err);
   }
 }