Scope config preflight note suppression (#84439)

src/cli/program/config-guard.test.ts

@@ -1,4 +1,5 @@
 import { beforeEach, describe, expect, it, vi } from "vitest";
+import { note } from "../../terminal/note.js";
 import { formatCliCommand } from "../command-format.js";
 import { ensureConfigReady, testApi } from "./config-guard.js";
 
@@ -39,10 +40,20 @@ function plainErrorCalls(runtime: ReturnType<typeof makeRuntime>): string[] {
 
 async function withCapturedStdout(run: () => Promise<void>): Promise<string> {
   const writes: string[] = [];
-  const writeSpy = vi.spyOn(process.stdout, "write").mockImplementation(((chunk: unknown) => {
-    writes.push(String(chunk));
-    return true;
-  }) as typeof process.stdout.write);
+  const writeSpy = vi
+    .spyOn(process.stdout, "write")
+    .mockImplementation(
+      ((
+        chunk: unknown,
+        encodingOrCallback?: BufferEncoding | ((error?: Error | null) => void),
+        callback?: (error?: Error | null) => void,
+      ) => {
+        writes.push(String(chunk));
+        const done = typeof encodingOrCallback === "function" ? encodingOrCallback : callback;
+        done?.();
+        return true;
+      }) as typeof process.stdout.write,
+    );
   try {
     await run();
     return writes.join("");
@@ -212,9 +223,9 @@ describe("ensureConfigReady", () => {
     expect(loadAndMaybeMigrateDoctorConfigMock).toHaveBeenCalledTimes(1);
   });
 
-  it("prevents preflight stdout noise when suppression is enabled", async () => {
+  it("prevents preflight note noise when suppression is enabled", async () => {
     loadAndMaybeMigrateDoctorConfigMock.mockImplementation(async () => {
-      process.stdout.write("Doctor warnings\n");
+      note("Doctor warnings", "Config warnings");
       return {
         snapshot: makeSnapshot(),
         baseConfig: {},
@@ -226,9 +237,9 @@ describe("ensureConfigReady", () => {
     expect(output).not.toContain("Doctor warnings");
   });
 
-  it("allows preflight stdout noise when suppression is not enabled", async () => {
+  it("allows preflight note noise when suppression is not enabled", async () => {
     loadAndMaybeMigrateDoctorConfigMock.mockImplementation(async () => {
-      process.stdout.write("Doctor warnings\n");
+      note("Doctor warnings", "Config warnings");
       return {
         snapshot: makeSnapshot(),
         baseConfig: {},
@@ -239,4 +250,39 @@ describe("ensureConfigReady", () => {
     });
     expect(output).toContain("Doctor warnings");
   });
+
+  it("does not suppress unrelated concurrent stdout writes while suppressing preflight notes", async () => {
+    let releasePreflight: (() => void) | undefined;
+    let preflightStarted: (() => void) | undefined;
+    const preflightStartedPromise = new Promise<void>((resolve) => {
+      preflightStarted = resolve;
+    });
+    const releasePreflightPromise = new Promise<void>((resolve) => {
+      releasePreflight = resolve;
+    });
+    loadAndMaybeMigrateDoctorConfigMock.mockImplementation(async () => {
+      note("Doctor warnings", "Config warnings");
+      preflightStarted?.();
+      await releasePreflightPromise;
+      return {
+        snapshot: makeSnapshot(),
+        baseConfig: {},
+      };
+    });
+
+    let callbackCalled = false;
+    const output = await withCapturedStdout(async () => {
+      const ready = runEnsureConfigReady(["message"], true);
+      await preflightStartedPromise;
+      process.stdout.write("Concurrent output\n", () => {
+        callbackCalled = true;
+      });
+      releasePreflight?.();
+      await ready;
+    });
+
+    expect(output).toContain("Concurrent output");
+    expect(output).not.toContain("Doctor warnings");
+    expect(callbackCalled).toBe(true);
+  });
 });

src/cli/program/config-guard.ts

@@ -1,5 +1,6 @@
 import { readConfigFileSnapshot, setRuntimeConfigSnapshot } from "../../config/config.js";
 import type { RuntimeEnv } from "../../runtime.js";
+import { withSuppressedNotes } from "../../terminal/note.js";
 import { shouldMigrateStateFromPath } from "../argv.js";
 
 const ALLOWED_INVALID_COMMANDS = new Set(["doctor", "logs", "health", "help", "status"]);
@@ -62,20 +63,7 @@ export async function ensureConfigReady(params: {
     if (!params.suppressDoctorStdout) {
       preflightSnapshot = (await runDoctorConfigPreflight()).snapshot;
     } else {
-      const originalStdoutWrite = process.stdout.write.bind(process.stdout);
-      const originalSuppressNotes = process.env.OPENCLAW_SUPPRESS_NOTES;
-      process.stdout.write = (() => true) as unknown as typeof process.stdout.write;
-      process.env.OPENCLAW_SUPPRESS_NOTES = "1";
-      try {
-        preflightSnapshot = (await runDoctorConfigPreflight()).snapshot;
-      } finally {
-        process.stdout.write = originalStdoutWrite;
-        if (originalSuppressNotes === undefined) {
-          delete process.env.OPENCLAW_SUPPRESS_NOTES;
-        } else {
-          process.env.OPENCLAW_SUPPRESS_NOTES = originalSuppressNotes;
-        }
-      }
+      preflightSnapshot = (await withSuppressedNotes(runDoctorConfigPreflight)).snapshot;
     }
   }