fix(core_process): demote expected port-clash + Windows bind ACL to warn (#2B, #AT, #BV, #BT) (#1628)

Co-authored-by: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
Co-authored-by: Steven Enamakel <enamakel@tinyhumans.ai>

app/src-tauri/src/core_process.rs

@@ -172,7 +172,11 @@ impl CoreProcessHandle {
                         "Core RPC port {} is in use by something that is not an OpenHuman core ({reason}). Refusing to attach (set OPENHUMAN_CORE_REUSE_EXISTING=1 to override) — quit the other process or set OPENHUMAN_CORE_PORT to a different port and relaunch.",
                         self.port
                     );
-                    log::error!("[core] {msg}");
+                    if is_expected_port_clash(&reason) {
+                        log::warn!("[core] {msg}");
+                    } else {
+                        log::error!("[core] {msg}");
+                    }
                     return Err(msg);
                 }
             }
@@ -236,7 +240,11 @@ impl CoreProcessHandle {
                     )
                     .await
                     {
-                        log::error!("[core] embedded core server exited with error: {e}");
+                        if is_expected_port_clash(&e.to_string()) {
+                            log::warn!("[core] embedded core server exited with error: {e}");
+                        } else {
+                            log::error!("[core] embedded core server exited with error: {e}");
+                        }
                     } else {
                         log::info!("[core] embedded core server exited cleanly");
                     }
@@ -380,14 +388,19 @@ impl CoreProcessHandle {
         self.shutdown().await;
 
         if !had_managed_task && self.is_rpc_port_open().await {
-            log::error!(
+            let msg = format!(
+                "Core RPC port {} is already in use by another process (OpenHuman did not start it). Quit any `openhuman-core run` in a terminal or set OPENHUMAN_CORE_PORT to a different port, then relaunch the app.",
+                self.port
+            );
+            // Precondition check: by the time we hit this branch we already
+            // know the port is held by something OpenHuman did not spawn, so
+            // the clash is always benign environment state — no need to gate
+            // through `is_expected_port_clash`.
+            log::warn!(
                 "[core] restart: nothing to stop but port {} is in use — another process owns it",
                 self.port
             );
-            return Err(format!(
-                "Core RPC port {} is already in use by another process (OpenHuman did not start it). Quit any `openhuman-core run` in a terminal or set OPENHUMAN_CORE_PORT to a different port, then relaunch the app.",
-                self.port
-            ));
+            return Err(msg);
         }
 
         const POLL_MS: u64 = 50;
@@ -586,6 +599,20 @@ fn is_openhuman_root_body(body: &str) -> bool {
         .unwrap_or(false)
 }
 
+/// Returns true when a port conflict is deterministic environment state, not
+/// a high-signal unknown squatter worth sending to Sentry at error level.
+fn is_expected_port_clash(reason: &str) -> bool {
+    let reason = reason.to_ascii_lowercase();
+    reason.contains("error sending request for url")
+        || reason.contains("connection refused")
+        || reason.contains("returned status 404")
+        || reason.contains("returned status 200")
+        || reason.contains("body did not identify as openhuman")
+        || reason.contains("already in use by another process")
+        || reason.contains("os error 10013")
+        || reason.contains("wsaeacces")
+}
+
 #[cfg(unix)]
 fn find_pid_on_port(port: u16) -> Option<u32> {
     let output = std::process::Command::new("lsof")

app/src-tauri/src/core_process_tests.rs

@@ -1,6 +1,6 @@
 use super::{
-    current_rpc_token, default_core_port, generate_rpc_token, is_openhuman_root_body,
-    parse_lsof_pid, parse_netstat_pid, CoreProcessHandle,
+    current_rpc_token, default_core_port, generate_rpc_token, is_expected_port_clash,
+    is_openhuman_root_body, parse_lsof_pid, parse_netstat_pid, CoreProcessHandle,
 };
 use std::sync::{Mutex, MutexGuard, OnceLock};
 
@@ -127,6 +127,43 @@ fn is_openhuman_root_body_rejects_other_services() {
     assert!(!is_openhuman_root_body(r#"{"name": 42}"#));
 }
 
+#[test]
+fn expected_port_clash_classifier_matches_benign_probe_shapes() {
+    assert!(is_expected_port_clash(
+        "probe GET / failed: error sending request for url (http://127.0.0.1:7788/)"
+    ));
+    assert!(is_expected_port_clash(
+        "probe GET / failed: connection refused"
+    ));
+    assert!(is_expected_port_clash(
+        "probe GET / returned status 404 Not Found"
+    ));
+    assert!(is_expected_port_clash("probe GET / returned status 200 OK"));
+    assert!(is_expected_port_clash(
+        "probe GET / body did not identify as openhuman (\"hello\")"
+    ));
+}
+
+#[test]
+fn expected_port_clash_classifier_matches_windows_acl_bind_shapes() {
+    assert!(is_expected_port_clash(
+        "Failed to bind to 127.0.0.1:7788: access denied (os error 10013)"
+    ));
+    assert!(is_expected_port_clash(
+        "Failed to bind to 127.0.0.1:7788: WSAEACCES"
+    ));
+}
+
+#[test]
+fn expected_port_clash_classifier_rejects_unknown_probe_shapes() {
+    assert!(!is_expected_port_clash(
+        "probe GET / failed: TLS handshake failed: protocol error"
+    ));
+    assert!(!is_expected_port_clash(
+        "probe GET / body read failed: unexpected eof"
+    ));
+}
+
 #[test]
 fn parse_lsof_pid_picks_first_pid() {
     assert_eq!(parse_lsof_pid("12345\n"), Some(12345));