fix: harden mac gateway attach smoke

apps/macos/Sources/OpenClaw/GatewayProcessManager.swift

@@ -44,6 +44,7 @@ final class GatewayProcessManager {
     private var logRefreshTask: Task<Void, Never>?
     #if DEBUG
     private var testingConnection: GatewayConnection?
+    private var testingSkipControlChannelRefresh = false
     #endif
     private let logger = Logger(subsystem: "ai.openclaw", category: "gateway.process")
 
@@ -364,6 +365,11 @@ final class GatewayProcessManager {
     }
 
     private func refreshControlChannelIfNeeded(reason: String) {
+        #if DEBUG
+        if self.testingSkipControlChannelRefresh {
+            return
+        }
+        #endif
         switch ControlChannel.shared.state {
         case .connected, .connecting:
             return
@@ -421,6 +427,10 @@ extension GatewayProcessManager {
         self.testingConnection = connection
     }
 
+    func setTestingSkipControlChannelRefresh(_ skip: Bool) {
+        self.testingSkipControlChannelRefresh = skip
+    }
+
     func setTestingDesiredActive(_ active: Bool) {
         self.desiredActive = active
     }
@@ -428,5 +438,9 @@ extension GatewayProcessManager {
     func setTestingLastFailureReason(_ reason: String?) {
         self.lastFailureReason = reason
     }
+
+    func _testAttachExistingGatewayIfAvailable() async -> Bool {
+        await self.attachExistingGatewayIfAvailable()
+    }
 }
 #endif

apps/macos/Sources/OpenClaw/PortGuardian.swift

@@ -23,6 +23,9 @@ actor PortGuardian {
 
     private var records: [Record] = []
     private let logger = Logger(subsystem: "ai.openclaw", category: "portguard")
+    #if DEBUG
+    private var testingDescriptors: [Int: Descriptor] = [:]
+    #endif
     private nonisolated static let appSupportDir: URL = {
         let base = FileManager().urls(for: .applicationSupportDirectory, in: .userDomainMask).first!
         return base.appendingPathComponent("OpenClaw", isDirectory: true)
@@ -130,6 +133,11 @@ actor PortGuardian {
     }
 
     func describe(port: Int) async -> Descriptor? {
+        #if DEBUG
+        if let descriptor = self.testingDescriptors[port] {
+            return descriptor
+        }
+        #endif
         guard let listener = await self.listeners(on: port).first else { return nil }
         let path = Self.executablePath(for: listener.pid)
         return Descriptor(pid: listener.pid, command: listener.command, executablePath: path)
@@ -406,6 +414,18 @@ actor PortGuardian {
     }
 }
 
+#if DEBUG
+extension PortGuardian {
+    func setTestingDescriptor(_ descriptor: Descriptor?, forPort port: Int) {
+        if let descriptor {
+            self.testingDescriptors[port] = descriptor
+        } else {
+            self.testingDescriptors.removeValue(forKey: port)
+        }
+    }
+}
+#endif
+
 #if DEBUG
 extension PortGuardian {
     static func _testParseListeners(_ text: String) -> [(

apps/macos/Tests/OpenClawIPCTests/GatewayProcessManagerTests.swift

@@ -35,4 +35,92 @@ struct GatewayProcessManagerTests {
         #expect(ready)
         #expect(manager.lastFailureReason == nil)
     }
+
+    @Test func `attaches to existing gateway without spawning launchd`() async throws {
+        let healthData = Data(
+            """
+            {
+              "ok": true,
+              "ts": 1,
+              "durationMs": 0,
+              "channels": {
+                "telegram": {
+                  "configured": true,
+                  "linked": true,
+                  "authAgeMs": 60000
+                }
+              },
+              "channelOrder": ["telegram"],
+              "channelLabels": {
+                "telegram": "Telegram"
+              },
+              "heartbeatSeconds": 30,
+              "sessions": {
+                "path": "/tmp/sessions",
+                "count": 1,
+                "recent": []
+              }
+            }
+            """.utf8)
+        let session = GatewayTestWebSocketSession(
+            taskFactory: {
+                GatewayTestWebSocketTask(
+                    sendHook: { task, message, sendIndex in
+                        guard sendIndex > 0 else { return }
+                        guard let id = GatewayWebSocketTestSupport.requestID(from: message) else { return }
+                        let json = """
+                        {
+                          "type": "res",
+                          "id": "\(id)",
+                          "ok": true,
+                          "payload": \(String(decoding: healthData, as: UTF8.self))
+                        }
+                        """
+                        task.emitReceiveSuccess(.data(Data(json.utf8)))
+                    })
+            })
+        let url = try #require(URL(string: "ws://example.invalid"))
+        let connection = GatewayConnection(
+            configProvider: { (url: url, token: nil, password: nil) },
+            sessionBox: WebSocketSessionBox(session: session))
+        let port = GatewayEnvironment.gatewayPort()
+        let descriptor = PortGuardian.Descriptor(
+            pid: 4242,
+            command: "openclaw-gateway",
+            executablePath: "/tmp/openclaw-gateway")
+
+        let manager = GatewayProcessManager.shared
+        await PortGuardian.shared.setTestingDescriptor(descriptor, forPort: port)
+        manager.setTestingConnection(connection)
+        manager.setTestingSkipControlChannelRefresh(true)
+        manager.setTestingLastFailureReason("stale")
+
+        func cleanup() async {
+            await PortGuardian.shared.setTestingDescriptor(nil, forPort: port)
+            manager.setTestingConnection(nil)
+            manager.setTestingSkipControlChannelRefresh(false)
+            manager.setTestingDesiredActive(false)
+            manager.setTestingLastFailureReason(nil)
+        }
+
+        do {
+            let attached = await manager._testAttachExistingGatewayIfAvailable()
+            #expect(attached)
+            #expect(manager.lastFailureReason == nil)
+            guard case let .attachedExisting(statusDetails) = manager.status else {
+                Issue.record("expected attachedExisting status")
+                await cleanup()
+                return
+            }
+            let details = try #require(statusDetails)
+            #expect(details.contains("port \(port)"))
+            #expect(details.contains("Telegram linked"))
+            #expect(details.contains("auth 1m"))
+            #expect(details.contains("pid 4242 openclaw-gateway @ /tmp/openclaw-gateway"))
+            await cleanup()
+        } catch {
+            await cleanup()
+            throw error
+        }
+    }
 }

apps/macos/Tests/OpenClawIPCTests/NodeServiceManagerTests.swift

@@ -3,17 +3,19 @@ import Testing
 @testable import OpenClaw
 
 @Suite(.serialized) struct NodeServiceManagerTests {
-    @Test func `builds node service commands with current CLI shape`() throws {
-        let tmp = try makeTempDirForTests()
-        CommandResolver.setProjectRoot(tmp.path)
+    @Test func `builds node service commands with current CLI shape`() async throws {
+        try await TestIsolation.withUserDefaultsValues(["openclaw.gatewayProjectRootPath": nil]) {
+            let tmp = try makeTempDirForTests()
+            CommandResolver.setProjectRoot(tmp.path)
 
-        let openclawPath = tmp.appendingPathComponent("node_modules/.bin/openclaw")
-        try makeExecutableForTests(at: openclawPath)
+            let openclawPath = tmp.appendingPathComponent("node_modules/.bin/openclaw")
+            try makeExecutableForTests(at: openclawPath)
 
-        let start = NodeServiceManager._testServiceCommand(["start"])
-        #expect(start == [openclawPath.path, "node", "start", "--json"])
+            let start = NodeServiceManager._testServiceCommand(["start"])
+            #expect(start == [openclawPath.path, "node", "start", "--json"])
 
-        let stop = NodeServiceManager._testServiceCommand(["stop"])
-        #expect(stop == [openclawPath.path, "node", "stop", "--json"])
+            let stop = NodeServiceManager._testServiceCommand(["stop"])
+            #expect(stop == [openclawPath.path, "node", "stop", "--json"])
+        }
     }
 }