feat: Add hardened error handling and retries (#2451)

- Closes #1830
 - Closes #2099

src/card-controller/config/config-manager.ts

@@ -1,4 +1,5 @@
 import { isEqual } from 'lodash-es';
+import { ConfigParseError } from './error.js';
 import { copyConfig, isConfigUpgradeable } from '../../config/management.js';
 import { setProfiles } from '../../config/profiles/set-profiles.js';
 import {
@@ -56,7 +57,7 @@ export class ConfigManager {
 
   public setConfig(inputConfig?: RawAdvancedCameraCardConfig): void {
     if (!inputConfig) {
-      throw new Error(localize('error.invalid_configuration'));
+      throw new ConfigParseError(localize('error.invalid_configuration'));
     }
 
     const parseResult = advancedCameraCardConfigSchema.safeParse(inputConfig);
@@ -67,7 +68,7 @@ export class ConfigManager {
       if (isConfigUpgradeable(inputConfig)) {
         upgradeMessage = `${localize('error.upgrade_available')}. `;
       }
-      throw new Error(
+      throw new ConfigParseError(
         upgradeMessage +
           `${localize('error.invalid_configuration')}: ` +
           (hint ?? localize('error.invalid_configuration_no_hint')),
@@ -109,7 +110,6 @@ export class ConfigManager {
     this._api.getInitializationManager().uninitialize(InitializationAspect.VIEW);
     this._api.getViewManager().reset();
 
-    this._api.getMessageManager().reset();
     this._api.getStatusBarItemManager().removeAllDynamicStatusBarItems();
 
     this._processOverrideConfig();
@@ -118,11 +118,28 @@ export class ConfigManager {
   }
 
   private _processOverrideConfig(): void {
-    const overriddenConfig = this._getOverriddenConfig();
+    /* istanbul ignore if: No (current) way to reach this code -- @preserve */
+    if (!this._config) {
+      return;
+    }
+
+    let overriddenConfig: AdvancedCameraCardConfig;
+    try {
+      overriddenConfig = this._overridesManager.getConfig(this._config);
+    } catch (ev) {
+      this._api.getIssueManager().trigger('config_error', { error: ev });
+      return;
+    }
+
+    // Clear any prior config error on success. This method runs both from
+    // setConfig() and from condition-change-driven override recomputations;
+    // resetting here ensures a transient override error is cleared when
+    // conditions change to produce a valid config again.
+    this._api.getIssueManager().reset('config_error');
 
     // Save on Lit re-rendering costs by only updating the configuration if it
     // actually changes.
-    if (!overriddenConfig || isEqual(overriddenConfig, this._overriddenConfig)) {
+    if (isEqual(overriddenConfig, this._overriddenConfig)) {
       return;
     }
 
@@ -189,20 +206,6 @@ export class ConfigManager {
     /* async */ this._initializeBackgroundAndUpdate(previousConfig);
   }
 
-  private _getOverriddenConfig(): AdvancedCameraCardConfig | null {
-    /* istanbul ignore if: No (current) way to reach this code -- @preserve */
-    if (!this._config) {
-      return null;
-    }
-
-    try {
-      return this._overridesManager.getConfig(this._config);
-    } catch (ev) {
-      this._api.getMessageManager().setErrorIfHigherPriority(ev);
-      return null;
-    }
-  }
-
   /**
    * Initialize config dependent items in the background. For items that the
    * card hard requires, use InitializationManager instead.

src/card-controller/config/error.ts

@@ -0,0 +1,5 @@
+import { AdvancedCameraCardError } from '../../types.js';
+
+class ConfigError extends AdvancedCameraCardError {}
+
+export class ConfigParseError extends ConfigError {}

src/card-controller/config/load-folders.ts

@@ -7,6 +7,6 @@ export const setFoldersFromConfig = (api: CardConfigLoaderAPI): void => {
       .getFoldersManager()
       .addFolders(api.getConfigManager().getConfig()?.folders ?? []);
   } catch (ev) {
-    api.getMessageManager().setErrorIfHigherPriority(ev);
+    api.getIssueManager().trigger('config_error', { error: ev });
   }
 };

src/card-controller/config/overrides-manager.ts

@@ -1,4 +1,4 @@
-import { merge } from 'lodash-es';
+import { get, merge } from 'lodash-es';
 import { ConditionsManager } from '../../conditions/conditions-manager';
 import { ConditionStateManagerReadonlyInterface } from '../../conditions/types';
 import {
@@ -92,9 +92,24 @@ export class OverridesManager {
 
     const parseResult = advancedCameraCardConfigSchema.safeParse(output);
     if (!parseResult.success) {
+      // Surface one co-located failure object per Zod issue — path, the value
+      // the user actually wrote, and the most informative "expected" field for
+      // this issue code. Avoids dumping the full merged config (which is
+      // mostly schema defaults the user never wrote) and keeps the reader from
+      // cross-referencing two parallel arrays.
+      const failures = parseResult.error.issues.map((issue) => ({
+        path: issue.path.map(String).join('.'),
+        received: get(output, issue.path),
+        expected:
+          issue.code === 'invalid_value'
+            ? issue.values
+            : issue.code === 'invalid_type'
+              ? issue.expected
+              : issue.message,
+      }));
       throw new OverrideConfigurationError(
         localize('error.invalid_configuration_override'),
-        [parseResult.error.issues, output],
+        { failures },
       );
     }
     return parseResult.data;