fix(document): timeout reason bucket + Sonar https hotspot (#892 round 2)

Round-2 review on PR #892:
- OcrProcessor.process now catches TimeoutError separately and returns
  parse_failed_reason="timeout" with a populated message ("OCR timed out after
  Ns"), instead of conflating timeouts with API errors under "error" and logging
  an empty suffix. Lets dashboards tell a too-low timeout from a failing
  provider. Test added.
- Add validator-rejection tests for DOCUMENT_OCR_TIMEOUT_SECONDS=0 (gte=1) and
  DOCUMENT_MAX_PDF_SIZE_MB=-1 (gte=0), matching the existing validator-test
  pattern.
- Comment the _Settings test fixture's max_pdf_size_mb=0.0 default.

SonarCloud: quality gate was failing on new_security_hotspots_reviewed (S5332
"use https") from an http:// URL in the new gateway-timeout test — switched to
https:// (mirrors commit 98c9d58e).

Co-Authored-By: Claude Opus 4.8 (1M context) <noreply@anthropic.com>

tests/unit/test_config.py

@@ -509,6 +509,22 @@ class TestDynaconfValidators:
         with pytest.raises(ValidationError, match="DOCUMENT_CHUNK_SIZE"):
             _reload_config()
 
+    @patch.dict(os.environ, {"DOCUMENT_OCR_TIMEOUT_SECONDS": "0"}, clear=True)
+    def test_ocr_timeout_zero_rejected(self):
+        """DOCUMENT_OCR_TIMEOUT_SECONDS=0 fails the gte=1 validator."""
+        from dynaconf import ValidationError
+
+        with pytest.raises(ValidationError, match="DOCUMENT_OCR_TIMEOUT_SECONDS"):
+            _reload_config()
+
+    @patch.dict(os.environ, {"DOCUMENT_MAX_PDF_SIZE_MB": "-1"}, clear=True)
+    def test_max_pdf_size_negative_rejected(self):
+        """DOCUMENT_MAX_PDF_SIZE_MB=-1 fails the gte=0 validator (0 = disabled)."""
+        from dynaconf import ValidationError
+
+        with pytest.raises(ValidationError, match="DOCUMENT_MAX_PDF_SIZE_MB"):
+            _reload_config()
+
     @patch.dict(os.environ, {"METRICS_PORT": "8080"}, clear=True)
     def test_valid_metrics_port(self):
         """Test valid METRICS_PORT passes validation."""

tests/unit/test_ocr_processor.py

@@ -132,6 +132,23 @@ async def test_processor_backend_error_returns_success_false(monkeypatch):
     assert r.metadata["parse_failed_reason"] == "error"
 
 
+async def test_processor_timeout_returns_timeout_reason(monkeypatch):
+    """A backend TimeoutError gets its own reason bucket (not 'error')."""
+
+    class _TimeoutBackend:
+        async def ocr(self, content, mime_type):
+            raise TimeoutError
+
+    monkeypatch.setattr(
+        ocr, "get_settings", lambda: _settings(document_ocr_timeout_seconds=5.0)
+    )
+    monkeypatch.setattr(ocr, "build_ocr_backend", lambda s: _TimeoutBackend())
+    r = await ocr.OcrProcessor().process(b"%PDF-1.7", "application/pdf")
+    assert r.success is False
+    assert r.metadata["parse_failed_reason"] == "timeout"
+    assert "timed out" in r.error
+
+
 async def test_gateway_backend_uses_configured_timeout(mocker, monkeypatch):
     """The gateway OCR call must use DOCUMENT_OCR_TIMEOUT_SECONDS (resolved per
     call), not the old hardcoded 180s constant."""
@@ -155,7 +172,7 @@ async def test_gateway_backend_uses_configured_timeout(mocker, monkeypatch):
         ocr, "get_settings", lambda: _settings(document_ocr_timeout_seconds=42.0)
     )
 
-    backend = ocr._GatewayOcrBackend("http://gw", "mistral/mistral-ocr-latest")
+    backend = ocr._GatewayOcrBackend("https://gw", "mistral/mistral-ocr-latest")
     await backend.ocr(b"%PDF-1.7", "application/pdf")
 
     # httpx.Timeout(42.0, connect=10.0): the read/overall budget is the setting.

tests/unit/test_registry_tiering.py

@@ -74,6 +74,8 @@ class _Settings:
         page_fraction=0.5,
         min_page_chars=16,
         detect_scanned=False,
+        # Guard off by default so existing tiering tests are unaffected; tests
+        # that exercise the size guard pass an explicit cap.
         max_pdf_size_mb=0.0,
     ):
         self.document_tier1_engine = engine