Merge remote-tracking branch 'origin/master' into fix/309-embed-resilience

# Conflicts:
#	nextcloud_mcp_server/vector/processor.py

CHANGELOG.md

@@ -5,6 +5,34 @@ All notable changes to the Nextcloud MCP Server will be documented in this file.
 The format is based on [Keep a Changelog](https://keepachangelog.com/en/1.0.0/),
 and this project adheres to [PEP 440](https://peps.python.org/pep-0440/).
 
+## v0.113.0 (2026-06-11)
+
+### Feat
+
+- **document**: configurable OCR timeout and fail-fast PDF size guard
+
+### Fix
+
+- **document**: catch httpx timeout from gateway OCR backend (#892 r3)
+- **document**: timeout reason bucket + Sonar https hotspot (#892 round 2)
+- **document**: apply OCR timeout to Mistral backend + review/Sonar fixes (#892)
+- **vector**: guard unbound doc_task + address review nits (#891)
+- **vector**: URL-encode DAV paths and unwrap TaskGroup exceptions
+
+## v0.112.0 (2026-06-11)
+
+### Feat
+
+- **worker**: structured logs + metrics + traces for ingest worker
+
+### Fix
+
+- **worker**: clear Sonar S5332 hotspot + address review nits
+
+### Refactor
+
+- **worker**: trim observability helper docstring; clarify test fake
+
 ## v0.111.0 (2026-06-10)
 
 ### Feat

docs/configuration.md

@@ -536,6 +536,23 @@ DOCUMENT_CHUNK_OVERLAP=200            # Overlapping characters between chunks (d
 
 > **Note:** The `VECTOR_SYNC_*` tuning parameters keep their names as they're implementation details. Only the user-facing feature flag was renamed to `ENABLE_SEMANTIC_SEARCH`.
 
+#### Document parsing robustness (PDF)
+
+These guard the parse/OCR tiers against pathological PDFs. Defaults are safe;
+tune per tenant when a corpus has very large scans or a gateway with its own
+shorter OCR ceiling:
+
+```dotenv
+DOCUMENT_PARSE_TIMEOUT_SECONDS=120    # Wall-clock cap per isolated parse (default: 120)
+DOCUMENT_OCR_TIMEOUT_SECONDS=180      # OCR backend request timeout (default: 180)
+DOCUMENT_MAX_PDF_SIZE_MB=50           # Pre-parse size cap; 0 disables (default: 50)
+```
+
+A PDF larger than `DOCUMENT_MAX_PDF_SIZE_MB` fails fast with reason `oversize`
+(exported on `astrolabe_document_parse_failed_total{reason="oversize"}`) instead
+of being handed to the tiers, where a 40+ MB scan would otherwise burn the full
+OCR timeout for zero recovered text.
+
 ### Embedding Service Configuration
 
 The server picks an embedding provider via auto-detection. Priority order

nextcloud_mcp_server/cli.py

@@ -6,6 +6,7 @@ import click
 import uvicorn
 
 from nextcloud_mcp_server.config import (
+    Settings,
     get_database_url,
     get_settings,
     is_ephemeral_token_db,
@@ -17,7 +18,12 @@ from nextcloud_mcp_server.migrations import (
     show_migration_history,
     upgrade_database,
 )
-from nextcloud_mcp_server.observability import get_uvicorn_logging_config
+from nextcloud_mcp_server.observability import (
+    get_uvicorn_logging_config,
+    setup_logging,
+    setup_metrics,
+    setup_tracing,
+)
 from nextcloud_mcp_server.server import AVAILABLE_APPS
 
 from .app import get_app
@@ -284,6 +290,41 @@ def run(
     )
 
 
+def _init_worker_observability(settings: Settings) -> None:
+    """Configure logging, metrics, and tracing for the standalone ingest worker."""
+    # Mirrors app.py's lifespan bootstrap; without it the worker's astrolabe_*
+    # metrics and document_processor.parse spans are invisible in external mode.
+    # Structured logging first, so every subsequent startup line is JSON like
+    # the API's — the worker entrypoint never went through uvicorn's log_config.
+    setup_logging(
+        log_format=settings.log_format,
+        log_level=settings.log_level,
+        include_trace_context=settings.log_include_trace_context,
+    )
+
+    if settings.metrics_enabled:
+        setup_metrics(port=settings.metrics_port)
+        logger.info(
+            "Prometheus metrics enabled on dedicated port %s", settings.metrics_port
+        )
+
+    if settings.otel_exporter_otlp_endpoint:
+        setup_tracing(
+            service_name=settings.otel_service_name,
+            otlp_endpoint=settings.otel_exporter_otlp_endpoint,
+            otlp_verify_ssl=settings.otel_exporter_verify_ssl,
+            sampling_rate=settings.otel_traces_sampler_arg,
+        )
+        logger.info(
+            "OpenTelemetry tracing enabled (endpoint: %s)",
+            settings.otel_exporter_otlp_endpoint,
+        )
+    else:
+        logger.info(
+            "OpenTelemetry tracing disabled (set OTEL_EXPORTER_OTLP_ENDPOINT to enable)"
+        )
+
+
 @click.command()
 @click.option(
     "--concurrency",
@@ -319,6 +360,11 @@ def worker(concurrency: int | None):
             f"resolved INGEST_QUEUE={settings.ingest_queue!r}"
         )
 
+    # Initialize observability here, not in a lifespan — the worker never runs
+    # uvicorn, so it skips app.py's bootstrap (the WHY lives in the helper's
+    # docstring). Done after the queue check so a misconfig fails fast.
+    _init_worker_observability(settings)
+
     from nextcloud_mcp_server.vector.queue.procrastinate import (  # noqa: PLC0415
         INGEST_QUEUE_NAME,
         apply_ingest_queue_schema,

nextcloud_mcp_server/client/webdav.py

@@ -5,7 +5,7 @@ import mimetypes
 import xml.etree.ElementTree as ET
 from email.utils import parsedate_to_datetime
 from typing import Any, Dict, List, Optional, Tuple
-from urllib.parse import unquote
+from urllib.parse import quote, unquote
 from xml.sax.saxutils import escape as xml_escape
 
 from httpx import HTTPStatusError
@@ -26,11 +26,42 @@ WEBDAV_SEARCH_PAGE_SIZE = 500
 WEBDAV_SEARCH_MAX_RESULTS = 50000
 
 
+def _encode_dav_path(path: str) -> str:
+    """Percent-encode a *decoded* DAV path for use in a request URL/header.
+
+    Paths flow through this client already URL-decoded (e.g. ``unquote`` on the
+    ``<d:href>`` of a PROPFIND/REPORT response, or raw user-supplied paths from
+    MCP tools), so characters like ``#``, ``,`` and spaces reach httpx verbatim.
+    An unencoded ``#`` is parsed as a URL fragment and silently truncates the
+    request path → spurious 404 on otherwise-valid files (issue: OHR-Bench
+    ingest, card 309). ``quote`` with ``safe="/"`` encodes the unsafe characters
+    while preserving the path separators; ASCII-only paths are unchanged.
+
+    Encode exactly once: the input is decoded, so a literal ``%`` becomes
+    ``%25`` (correct) rather than being mistaken for an existing escape.
+    """
+    return quote(path, safe="/")
+
+
 class WebDAVClient(BaseNextcloudClient):
     """Client for Nextcloud WebDAV operations."""
 
     app_name = "webdav"
 
+    def _webdav_path(self, path: str) -> str:
+        """Build the request path for ``path`` under the user's DAV root.
+
+        Percent-encodes the caller-supplied portion (see ``_encode_dav_path``)
+        so names with ``#``, commas, or spaces don't truncate/404; the base
+        ``/remote.php/dav/files/<user>`` segment is left as-is.
+
+        Precondition: ``path`` is a **decoded** path (the convention everywhere
+        in this client — PROPFIND/REPORT hrefs are ``unquote``d before storage,
+        and MCP-tool inputs are raw). It is encoded exactly once, so passing an
+        already-encoded path would double-encode it (``%20`` → ``%2520``).
+        """
+        return f"{self._get_webdav_base_path()}/{_encode_dav_path(path.lstrip('/'))}"
+
     async def delete_resource(self, path: str) -> Dict[str, Any]:
         """Delete a resource (file or directory) via WebDAV DELETE."""
         # Ensure path ends with a slash if it's a directory
@@ -39,7 +70,7 @@ class WebDAVClient(BaseNextcloudClient):
         else:
             path_with_slash = path
 
-        webdav_path = f"{self._get_webdav_base_path()}/{path_with_slash.lstrip('/')}"
+        webdav_path = self._webdav_path(path_with_slash)
         logger.debug("Deleting WebDAV resource: %s", webdav_path)
 
         headers = {"OCS-APIRequest": "true"}
@@ -124,15 +155,15 @@ class WebDAVClient(BaseNextcloudClient):
         mime_type: Optional[str] = None,
     ) -> Dict[str, Any]:
         """Add/Update an attachment to a note via WebDAV PUT."""
-        # Construct paths based on provided category
+        # Construct paths based on provided category. Encode via _webdav_path so
-        webdav_base = self._get_webdav_base_path()
+        # categories/filenames with '#', commas or spaces don't truncate/404.
         category_path_part = f"{category}/" if category else ""
         attachment_dir_segment = f".attachments.{note_id}"
         parent_dir_webdav_rel_path = (
             f"Notes/{category_path_part}{attachment_dir_segment}"
         )
-        parent_dir_path = f"{webdav_base}/{parent_dir_webdav_rel_path}"
+        parent_dir_path = self._webdav_path(parent_dir_webdav_rel_path)
-        attachment_path = f"{parent_dir_path}/{filename}"
+        attachment_path = self._webdav_path(f"{parent_dir_webdav_rel_path}/{filename}")
 
         logger.debug("Uploading attachment '%s' for note %s", filename, note_id)
 
@@ -144,7 +175,7 @@ class WebDAVClient(BaseNextcloudClient):
         headers = {"Content-Type": mime_type, "OCS-APIRequest": "true"}
         try:
             # First check if we can access WebDAV at all
-            notes_dir_path = f"{webdav_base}/Notes"
+            notes_dir_path = self._webdav_path("Notes")
             propfind_headers = {"Depth": "0", "OCS-APIRequest": "true"}
             notes_dir_response = await self._make_request(
                 "PROPFIND", notes_dir_path, headers=propfind_headers
@@ -209,10 +240,11 @@ class WebDAVClient(BaseNextcloudClient):
         self, note_id: int, filename: str, category: Optional[str] = None
     ) -> Tuple[bytes, str]:
         """Fetch a specific attachment from a note via WebDAV GET."""
-        webdav_base = self._get_webdav_base_path()
         category_path_part = f"{category}/" if category else ""
         attachment_dir_segment = f".attachments.{note_id}"
-        attachment_path = f"{webdav_base}/Notes/{category_path_part}{attachment_dir_segment}/{filename}"
+        attachment_path = self._webdav_path(
+            f"Notes/{category_path_part}{attachment_dir_segment}/{filename}"
+        )
 
         logger.debug("Fetching attachment '%s' for note %s", filename, note_id)
 
@@ -252,7 +284,7 @@ class WebDAVClient(BaseNextcloudClient):
 
     async def list_directory(self, path: str = "") -> List[Dict[str, Any]]:
         """List files and directories in the specified path via WebDAV PROPFIND."""
-        webdav_path = f"{self._get_webdav_base_path()}/{path.lstrip('/')}"
+        webdav_path = self._webdav_path(path)
         if not webdav_path.endswith("/"):
             webdav_path += "/"
 
@@ -352,7 +384,7 @@ class WebDAVClient(BaseNextcloudClient):
 
     async def read_file(self, path: str) -> Tuple[bytes, str]:
         """Read a file's content via WebDAV GET."""
-        webdav_path = f"{self._get_webdav_base_path()}/{path.lstrip('/')}"
+        webdav_path = self._webdav_path(path)
 
         logger.debug("Reading file: %s", path)
 
@@ -379,7 +411,7 @@ class WebDAVClient(BaseNextcloudClient):
         self, path: str, content: bytes, content_type: Optional[str] = None
     ) -> Dict[str, Any]:
         """Write content to a file via WebDAV PUT."""
-        webdav_path = f"{self._get_webdav_base_path()}/{path.lstrip('/')}"
+        webdav_path = self._webdav_path(path)
 
         logger.debug("Writing file: %s", path)
 
@@ -410,7 +442,7 @@ class WebDAVClient(BaseNextcloudClient):
         self, path: str, recursive: bool = False
     ) -> Dict[str, Any]:
         """Create a directory via WebDAV MKCOL."""
-        webdav_path = f"{self._get_webdav_base_path()}/{path.lstrip('/')}"
+        webdav_path = self._webdav_path(path)
         if not webdav_path.endswith("/"):
             webdav_path += "/"
 
@@ -468,10 +500,8 @@ class WebDAVClient(BaseNextcloudClient):
         Returns:
             Dict with status_code and optional message
         """
-        source_webdav_path = f"{self._get_webdav_base_path()}/{source_path.lstrip('/')}"
+        source_webdav_path = self._webdav_path(source_path)
-        destination_webdav_path = (
+        destination_webdav_path = self._webdav_path(destination_path)
-            f"{self._get_webdav_base_path()}/{destination_path.lstrip('/')}"
-        )
 
         # Ensure paths have consistent trailing slashes for directories
         if source_path.endswith("/") and not destination_path.endswith("/"):
@@ -552,10 +582,8 @@ class WebDAVClient(BaseNextcloudClient):
         Returns:
             Dict with status_code and optional message
         """
-        source_webdav_path = f"{self._get_webdav_base_path()}/{source_path.lstrip('/')}"
+        source_webdav_path = self._webdav_path(source_path)
-        destination_webdav_path = (
+        destination_webdav_path = self._webdav_path(destination_path)
-            f"{self._get_webdav_base_path()}/{destination_path.lstrip('/')}"
-        )
 
         # Ensure paths have consistent trailing slashes for directories
         if source_path.endswith("/") and not destination_path.endswith("/"):
@@ -1678,7 +1706,7 @@ class WebDAVClient(BaseNextcloudClient):
                 distinguish a definitive absence (HTTP 404) from a
                 brittle response (None).
         """
-        webdav_path = f"{self._get_webdav_base_path()}/{path.lstrip('/')}"
+        webdav_path = self._webdav_path(path)
 
         propfind_body = """<?xml version="1.0"?>
 <d:propfind xmlns:d="DAV:" xmlns:oc="http://owncloud.org/ns">

nextcloud_mcp_server/config.py

@@ -146,6 +146,10 @@ _DEFAULTS: dict[str, Any] = {
     "document_pdf_graphics_limit": 1000,
     "document_parse_timeout_seconds": 120.0,
     "document_parse_mem_limit_mb": 1536,
+    # Pre-parse size cap (MB): PDFs larger than this fail fast with reason
+    # "oversize" instead of burning the OCR timeout to 0 chars on a pathological
+    # file. 0 disables the guard.
+    "document_max_pdf_size_mb": 50.0,
     # Tier-0 classifier (records classification metrics on the tiered path)
     "document_classify_enabled": True,
     # Tiered PDF pipeline: pypdfium2 is the default/only hot-path extractor;
@@ -168,6 +172,10 @@ _DEFAULTS: dict[str, Any] = {
     "document_ocr_page_fraction": 0.5,
     "document_ocr_min_page_chars": 16,
     "document_ocr_detect_scanned": True,
+    # OCR backend request timeout (seconds). Slow scanned newspapers can take
+    # 20-60s; raise/lower per tenant. Configurable so a tenant isn't stuck with
+    # the 180s default when its gateway has its own shorter ceiling.
+    "document_ocr_timeout_seconds": 180.0,
     # Observability
     "metrics_enabled": True,
     "metrics_port": 9090,
@@ -319,7 +327,10 @@ _dynaconf = Dynaconf(
         Validator("VERIFICATION_CONCURRENCY", gte=1),
         Validator("DOCUMENT_CHUNK_SIZE", gte=1),
         Validator("DOCUMENT_PARSE_TIMEOUT_SECONDS", gte=1),
+        Validator("DOCUMENT_OCR_TIMEOUT_SECONDS", gte=1),
         Validator("DOCUMENT_PARSE_MEM_LIMIT_MB", gte=128),
+        # 0 disables the pre-parse PDF size cap; otherwise it must be positive.
+        Validator("DOCUMENT_MAX_PDF_SIZE_MB", gte=0),
         # >=1: pymupdf4llm treats graphics_limit=0 as "no cap", which would
         # re-expose the OOM this guards against.
         Validator("DOCUMENT_PDF_GRAPHICS_LIMIT", gte=1),
@@ -782,6 +793,11 @@ class Settings:
     # float so a fractional DOCUMENT_PARSE_TIMEOUT_SECONDS is honoured, matching
     # anyio.move_on_after's float seconds.
     document_parse_timeout_seconds: float = 120.0
+    # Pre-parse PDF size cap (MB). A PDF larger than this fails fast with
+    # parse_failed_reason="oversize" (placeholder marked "failed") rather than
+    # being handed to the fast/OCR tiers, where a pathological large file burns
+    # the OCR timeout for 0 chars. 0 disables the guard.
+    document_max_pdf_size_mb: float = 50.0
     # RLIMIT_AS in the parse subprocess (below the pod limit). Applied once per
     # worker for its lifetime, so changing it needs a pod restart.
     document_parse_mem_limit_mb: int = 1536
@@ -801,6 +817,10 @@ class Settings:
     # gateway routes on the "<provider>/" prefix; the direct mistral backend
     # strips it.
     document_ocr_model: str = "mistral/mistral-ocr-latest"
+    # OCR backend HTTP request timeout (seconds). float for parity with the
+    # parse timeout / httpx.Timeout; per-tenant tunable so a gateway with a
+    # shorter ceiling isn't masked by the 180s default.
+    document_ocr_timeout_seconds: float = 180.0
     # OCR escalation triggers (tier-0), per-tenant tunable. A page is OCR-worthy
     # if near-empty (< min_page_chars) OR low text-quality (< min_text_quality)
     # OR (when detect_scanned, image-analysis only runs when OCR is enabled)
@@ -1431,12 +1451,14 @@ def get_settings() -> Settings:
         "document_chunk_page_aware": "DOCUMENT_CHUNK_PAGE_AWARE",
         "document_pdf_graphics_limit": "DOCUMENT_PDF_GRAPHICS_LIMIT",
         "document_parse_timeout_seconds": "DOCUMENT_PARSE_TIMEOUT_SECONDS",
+        "document_max_pdf_size_mb": "DOCUMENT_MAX_PDF_SIZE_MB",
         "document_parse_mem_limit_mb": "DOCUMENT_PARSE_MEM_LIMIT_MB",
         "document_classify_enabled": "DOCUMENT_CLASSIFY_ENABLED",
         "document_tier1_engine": "DOCUMENT_TIER1_ENGINE",
         "document_ocr_enabled": "DOCUMENT_OCR_ENABLED",
         "document_ocr_provider": "DOCUMENT_OCR_PROVIDER",
         "document_ocr_model": "DOCUMENT_OCR_MODEL",
+        "document_ocr_timeout_seconds": "DOCUMENT_OCR_TIMEOUT_SECONDS",
         "document_ocr_min_text_quality": "DOCUMENT_OCR_MIN_TEXT_QUALITY",
         "document_ocr_page_fraction": "DOCUMENT_OCR_PAGE_FRACTION",
         "document_ocr_min_page_chars": "DOCUMENT_OCR_MIN_PAGE_CHARS",

nextcloud_mcp_server/document_processors/ocr.py

@@ -31,7 +31,9 @@ from .base import DocumentProcessor, ProcessingResult
 
 logger = logging.getLogger(__name__)
 
-_OCR_TIMEOUT_SECONDS = 180.0
+# Connect timeout for the OCR backend request. The overall (read) timeout is
+# configurable via DOCUMENT_OCR_TIMEOUT_SECONDS and resolved per call.
+_OCR_CONNECT_TIMEOUT_SECONDS = 10.0
 
 
 def _pages_to_text(
@@ -93,8 +95,12 @@ class _GatewayOcrBackend(_OcrBackend):
             "document_b64": base64.b64encode(content).decode("ascii"),
             "mime_type": mime_type,
         }
+        # Resolved per call (get_settings builds fresh) so test monkeypatching is
+        # honoured; a live tenant change still needs a restart because the backend
+        # instance itself is cached for the pod's lifetime.
+        ocr_timeout = get_settings().document_ocr_timeout_seconds
         async with httpx.AsyncClient(
-            timeout=httpx.Timeout(_OCR_TIMEOUT_SECONDS, connect=10.0)
+            timeout=httpx.Timeout(ocr_timeout, connect=_OCR_CONNECT_TIMEOUT_SECONDS)
         ) as client:
             resp = await client.post(self._url, json=payload, headers=headers)
             resp.raise_for_status()
@@ -120,10 +126,17 @@ class _MistralOcrBackend(_OcrBackend):
         data_url = (
             f"data:{mime_type};base64,{base64.b64encode(content).decode('ascii')}"
         )
-        resp = await self._client.ocr.process_async(
+        # Apply DOCUMENT_OCR_TIMEOUT_SECONDS uniformly with the gateway backend.
-            model=self._model,
+        # The Mistral SDK manages its own httpx client, so wrap the call in an
-            document={"type": "document_url", "document_url": data_url},
+        # anyio cancel-scope timeout rather than threading a per-request timeout
-        )
+        # through the SDK; on expiry this raises TimeoutError, which the
+        # OcrProcessor turns into a clean parse failure.
+        ocr_timeout = get_settings().document_ocr_timeout_seconds
+        with anyio.fail_after(ocr_timeout):
+            resp = await self._client.ocr.process_async(
+                model=self._model,
+                document={"type": "document_url", "document_url": data_url},
+            )
         pages = [(p.index, p.markdown or "") for p in (resp.pages or [])]
         return _pages_to_text(pages)
 
@@ -251,6 +264,24 @@ class OcrProcessor(DocumentProcessor):
             text, boundaries = await backend.ocr(
                 content, content_type.split(";")[0].strip().lower()
             )
+        except (TimeoutError, httpx.TimeoutException):
+            # Two timeout shapes reach here: the Mistral backend's
+            # anyio.fail_after raises the builtin TimeoutError, while the gateway
+            # backend's httpx.Timeout raises httpx.ReadTimeout (a
+            # httpx.TimeoutException, NOT a TimeoutError). Catch both so a
+            # too-low DOCUMENT_OCR_TIMEOUT_SECONDS lands in its own reason bucket
+            # rather than being conflated with provider errors.
+            timeout = settings.document_ocr_timeout_seconds
+            logger.warning(
+                "OCR timed out for %s after %.1fs", filename or "<bytes>", timeout
+            )
+            return ProcessingResult(
+                text="",
+                metadata={"parse_failed_reason": "timeout"},
+                processor=self.name,
+                success=False,
+                error=f"OCR timed out after {timeout:.1f}s",
+            )
         except Exception as e:
             logger.warning("OCR failed for %s: %s", filename or "<bytes>", e)
             return ProcessingResult(

nextcloud_mcp_server/document_processors/registry.py

@@ -202,6 +202,33 @@ class ProcessorRegistry:
         """
         settings = get_settings()
 
+        # Pre-parse size guard: a pathologically large PDF (e.g. a 42 MB scanned
+        # DUDE) burns the OCR timeout for 0 chars. Fail fast with an explicit
+        # reason so the caller marks the placeholder "failed" instead of
+        # retrying. 0 disables the cap. This lives on the auto-tiered path only:
+        # an explicit processor_name="ocr" override (registry.process) bypasses
+        # _process_pdf entirely and is intentionally not size-gated (power-user
+        # escape hatch). Returning here also skips _run_processor, so the
+        # rejection is counted on astrolabe_document_parse_failed_total{oversize}
+        # (via vector/processor.py) but deliberately not on the parse-duration
+        # histogram -- there is no parse to time.
+        max_pdf_mb = settings.document_max_pdf_size_mb
+        if max_pdf_mb > 0 and len(content) > max_pdf_mb * 1024 * 1024:
+            size_mb = len(content) / (1024 * 1024)
+            logger.warning(
+                "PDF %s is %.1f MB (> %.1f MB cap); failing fast as oversize",
+                filename or "<bytes>",
+                size_mb,
+                max_pdf_mb,
+            )
+            return ProcessingResult(
+                text="",
+                metadata={"parse_failed_reason": "oversize"},
+                processor="size_guard",
+                success=False,
+                error=(f"PDF exceeds size cap: {size_mb:.1f} MB > {max_pdf_mb:.1f} MB"),
+            )
+
         if settings.document_tier1_engine == "pymupdf":
             processor = self._pdf_processor_for_tier("structured")
             if processor is None:

nextcloud_mcp_server/vector/_errors.py

@@ -0,0 +1,35 @@
+"""Error-formatting helpers for the vector-sync pipeline.
+
+Vector-sync work runs inside anyio task groups, so a failure in a child task
+surfaces as a ``BaseExceptionGroup`` whose default ``str()`` is the useless
+``"unhandled errors in a TaskGroup (N sub-exception)"`` -- it hides the real
+``ConnectError`` / ``APIConnectionError`` that operators need to triage embed
+drops (card 309). ``format_exception_group`` flattens the group to the leaf
+exceptions so log lines name the actual cause; pair it with ``exc_info=True`` to
+keep the full traceback.
+"""
+
+
+def format_exception_group(exc: BaseException) -> str:
+    """Return a concise, leaf-naming string for ``exc``.
+
+    For a (possibly nested) ``BaseExceptionGroup`` this joins the ``repr`` of
+    each leaf exception; for an ordinary exception it returns its ``repr``. The
+    result is meant for the human-readable portion of a log message, not for
+    parsing.
+    """
+    if not isinstance(exc, BaseExceptionGroup):
+        return repr(exc)
+    leaves = _flatten(exc)
+    noun = "sub-exception" if len(leaves) == 1 else "sub-exceptions"
+    return f"{len(leaves)} {noun}: " + "; ".join(repr(e) for e in leaves)
+
+
+def _flatten(exc: BaseException) -> list[BaseException]:
+    """Depth-first list of the leaf exceptions within ``exc``."""
+    if isinstance(exc, BaseExceptionGroup):
+        leaves: list[BaseException] = []
+        for sub in exc.exceptions:
+            leaves.extend(_flatten(sub))
+        return leaves
+    return [exc]

nextcloud_mcp_server/vector/oauth_sync.py

@@ -30,6 +30,7 @@ from httpx import BasicAuth, HTTPStatusError
 from nextcloud_mcp_server.auth.storage import RefreshTokenStorage
 from nextcloud_mcp_server.client import NextcloudClient
 from nextcloud_mcp_server.config import get_settings
+from nextcloud_mcp_server.vector._errors import format_exception_group
 from nextcloud_mcp_server.vector.processor import process_document
 from nextcloud_mcp_server.vector.queue.ports import TaskProducer
 from nextcloud_mcp_server.vector.scanner import DocumentTask, scan_user_documents
@@ -257,7 +258,7 @@ async def user_scanner_task(
             logger.error(
                 "[BasicAuth] Scanner error for %s: %s (%s/%s)",
                 user_id,
-                e,
+                format_exception_group(e),
                 consecutive_errors,
                 max_consecutive_errors,
                 exc_info=True,
@@ -331,7 +332,7 @@ async def multi_user_processor_task(
             break
 
         except NotProvisionedError:
-            if doc_task:
+            if doc_task is not None:
                 logger.warning(
                     "[BasicAuth] User %s not provisioned, skipping %s_%s",
                     doc_task.user_id,
@@ -341,18 +342,21 @@ async def multi_user_processor_task(
             continue
 
         except Exception as e:
-            if doc_task:
+            if doc_task is not None:
                 logger.error(
                     "[BasicAuth] Processor %s error processing %s_%s: %s",
                     worker_id,
                     doc_task.doc_type,
                     doc_task.doc_id,
-                    e,
+                    format_exception_group(e),
                     exc_info=True,
                 )
             else:
                 logger.error(
-                    "[BasicAuth] Processor %s error: %s", worker_id, e, exc_info=True
+                    "[BasicAuth] Processor %s error: %s",
+                    worker_id,
+                    format_exception_group(e),
+                    exc_info=True,
                 )
 
         finally:
@@ -481,7 +485,11 @@ async def user_manager_task(
                 logger.info("[BasicAuth] Stopped %s scanner(s)", len(revoked_users))
 
         except Exception as e:
-            logger.error("[BasicAuth] User manager error: %s", e, exc_info=True)
+            logger.error(
+                "[BasicAuth] User manager error: %s",
+                format_exception_group(e),
+                exc_info=True,
+            )
 
         # Sleep until next poll
         try:

nextcloud_mcp_server/vector/processor.py

@@ -33,6 +33,7 @@ from nextcloud_mcp_server.observability.tracing import trace_operation
 from nextcloud_mcp_server.search.pdf_highlighter import PDFHighlighter
 from nextcloud_mcp_server.usage import UsageEventStore
 from nextcloud_mcp_server.vector import payload_keys
+from nextcloud_mcp_server.vector._errors import format_exception_group
 from nextcloud_mcp_server.vector.document_chunker import (
     DocumentChunker,
     PageAwareChunker,
@@ -284,6 +285,11 @@ async def processor_task(
     # Signal that the task has started and is ready
     task_status.started()
 
+    # Initialised before the loop so the broad except handler below can't hit an
+    # unbound name if receive() itself raises a non-TimeoutError/EndOfStream
+    # exception on the very first iteration (mirrors multi_user_processor_task).
+    doc_task: DocumentTask | None = None
+
     while not shutdown_event.is_set():
         try:
             # Get document with timeout (allows checking shutdown)
@@ -313,14 +319,22 @@ async def processor_task(
             break
 
         except Exception as e:
-            logger.error(
+            if doc_task is not None:
-                "Processor %s error processing %s_%s: %s",
+                logger.error(
-                worker_id,
+                    "Processor %s error processing %s_%s: %s",
-                doc_task.doc_type,
+                    worker_id,
-                doc_task.doc_id,
+                    doc_task.doc_type,
-                e,
+                    doc_task.doc_id,
-                exc_info=True,
+                    format_exception_group(e),
-            )
+                    exc_info=True,
+                )
+            else:
+                logger.error(
+                    "Processor %s error: %s",
+                    worker_id,
+                    format_exception_group(e),
+                    exc_info=True,
+                )
             # Continue to next document (no task_done() needed with streams)
 
     logger.info("Processor %s stopped", worker_id)
@@ -499,7 +513,7 @@ async def process_document(
                             max_retries,
                             doc_task.doc_type,
                             doc_task.doc_id,
-                            e,
+                            format_exception_group(e),
                             extra={
                                 "doc_id": doc_task.doc_id,
                                 "doc_type": doc_task.doc_type,
@@ -518,7 +532,7 @@ async def process_document(
                             doc_task.doc_id,
                             max_retries,
                             reason,
-                            e,
+                            format_exception_group(e),
                             extra={
                                 "doc_id": doc_task.doc_id,
                                 "doc_type": doc_task.doc_type,

pyproject.toml

@@ -1,6 +1,6 @@
 [project]
 name = "nextcloud-mcp-server"
-version = "0.111.0"
+version = "0.113.0"
 description = "Model Context Protocol (MCP) server for Nextcloud integration - enables AI assistants to interact with Nextcloud data"
 authors = [
     {name = "Chris Coutinho", email = "chris@coutinho.io"}

tests/test_cli.py

@@ -1,11 +1,12 @@
 """Tests for CLI options using Click's testing utilities."""
 
 import os
+from types import SimpleNamespace
 
 import pytest
 from click.testing import CliRunner
 
-from nextcloud_mcp_server.cli import run
+from nextcloud_mcp_server.cli import _init_worker_observability, run, worker
 
 
 @pytest.fixture
@@ -324,3 +325,146 @@ def test_stdio_calls_get_stdio_mcp(runner, clean_env, monkeypatch):
     assert result.exit_code == 0, result.output
     assert called_with.get("transport") == "stdio"
     assert called_with.get("enabled_apps") is None
+
+
+# ---------------------------------------------------------------------------
+# Ingest worker observability bootstrap (Deck #310 / #175)
+# ---------------------------------------------------------------------------
+
+
+def _fake_settings(**overrides):
+    """A lightweight settings stand-in for the worker observability helper.
+
+    The helper only reads attributes, so a SimpleNamespace avoids running the
+    real Settings.__post_init__ validation/derivation.
+    """
+    base = dict(
+        ingest_queue="postgres",  # for realism / worker() gating; unused by the helper
+        log_format="json",
+        log_level="INFO",
+        log_include_trace_context=True,
+        metrics_enabled=True,
+        metrics_port=9090,
+        otel_exporter_otlp_endpoint=None,
+        otel_service_name="nextcloud-mcp-server",
+        otel_exporter_verify_ssl=False,
+        otel_traces_sampler_arg=1.0,
+    )
+    base.update(overrides)
+    return SimpleNamespace(**base)
+
+
+@pytest.fixture
+def patched_observability(monkeypatch):
+    """Patch the worker's observability entrypoints and record their kwargs."""
+    calls: dict[str, dict] = {}
+    monkeypatch.setattr(
+        "nextcloud_mcp_server.cli.setup_logging",
+        lambda **kw: calls.__setitem__("logging", kw),
+    )
+    monkeypatch.setattr(
+        "nextcloud_mcp_server.cli.setup_metrics",
+        lambda **kw: calls.__setitem__("metrics", kw),
+    )
+    monkeypatch.setattr(
+        "nextcloud_mcp_server.cli.setup_tracing",
+        lambda **kw: calls.__setitem__("tracing", kw),
+    )
+    return calls
+
+
+def test_init_worker_observability_configures_logging(patched_observability):
+    """Worker initializes structured logging from settings (AC: JSON logs)."""
+    _init_worker_observability(_fake_settings())
+
+    assert patched_observability["logging"] == {
+        "log_format": "json",
+        "log_level": "INFO",
+        "include_trace_context": True,
+    }
+
+
+def test_init_worker_observability_starts_metrics_when_enabled(patched_observability):
+    """Worker starts the Prometheus server on the configured port (AC: /metrics)."""
+    _init_worker_observability(_fake_settings(metrics_port=9123))
+
+    assert patched_observability["metrics"] == {"port": 9123}
+
+
+def test_init_worker_observability_skips_metrics_when_disabled(patched_observability):
+    """METRICS_ENABLED=false leaves the worker without a metrics server."""
+    _init_worker_observability(_fake_settings(metrics_enabled=False))
+
+    assert "metrics" not in patched_observability
+    # Logging is still configured regardless of the metrics toggle.
+    assert "logging" in patched_observability
+
+
+def test_init_worker_observability_sets_up_tracing_when_endpoint(
+    patched_observability,
+):
+    """An OTLP endpoint enables tracing so worker spans (parse/embed) export."""
+    _init_worker_observability(
+        _fake_settings(
+            otel_exporter_otlp_endpoint="https://otel:4317",
+            otel_traces_sampler_arg=0.5,
+        )
+    )
+
+    assert patched_observability["tracing"] == {
+        "service_name": "nextcloud-mcp-server",
+        "otlp_endpoint": "https://otel:4317",
+        "otlp_verify_ssl": False,
+        "sampling_rate": 0.5,
+    }
+
+
+def test_init_worker_observability_skips_tracing_without_endpoint(
+    patched_observability,
+):
+    """No OTLP endpoint → tracing stays disabled (matches API pod behavior)."""
+    _init_worker_observability(_fake_settings(otel_exporter_otlp_endpoint=None))
+
+    assert "tracing" not in patched_observability
+
+
+def test_worker_initializes_observability_on_postgres_queue(runner, monkeypatch):
+    """The worker command wires up observability once config is runnable."""
+    monkeypatch.setattr(
+        "nextcloud_mcp_server.cli.get_settings",
+        lambda: _fake_settings(ingest_queue="postgres"),
+    )
+
+    called = {}
+
+    def fake_init(settings):
+        called["settings"] = settings
+        # Stop before the procrastinate/worker machinery.
+        raise SystemExit(0)
+
+    monkeypatch.setattr(
+        "nextcloud_mcp_server.cli._init_worker_observability", fake_init
+    )
+
+    result = runner.invoke(worker, [])
+    assert result.exit_code == 0, result.output
+    assert called.get("settings") is not None
+
+
+def test_worker_rejects_non_postgres_queue_before_observability(runner, monkeypatch):
+    """A non-postgres queue fails fast, before any metrics server is started."""
+    monkeypatch.setattr(
+        "nextcloud_mcp_server.cli.get_settings",
+        lambda: _fake_settings(ingest_queue="memory"),
+    )
+
+    called = {}
+    monkeypatch.setattr(
+        "nextcloud_mcp_server.cli._init_worker_observability",
+        lambda settings: called.setdefault("init", True),
+    )
+
+    result = runner.invoke(worker, [])
+    assert result.exit_code != 0
+    assert "INGEST_QUEUE=postgres" in result.output
+    assert "init" not in called

tests/unit/client/test_webdav.py

@@ -510,3 +510,133 @@ def test_parse_search_response_decodes_non_ascii_paths(mocker):
     assert results[0]["href"] == "/remote.php/dav/files/testuser/学生邮箱/report.pdf"
     # name comes from <d:displayname>, which is not URL-encoded; sanity-check it.
     assert results[0]["name"] == "report.pdf"
+
+
+def _request_url(mock_http_client) -> str:
+    """Positional URL passed to the underlying httpx ``request`` call."""
+    return mock_http_client.request.call_args[0][1]
+
+
+@pytest.mark.unit
+@pytest.mark.parametrize(
+    "path, expected",
+    [
+        ("", "/remote.php/dav/files/testuser/"),
+        ("/Documents/notes.txt", "/remote.php/dav/files/testuser/Documents/notes.txt"),
+        ("Documents/notes.txt", "/remote.php/dav/files/testuser/Documents/notes.txt"),
+        ("a/b #1.pdf", "/remote.php/dav/files/testuser/a/b%20%231.pdf"),
+        ("law/x, y  z.pdf", "/remote.php/dav/files/testuser/law/x%2C%20y%20%20z.pdf"),
+        (
+            "学生邮箱/r.pdf",
+            "/remote.php/dav/files/testuser/%E5%AD%A6%E7%94%9F%E9%82%AE%E7%AE%B1/r.pdf",
+        ),
+    ],
+)
+def test_webdav_path_encoding(path, expected):
+    """_webdav_path encodes the decoded caller path once, preserving '/', and
+    strips a leading slash. Every caller-path builder routes through this, so
+    it is the single source of truth for their encoding."""
+    client = WebDAVClient(AsyncMock(), "testuser")
+    assert client._webdav_path(path) == expected
+
+
+@pytest.mark.unit
+def test_encode_dav_path_encodes_exactly_once():
+    """Pins the decoded-input precondition: a literal '%' becomes '%25', so an
+    already-encoded path passed in error would double-encode (caught here)."""
+    from nextcloud_mcp_server.client.webdav import _encode_dav_path
+
+    assert _encode_dav_path("already%20encoded.pdf") == "already%2520encoded.pdf"
+
+
+@pytest.mark.unit
+async def test_read_file_encodes_special_chars(mocker):
+    """read_file must percent-encode '#', commas, and spaces in the path (card 309).
+
+    Paths arrive already URL-decoded from PROPFIND/REPORT, so an unencoded '#'
+    reaches httpx as a URL fragment and silently truncates the request → 404 on
+    valid files (e.g. OHR-Bench law filenames). The outgoing request path must be
+    percent-encoded.
+    """
+    mock_http_client = AsyncMock()
+    client = WebDAVClient(mock_http_client, "testuser")
+
+    mock_response = AsyncMock()
+    mock_response.content = b"%PDF-1.4 data"
+    mock_response.headers = {"content-type": "application/pdf"}
+    mock_response.raise_for_status = mocker.Mock()
+    mock_http_client.request = AsyncMock(return_value=mock_response)
+
+    # Name with a '#', a comma, a double space and a trailing space before ".pdf".
+    await client.read_file("law/ADMA BioManufacturing, LLC -  Amendment #2 .pdf")
+
+    url = _request_url(mock_http_client)
+    assert url.startswith("/remote.php/dav/files/testuser/")
+    # The hazardous characters are encoded; path separators are preserved.
+    assert "%23" in url  # '#'
+    assert "%2C" in url  # ','
+    assert "%20" in url  # space
+    assert "#" not in url
+    assert ", " not in url
+    assert "/law/" in url
+
+
+@pytest.mark.unit
+async def test_read_file_ascii_path_unchanged(mocker):
+    """A plain ASCII path must pass through unchanged (no spurious encoding)."""
+    mock_http_client = AsyncMock()
+    client = WebDAVClient(mock_http_client, "testuser")
+
+    mock_response = AsyncMock()
+    mock_response.content = b"data"
+    mock_response.headers = {"content-type": "text/plain"}
+    mock_response.raise_for_status = mocker.Mock()
+    mock_http_client.request = AsyncMock(return_value=mock_response)
+
+    await client.read_file("Documents/notes.txt")
+
+    assert (
+        _request_url(mock_http_client)
+        == "/remote.php/dav/files/testuser/Documents/notes.txt"
+    )
+
+
+@pytest.mark.unit
+async def test_move_resource_encodes_destination_header(mocker):
+    """The MOVE Destination header must be percent-encoded too (card 309)."""
+    mock_http_client = AsyncMock()
+    client = WebDAVClient(mock_http_client, "testuser")
+
+    mock_response = AsyncMock()
+    mock_response.status_code = 201
+    mock_response.raise_for_status = mocker.Mock()
+    mock_http_client.request = AsyncMock(return_value=mock_response)
+
+    await client.move_resource("a/old.pdf", "b/new #1.pdf")
+
+    call = mock_http_client.request.call_args
+    # Source is the request path; destination is the header.
+    assert call[0][1] == "/remote.php/dav/files/testuser/a/old.pdf"
+    destination = call.kwargs["headers"]["Destination"]
+    assert "%23" in destination
+    assert "#" not in destination
+
+
+@pytest.mark.unit
+async def test_copy_resource_encodes_destination_header(mocker):
+    """The COPY Destination header must be percent-encoded too (card 309)."""
+    mock_http_client = AsyncMock()
+    client = WebDAVClient(mock_http_client, "testuser")
+
+    mock_response = AsyncMock()
+    mock_response.status_code = 201
+    mock_response.raise_for_status = mocker.Mock()
+    mock_http_client.request = AsyncMock(return_value=mock_response)
+
+    await client.copy_resource("a/old.pdf", "b/new #1.pdf")
+
+    call = mock_http_client.request.call_args
+    assert call[0][1] == "/remote.php/dav/files/testuser/a/old.pdf"
+    destination = call.kwargs["headers"]["Destination"]
+    assert "%23" in destination
+    assert "#" not in destination

tests/unit/test_config.py

@@ -213,6 +213,24 @@ class TestChunkConfigValidation:
         _reload_config()
         assert get_settings().document_chunk_page_aware is False
 
+    def test_ocr_timeout_default_and_env_override(self):
+        """document_ocr_timeout_seconds defaults to 180 and reads its env var.
+
+        Guards the _DEFAULTS-key-must-match-env-var footgun: a mismatch would
+        leave the override silently ignored.
+        """
+        assert Settings().document_ocr_timeout_seconds == pytest.approx(180.0)
+        with patch.dict(os.environ, {"DOCUMENT_OCR_TIMEOUT_SECONDS": "45"}, clear=True):
+            _reload_config()
+            assert get_settings().document_ocr_timeout_seconds == pytest.approx(45.0)
+
+    def test_max_pdf_size_default_and_env_override(self):
+        """document_max_pdf_size_mb defaults to 50 and reads its env var."""
+        assert Settings().document_max_pdf_size_mb == pytest.approx(50.0)
+        with patch.dict(os.environ, {"DOCUMENT_MAX_PDF_SIZE_MB": "12.5"}, clear=True):
+            _reload_config()
+            assert get_settings().document_max_pdf_size_mb == pytest.approx(12.5)
+
     def test_valid_chunk_settings(self):
         """Test valid chunk size and overlap configuration."""
         settings = Settings(
@@ -491,6 +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

@@ -3,6 +3,7 @@
 from types import SimpleNamespace
 from typing import Any
 
+import anyio
 import pytest
 
 from nextcloud_mcp_server.document_processors import ocr
@@ -14,6 +15,7 @@ def _settings(**kw) -> Any:  # a Settings stand-in (only the read fields matter)
     base = dict(
         document_ocr_provider="auto",
         document_ocr_model="mistral/mistral-ocr-latest",
+        document_ocr_timeout_seconds=180.0,
         embedding_gateway_url=None,
         embedding_gateway_client_id=None,
         embedding_gateway_client_secret=None,
@@ -128,3 +130,91 @@ async def test_processor_backend_error_returns_success_false(monkeypatch):
     r = await ocr.OcrProcessor().process(b"%PDF-1.7", "application/pdf")
     assert r.success is False
     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_httpx_timeout_maps_to_timeout_reason(monkeypatch):
+    """A gateway httpx.ReadTimeout (not a builtin TimeoutError) must still map to
+    parse_failed_reason='timeout', not 'error'."""
+    import httpx
+
+    class _HttpxTimeoutBackend:
+        async def ocr(self, content, mime_type):
+            raise httpx.ReadTimeout("read timed out")
+
+    monkeypatch.setattr(
+        ocr, "get_settings", lambda: _settings(document_ocr_timeout_seconds=5.0)
+    )
+    monkeypatch.setattr(ocr, "build_ocr_backend", lambda s: _HttpxTimeoutBackend())
+    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."""
+    resp = mocker.Mock()
+    resp.raise_for_status = mocker.Mock()
+    resp.json = mocker.Mock(return_value={"pages": [{"index": 0, "markdown": "ok"}]})
+
+    client = mocker.MagicMock()
+    client.__aenter__ = mocker.AsyncMock(return_value=client)
+    client.__aexit__ = mocker.AsyncMock(return_value=False)
+    client.post = mocker.AsyncMock(return_value=resp)
+
+    captured: dict[str, Any] = {}
+
+    def _make_client(*args, **kwargs):
+        captured["timeout"] = kwargs.get("timeout")
+        return client
+
+    monkeypatch.setattr(ocr.httpx, "AsyncClient", _make_client)
+    monkeypatch.setattr(
+        ocr, "get_settings", lambda: _settings(document_ocr_timeout_seconds=42.0)
+    )
+
+    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.
+    assert captured["timeout"].read == pytest.approx(42.0)
+    assert captured["timeout"].connect == pytest.approx(10.0)
+
+
+async def test_mistral_backend_applies_timeout(mocker, monkeypatch):
+    """The Mistral backend wraps process_async in DOCUMENT_OCR_TIMEOUT_SECONDS,
+    so a slow OCR call fails fast instead of hanging on the SDK default."""
+    monkeypatch.setattr(
+        ocr, "get_settings", lambda: _settings(document_ocr_timeout_seconds=0.01)
+    )
+
+    # Bypass the SDK constructor; only the two attributes ocr() reads matter.
+    backend = ocr._MistralOcrBackend.__new__(ocr._MistralOcrBackend)
+    backend._model = "mistral-ocr-latest"
+
+    async def _slow(*args, **kwargs):
+        await anyio.sleep(1.0)
+
+    backend._client = mocker.MagicMock()
+    backend._client.ocr.process_async = _slow
+
+    with pytest.raises(TimeoutError):
+        await backend.ocr(b"%PDF-1.7", "application/pdf")

tests/unit/test_registry_tiering.py

@@ -74,6 +74,9 @@ 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
         self.document_classify_enabled = classify
@@ -82,6 +85,7 @@ class _Settings:
         self.document_ocr_page_fraction = page_fraction
         self.document_ocr_min_page_chars = min_page_chars
         self.document_ocr_detect_scanned = detect_scanned
+        self.document_max_pdf_size_mb = max_pdf_size_mb
 
 
 def _registry(*procs: tuple[DocumentProcessor, int]) -> ProcessorRegistry:
@@ -98,6 +102,43 @@ async def test_pdf_routes_to_fast_tier(monkeypatch):
     assert res.processor == "fast"
 
 
+async def test_oversize_pdf_fails_fast_without_parsing(monkeypatch):
+    """A PDF over the size cap must fail fast as 'oversize' before any tier runs."""
+    monkeypatch.setattr(
+        reg_mod, "get_settings", lambda: _Settings(max_pdf_size_mb=0.001)
+    )
+    fast = _Fake("fast", "fast")
+    ran = False
+    orig = fast.process
+
+    async def _tracking(*a, **k):
+        nonlocal ran
+        ran = True
+        return await orig(*a, **k)
+
+    fast.process = _tracking  # type: ignore[method-assign]
+    r = _registry((fast, 20))
+
+    # ~2 KB > 0.001 MB (~1 KB) cap.
+    res = await r.process(b"%PDF-1.7" + b"0" * 2048, "application/pdf", "big.pdf")
+
+    assert res.success is False
+    assert res.metadata["parse_failed_reason"] == "oversize"
+    assert res.processor == "size_guard"
+    assert ran is False, "size guard must short-circuit before the fast tier runs"
+
+
+async def test_under_cap_pdf_still_parses(monkeypatch):
+    """A PDF under the cap is unaffected by the guard."""
+    monkeypatch.setattr(
+        reg_mod, "get_settings", lambda: _Settings(max_pdf_size_mb=10.0)
+    )
+    r = _registry((_Fake("fast", "fast"), 20))
+    res = await r.process(b"%PDF-1.7", "application/pdf")
+    assert res.success is True
+    assert res.processor == "fast"
+
+
 async def test_engine_rollback_uses_structured(monkeypatch):
     monkeypatch.setattr(reg_mod, "get_settings", lambda: _Settings(engine="pymupdf"))
     r = _registry((_Fake("fast", "fast"), 20), (_Fake("structured", "structured"), 10))

tests/unit/vector/test_errors.py

@@ -0,0 +1,44 @@
+"""Unit tests for vector-sync error formatting (card 309)."""
+
+import httpx
+import pytest
+
+from nextcloud_mcp_server.vector._errors import format_exception_group
+
+
+@pytest.mark.unit
+def test_format_plain_exception_returns_repr():
+    exc = httpx.ConnectError("Connection error")
+    assert format_exception_group(exc) == repr(exc)
+
+
+@pytest.mark.unit
+def test_format_exception_group_names_leaf_cause():
+    """A single-child group must surface the real ConnectError, not the group's
+    useless 'unhandled errors in a TaskGroup' default message."""
+    leaf = httpx.ConnectError("Connection error")
+    group = BaseExceptionGroup("unhandled errors in a TaskGroup", [leaf])
+
+    formatted = format_exception_group(group)
+
+    assert "ConnectError" in formatted
+    # Assert the full leaf repr survives, not just the type name -- guards a
+    # future format change that kept the type but dropped the message.
+    assert repr(leaf) in formatted
+    assert "unhandled errors in a TaskGroup" not in formatted
+    assert "1 sub-exception" in formatted
+
+
+@pytest.mark.unit
+def test_format_nested_exception_group_flattens_all_leaves():
+    inner = BaseExceptionGroup(
+        "inner", [ValueError("bad value"), httpx.ConnectError("conn")]
+    )
+    outer = BaseExceptionGroup("outer", [inner, RuntimeError("boom")])
+
+    formatted = format_exception_group(outer)
+
+    assert "ValueError" in formatted
+    assert "ConnectError" in formatted
+    assert "RuntimeError" in formatted
+    assert "3 sub-exceptions" in formatted

tests/unit/vector/test_processor_task.py

@@ -0,0 +1,50 @@
+"""Regression test for processor_task's exception handler (card 309 / PR #891).
+
+If ``receive_stream.receive()`` raises something other than
+``TimeoutError``/``EndOfStream`` before any document is bound, the broad
+``except`` handler must not crash on an unbound ``doc_task`` name.
+"""
+
+from unittest.mock import MagicMock
+
+import anyio
+import pytest
+
+from nextcloud_mcp_server.vector.processor import processor_task
+
+
+class _ReceiveBoomThenEnd:
+    """First receive() raises a non-Timeout error (no doc_task bound yet); the
+    second ends the stream so the loop exits."""
+
+    def __init__(self, shutdown: anyio.Event):
+        self._calls = 0
+        self._shutdown = shutdown
+
+    async def receive(self):
+        self._calls += 1
+        if self._calls == 1:
+            raise RuntimeError("transport blew up before any document")
+        self._shutdown.set()
+        raise anyio.EndOfStream
+
+    def statistics(self):  # pragma: no cover - not reached on the error path
+        return MagicMock(current_buffer_used=0)
+
+
+@pytest.mark.unit
+async def test_processor_task_receive_error_does_not_raise_unbound(caplog):
+    shutdown = anyio.Event()
+    stream = _ReceiveBoomThenEnd(shutdown)
+
+    # Must complete without a NameError leaking out of the except handler.
+    with caplog.at_level("ERROR", logger="nextcloud_mcp_server.vector.processor"):
+        await processor_task(
+            worker_id=0,
+            receive_stream=stream,  # type: ignore[arg-type]
+            shutdown_event=shutdown,
+            nc_client=MagicMock(),
+            user_id="alice",
+        )
+
+    assert any("RuntimeError" in rec.message for rec in caplog.records)

uv.lock

@@ -2183,7 +2183,7 @@ wheels = [
 
 [[package]]
 name = "nextcloud-mcp-server"
-version = "0.111.0"
+version = "0.113.0"
 source = { editable = "." }
 dependencies = [
     { name = "aiosqlite" },