[superlog] Log batch_union fallback as WARN instead of ERROR

[izadoesdev]

Summary

• add a request-aware captureWarning helper for recovered AI warnings
• log recovered batch_union fallback failures at WARN instead of ERROR
• preserve batch fallback metadata on the warning event
• add focused coverage that recovered union fallback warns without error logging

Supersedes #502 with a clean branch from current staging.

Verification

• cd packages/ai && bun test src/query/batch-executor.test.ts
• cd packages/ai && bun run check-types
• bun run lint
• bun run check-types
• bun run test

---

Summary by cubic

Logs recovered batch_union fallbacks as WARN instead of ERROR to reduce noise while keeping context. Adds a request-aware captureWarning and preserves fallback metadata on the warning event.

• Bug Fixes
  • Use captureWarning to log union failures at WARN when single-query fallbacks succeed.
  • Preserve batch_union metadata on the warning: batch_union_fallback, batch_union_error, batch_size, batch_types.
  • Add tests to assert WARN (no ERROR) on recovered union fallback and correct results.

^{Written for commit 6dfcd52. Summary will update on new commits.}

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[izadoesdev]

Clean replacement for #502, rebased onto current staging after #512 merged.

What changed:

• adds captureWarning for recovered AI warning paths
• logs recovered batch_union fallback failures at WARN instead of ERROR
• preserves fallback/error metadata on the warning payload
• adds focused coverage proving recovered union fallback warns without error logging

Local verification passed:

• cd packages/ai && bun test src/query/batch-executor.test.ts
• cd packages/ai && bun run check-types
• bun run lint
• bun run check-types
• bun run test

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Name	Status	Preview	Inspect	Updated (UTC)
api (preview)	Failed	Visit Preview	Inspect	Jun 30, 2026 4:15pm

[greptile-apps]

Greptile Summary

This PR downgrades the batch_union fallback from an error to a warning, since the executor recovers by running each query individually. It introduces a new captureWarning helper in tracing.ts and wires it into the catch block alongside focused test coverage.

• captureWarning helper — mirrors captureError's structure (request-logger-aware), calling requestLog.warn(message, payload) when a logger is active and log.warn(...) otherwise; the fallback path additionally spreads error_stack unlike captureError.
• batch-executor.ts catch block — replaces captureError with captureWarning, deduplicates the batchUnionError string, and adds batch_union_fallback/batch_union_error to both the warning payload and mergeWideEvent.
• Test — new describe block verifies warn fires with correct metadata and error is not called after a union failure that recovers via single-query fallback.

Confidence Score: 4/5

The change is a focused, well-tested reclassification of a recovered error path from ERROR to WARN; the executor's fallback behavior itself is unchanged.

The new captureWarning helper contains a small asymmetry: its fallback log.warn spreads error_stack while the adjacent captureError fallback log.error does not. This means a recovered warning carries more stack context in the fallback logger than a genuine error, which could complicate triage. Everything else — the logger dispatch logic, deduplication of batchUnionError, and test coverage — is clean and correct.

packages/ai/src/lib/tracing.ts — the error_stack inclusion in captureWarning's fallback path deserves a second look for consistency with captureError.

Important Files Changed

Filename	Overview
packages/ai/src/lib/tracing.ts	Adds captureWarning helper mirroring captureError structure; minor inconsistency: fallback log.warn includes error_stack while sibling captureError's fallback log.error does not
packages/ai/src/query/batch-executor.ts	Swaps captureError → captureWarning for recovered batch_union fallback; deduplicates batchUnionError computation; adds fallback metadata to the warning payload — logic is correct
packages/ai/src/query/batch-executor.test.ts	Adds focused test for union fallback warn path; correctly resets singleton provider in beforeEach; mock covers all called logger methods

Sequence Diagram

%%{init: {'theme': 'neutral'}}%%
sequenceDiagram
    participant BE as batch-executor
    participant TRC as tracing.ts
    participant RL as RequestLogger (evlog)
    participant LOG as log (evlog fallback)

    BE->>TRC: "captureWarning(error, {operation, batch_types, batch_size, batch_union_fallback, batch_union_error})"
    alt Request logger active
        TRC->>RL: requestLog.warn(err.message, payload)
        TRC-->>BE: return
        BE->>TRC: "mergeWideEvent({batch_union_fallback, batch_union_error})"
        TRC->>RL: "requestLog.set({batch_union_fallback, batch_union_error})"
    else No request logger
        TRC->>LOG: "log.warn({service, error_message, error_stack?, ...payload})"
        TRC-->>BE: return
        BE->>TRC: "mergeWideEvent({batch_union_fallback, batch_union_error})"
        TRC->>LOG: "log.info({service, batch_union_fallback, batch_union_error})"
    end
    BE->>BE: runSingle() per item (fallback)

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sequenceDiagram
    participant BE as batch-executor
    participant TRC as tracing.ts
    participant RL as RequestLogger (evlog)
    participant LOG as log (evlog fallback)

    BE->>TRC: "captureWarning(error, {operation, batch_types, batch_size, batch_union_fallback, batch_union_error})"
    alt Request logger active
        TRC->>RL: requestLog.warn(err.message, payload)
        TRC-->>BE: return
        BE->>TRC: "mergeWideEvent({batch_union_fallback, batch_union_error})"
        TRC->>RL: "requestLog.set({batch_union_fallback, batch_union_error})"
    else No request logger
        TRC->>LOG: "log.warn({service, error_message, error_stack?, ...payload})"
        TRC-->>BE: return
        BE->>TRC: "mergeWideEvent({batch_union_fallback, batch_union_error})"
        TRC->>LOG: "log.info({service, batch_union_fallback, batch_union_error})"
    end
    BE->>BE: runSingle() per item (fallback)

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[greptile-apps]

captureWarning's fallback path includes error_stack in the structured log object, but the sibling captureError function's fallback log.error call does not. This means a recovered warning ends up with more stack context in the fallback logger than a genuine error, which inverts expectations and could make error triage harder when the request logger is absent.

Suggested change

	log.warn({
	service: "api",
	error_message: err.message,
	...(err.stack ? { error_stack: err.stack } : {}),
	...(payload ?? {}),
	});
	log.warn({
	service: "api",
	error_message: err.message,
	...(payload ?? {}),
	});