config.toml corruption: stream did not contain valid UTF-8 — two users affected #5167

Sentry (primary): https://sentry.tinyhumans.ai/organizations/tinyhumans/issues/24058/ (TAURI-RUST-NPZ)
Impact (grouped): ~946 events · 2 users across 2 shortIds · error
Seen: first 2026-07-10 · last 2026-07-13
Release / env: openhuman@0.57.40+abddfcbd1b1d / production

Exception: Failed to read config file: C:\Users\...\.openhuman\users\...\config.toml: stream did not contain valid UTF-8
Culprit: (none)

Grouped shortIds: TAURI-RUST-NPZ (518e/1u on Administrator), TAURI-RUST-PCD (428e/1u on 57801)

Analysis: Two Windows users have corrupted config.toml files that fail UTF-8 validation. Both are generating hundreds of events in rapid succession, suggesting an unthrottled retry loop on config read failure. The fix should: (1) rate-limit the error reporting, (2) add a fallback/recovery path (e.g. rename corrupt file and create fresh defaults), and (3) surface a user-visible warning.

Source: Sentry TAURI-RUST-NPZ (and 1 related).