feat(machine): persist scanned spire-seed + signal unpaired state for wizard

Foundation for the on-machine QR-pairing wizard (aiolabs/bitspire#52). An
unpaired ATM can now have a seed planted at runtime rather than only via
provisioning:

- electron IPC `state:save-spire-seed` writes VITE_SPIRE_SEED into the runtime
  .env (0600), and `app:relaunch` restarts the kiosk so the normal boot path
  (signer-resolver → connectNewSeed) does the actual bunker pairing. We
  deliberately do NOT pair in-renderer — persist + relaunch reuses the single,
  hardware-tested pairing path.
- signer-resolver throws a typed `NoPairingError` (distinct `.name`, survives
  the bundle boundary) when there's no seed and no binding, instead of a
  generic Error.
- init-error maps NoPairingError → `unpaired`, so the renderer can route a
  fresh machine to the interactive wizard (next commit) rather than a
  dead-end fault screen. Revoked/TTL bindings already map there too — re-pair
  is the same scan-a-fresh-seed flow.

Co-Authored-By: Claude Opus 4.8 <noreply@anthropic.com>

apps/machine/electron/main.ts

@@ -353,6 +353,50 @@ ipcMain.handle('state:reset-bootstrap-gate', (): void => {
   resetBootstrapGate()
 })
 
+// QR-pairing wizard (aiolabs/bitspire#52): an unpaired machine scans a
+// spire-seed off its camera, and we persist it as VITE_SPIRE_SEED in the
+// runtime .env so the next boot's signer-resolver redeems it (connectNewSeed)
+// exactly as if it had been provisioned. We deliberately do NOT pair here —
+// persisting + relaunching reuses the single, tested pairing path rather than
+// duplicating it in the renderer.
+function runtimeEnvPath(): string {
+  const base = fs.existsSync('/var/lib/bitspire') ? '/var/lib/bitspire' : process.cwd()
+  return path.join(base, '.env')
+}
+
+ipcMain.handle('state:save-spire-seed', (_event, seed: string): void => {
+  const trimmed = (seed || '').trim()
+  if (!trimmed) throw new Error('save-spire-seed: empty seed')
+  const envPath = runtimeEnvPath()
+  const line = `VITE_SPIRE_SEED=${trimmed}`
+  let lines: string[] = []
+  if (fs.existsSync(envPath)) {
+    lines = fs.readFileSync(envPath, 'utf8').split('\n')
+  }
+  const idx = lines.findIndex((l) => l.startsWith('VITE_SPIRE_SEED='))
+  if (idx >= 0) {
+    lines[idx] = line
+  } else {
+    // Drop a trailing empty element so we don't accumulate blank lines.
+    if (lines.length && lines[lines.length - 1] === '') lines.pop()
+    lines.push(line)
+  }
+  fs.writeFileSync(envPath, lines.join('\n') + '\n', { mode: 0o600 })
+  // Keep this process's view in sync so get-atm-secrets reflects the new seed
+  // even before relaunch (belt-and-suspenders; relaunch re-reads from disk).
+  process.env.VITE_SPIRE_SEED = trimmed
+  console.log('[Pairing] Spire seed persisted to', envPath)
+})
+
+// Relaunch the kiosk so the new seed is picked up by a clean boot. Under
+// systemd (bitspire.service) the exit triggers an automatic restart; in dev
+// Electron's relaunch re-spawns the process.
+ipcMain.handle('app:relaunch', (): void => {
+  console.log('[Pairing] Relaunching to apply new pairing')
+  app.relaunch()
+  app.exit(0)
+})
+
 // State persistence IPC handlers
 ipcMain.handle('state:load-cassettes', () => loadCassettes())
 ipcMain.handle('state:set-cassettes', (_event, cassettes) => setCassettes(cassettes))

apps/machine/electron/preload.ts

@@ -119,6 +119,11 @@ contextBridge.exposeInMainWorld('electronAPI', {
   clearBunkerBinding: (): Promise<void> => ipcRenderer.invoke('state:clear-bunker-binding'),
   resetBootstrapGate: (): Promise<void> => ipcRenderer.invoke('state:reset-bootstrap-gate'),
 
+  // QR-pairing wizard (aiolabs/bitspire#52): persist a scanned spire-seed,
+  // then relaunch so the normal boot flow pairs it.
+  saveSpireSeed: (seed: string): Promise<void> => ipcRenderer.invoke('state:save-spire-seed', seed),
+  relaunchApp: (): Promise<void> => ipcRenderer.invoke('app:relaunch'),
+
   applyOperatorCassettesConfig: (
     payload: {
       positions: Record<string, { denomination: number; count: number }>
@@ -234,6 +239,8 @@ declare global {
       saveBunkerBinding: (binding: BunkerBindingRecord) => Promise<void>
       clearBunkerBinding: () => Promise<void>
       resetBootstrapGate: () => Promise<void>
+      saveSpireSeed: (seed: string) => Promise<void>
+      relaunchApp: () => Promise<void>
       applyOperatorCassettesConfig: (
         payload: { positions: Record<string, { denomination: number; count: number }> },
         eventCreatedAt: number

apps/machine/src/services/init-error.ts

@@ -3,14 +3,17 @@
  * (see App.vue's MAINTENANCE_SCREENS).
  *
  * Bunker failures (aiolabs/bitspire#52) get dedicated screens:
+ * - `NoPairingError` (fresh machine, never paired) → `unpaired` — render the
+ *   interactive QR-pairing wizard so the operator can scan a spire-seed.
  * - `BunkerRejectedError` (revoked / TTL-expired / off-policy binding) →
- *   `unpaired` — the operator must re-pair the machine.
+ *   `unpaired` too — re-pairing is the same scan-a-fresh-seed flow.
  * - `BunkerTimeoutError` (signer/relay unreachable) → `signer-unreachable`,
  *   a transient condition.
  * Everything else surfaces its raw message (or the caller's fallback).
  */
 export function classifyInitError(error: unknown, fallback = 'Initialization failed'): string {
   const name = (error as { name?: string } | null)?.name
+  if (name === 'NoPairingError') return 'unpaired'
   if (name === 'BunkerRejectedError') return 'unpaired'
   if (name === 'BunkerTimeoutError') return 'signer-unreachable'
   return error instanceof Error ? error.message : fallback

apps/machine/src/services/signer-resolver.ts

@@ -31,6 +31,20 @@ import type { BunkerBindingRecord } from '@/types/electron'
 
 const isElectron = typeof window !== 'undefined' && window.electronAPI !== undefined
 
+/**
+ * Thrown in strict mode when the machine has no seed and no binding — it is
+ * genuinely unpaired, not misconfigured. The renderer catches this to show the
+ * QR-pairing wizard (camera scan of a spire-seed) rather than a fault screen.
+ * Distinct `.name` so it survives the bundle boundary (instanceof is fragile
+ * across the electron/renderer split). See services/init-error.ts.
+ */
+export class NoPairingError extends Error {
+  override readonly name = 'NoPairingError'
+  constructor() {
+    super('[Signer] Machine is unpaired — no spire seed and no bunker binding.')
+  }
+}
+
 export interface ResolveSignerOptions {
   /** Allow an ephemeral LocalSigner when no seed/binding exists (dev only). */
   allowEphemeral: boolean
@@ -109,8 +123,5 @@ export async function resolveSigner(opts: ResolveSignerOptions): Promise<Signer>
     return new LocalSigner(generateIdentity())
   }
 
-  throw new Error(
-    '[Signer] No spire seed and no bunker binding — cannot resolve a signing identity (strict mode). ' +
-      'Set VITE_SPIRE_SEED or pair the ATM.'
-  )
+  throw new NoPairingError()
 }

apps/machine/src/types/electron.d.ts

@@ -98,6 +98,8 @@ declare global {
       saveBunkerBinding: (binding: BunkerBindingRecord) => Promise<void>
       clearBunkerBinding: () => Promise<void>
       resetBootstrapGate: () => Promise<void>
+      saveSpireSeed: (seed: string) => Promise<void>
+      relaunchApp: () => Promise<void>
       applyOperatorCassettesConfig: (
         payload: { positions: Record<string, { denomination: number; count: number }> },
         eventCreatedAt: number