fix(onboard): clarify existing vLLM GPU conflicts

docs/inference/set-up-vllm.mdx

@@ -46,15 +46,15 @@ $$nemoclaw onboard
 
 Select **Local vLLM**.
 On generic hosts, the entry includes an experimental label.
-N1x does not offer the existing-server entry; it offers only the managed **Install vLLM** or **Start vLLM** entry with the **Deferred preview** label.
+On N1x, the readiness gate admits only explicit managed-preview intent, so the user-facing onboarding flow does not offer the existing-server entry.
 NemoClaw validates the detected endpoint and records the model reported by `/v1/models`.
 
 When you request a vLLM serving profile, the detected server must report the profile's served model alias or a safe `root` that matches the profile's declared model.
 NemoClaw stops onboarding when neither identifier matches, rather than recording a route that the profile does not declare.
 Stop the server and rerun the original command, or unset `NEMOCLAW_SERVING_PRESET` and `NEMOCLAW_PROVIDER` before you start fresh onboarding to keep the detected model.
 
-On hosts other than N1x, when an install request encounters an already-running server, NemoClaw selects that server instead of starting another container.
-On N1x, explicit managed-preview intent never reuses an already-running server.
+On hosts other than N1x, when an install request without a managed GPU selection encounters an already-running server, NemoClaw selects that server instead of starting another container.
+On N1x, explicit managed-preview intent keeps the managed entry and stops onboarding when another vLLM server occupies the configured port.
 Stop the server, then rerun managed onboarding.
 
 ```bash
@@ -146,6 +146,47 @@ Only managed single-host vLLM installation accepts this selector.
 $$nemoclaw onboard --profile <profile-id> --vllm-gpu-device <index-or-uuid>
 ```
 
+#### Handle a Running vLLM Server
+
+The single-host managed vLLM runtime is host-global.
+Destroying a sandbox does not stop it, and the container remains available for other sandboxes.
+On hosts other than N1x, later onboarding normally reuses a server that is already listening on the configured vLLM port instead of replacing it automatically.
+When a managed GPU selection accompanies explicit managed-install intent, NemoClaw preserves that intent and reports the running-server conflict.
+
+Choose one action:
+
+- On hosts other than N1x, to reuse the running server, omit `--vllm-gpu-device` and select **Local vLLM**.
+- To change the GPU or port, inspect the sandbox registry for every gateway-port environment on the host.
+  Run `NEMOCLAW_GATEWAY_PORT=<port> $$nemoclaw list` for port `8080` and for every non-default port represented by a numeric directory under `~/.nemoclaw/gateways/`.
+  Treat every sandbox that reports provider `vllm-local` as a possible consumer because the list output does not distinguish local vLLM from Local NIM.
+  Continue only when no environment reports that provider; otherwise, keep the server running or move each possible consumer to another inference provider.
+  Stop an operator-managed server through the system service, container, or process workflow that started it.
+  For a NemoClaw-managed container, inspect its ID and labels before stopping it:
+
+  ```bash
+  docker container inspect \
+    --format '{{.Id}} {{json .Config.Labels}}' \
+    nemoclaw-vllm
+  ```
+
+  Continue only when the output includes `"com.nvidia.nemoclaw.managed-vllm":"true"` and does not include `com.nvidia.nemoclaw.vllm-role`, `com.nvidia.nemoclaw.vllm-endpoint`, or `com.nvidia.nemoclaw.vllm-cluster`.
+  Do not stop the container when any distributed label is present; follow the matching multi-node vLLM guide instead.
+  Stop that exact container ID:
+
+  ```bash
+  docker container stop <container-id>
+  ```
+
+  Set `NEMOCLAW_VLLM_PORT` before onboarding if you are changing the port.
+  Rerun managed onboarding:
+
+  ```bash
+  $$nemoclaw onboard --profile <profile-id> --vllm-gpu-device <index-or-uuid>
+  ```
+
+Accept the result when onboarding completes and `$$nemoclaw list` reports the new sandbox with provider `vllm-local` and the expected model.
+NemoClaw does not stop or recreate a running vLLM server automatically because another sandbox can use it.
+
 NemoClaw requires a resumed session to reuse the recorded GPU selector.
 A legacy in-progress session cannot add one, and a resumed session cannot change one.
 Run `$$nemoclaw onboard --fresh` when you need a different GPU selection.
@@ -166,7 +207,7 @@ The container carries NemoClaw ownership and immutable catalog labels so later o
 NemoClaw also records an owner-only, credential-free runtime receipt that binds those labels to the container ID and API-key fingerprint.
 
 If an existing `nemoclaw-vllm` container does not carry that label, NemoClaw preserves it and asks you to remove or rename it before installing managed vLLM.
-On hosts other than N1x, if another vLLM server already occupies the configured vLLM port, NemoClaw selects the existing-server path and applies the model-identity checks described above.
+On hosts other than N1x, if another vLLM server already occupies the configured vLLM port and no managed GPU selection accompanies explicit managed-install intent, NemoClaw selects the existing-server path and applies the model-identity checks described above.
 On N1x, NemoClaw stops managed onboarding and requires you to stop that server before trying the Deferred preview again.
 If another process holds the configured single-host port, NemoClaw stops the managed install before it persists a bearer key or records the selected model.
 NemoClaw also stops before storage prompts, cache creation, image pull, or container start.

src/lib/onboard/setup-nim-flow-vllm-gpu-device.test.ts

@@ -3,6 +3,7 @@
 
 import { afterEach, describe, expect, it, vi } from "vitest";
 
+import type { VllmProfile } from "../inference/vllm";
 import { NEMOCLAW_VLLM_GPU_DEVICE_ENV } from "../inference/vllm-models";
 import { makeDeps, makeHostState } from "./__test-helpers__/setup-nim-flow";
 import type { SetupNimFlowDeps } from "./setup-nim-flow";
@@ -44,6 +45,7 @@ describe("managed vLLM GPU provider selection", () => {
       makeDeps({
         isNonInteractive: () => true,
         getNonInteractiveProvider: () => "vllm",
+        vllmPort: 18000,
         detectInferenceProviderHostState: () =>
           makeHostState({
             vllmRunning: true,
@@ -54,15 +56,49 @@ describe("managed vLLM GPU provider selection", () => {
       }),
     );
 
-    await expect(setupNim(null)).rejects.toThrow(
-      "applies only when NemoClaw installs managed vLLM",
+    await expect(setupNim(null)).rejects.toThrow("vLLM is already running on localhost:18000");
+    expect(abortNonInteractive).toHaveBeenCalledWith(
+      expect.stringContaining("Omit --vllm-gpu-device to reuse that server"),
     );
     expect(abortNonInteractive).toHaveBeenCalledWith(
-      expect.stringContaining("selected provider is 'vllm'"),
+      expect.stringContaining("stop the existing server"),
     );
     expect(handleVllmSelection).not.toHaveBeenCalled();
   });
 
+  it("preserves managed intent and explains how to resolve a running-server conflict", async () => {
+    vi.stubEnv(NEMOCLAW_VLLM_GPU_DEVICE_ENV, "2");
+    const abortNonInteractive = vi.fn((message: string): never => {
+      throw new Error(message);
+    });
+    const installVllm = vi.fn<SetupNimFlowDeps["installVllm"]>();
+    const profile = { name: "DGX Station" } as VllmProfile;
+    const setupNim = createSetupNim(
+      makeDeps({
+        isNonInteractive: () => true,
+        getNonInteractiveProvider: () => "install-vllm",
+        vllmPort: 18000,
+        detectInferenceProviderHostState: () =>
+          makeHostState({
+            vllmRunning: true,
+            vllmProfile: profile,
+            vllmEntries: [{ key: "install-vllm", label: "Start vLLM (DGX Station)" }],
+          }),
+        abortNonInteractive,
+        installVllm,
+      }),
+    );
+
+    await expect(setupNim(null)).rejects.toThrow("vLLM is already running on localhost:18000");
+    expect(abortNonInteractive).toHaveBeenCalledWith(
+      expect.stringContaining("Omit --vllm-gpu-device and select Local vLLM"),
+    );
+    expect(abortNonInteractive).toHaveBeenCalledWith(
+      expect.stringContaining("stop the existing server"),
+    );
+    expect(installVllm).not.toHaveBeenCalled();
+  });
+
   it("allows the persisted device when resuming its managed vLLM provider", async () => {
     vi.stubEnv(NEMOCLAW_VLLM_GPU_DEVICE_ENV, "2");
     const handleVllmSelection = vi.fn<SetupNimFlowDeps["handleVllmSelection"]>(async (state) => {

src/lib/onboard/setup-nim-flow.test.ts

@@ -1436,6 +1436,7 @@ describe("createSetupNim", () => {
     expect(prompt).toHaveBeenCalledTimes(2);
     expect(selectFromNumberedMenu).toHaveBeenCalledTimes(2);
     expect(error).toHaveBeenCalledWith(expect.stringContaining("stop the existing server"));
+    expect(error).toHaveBeenCalledWith(expect.stringContaining("change its GPU or port"));
     expect(installVllm).not.toHaveBeenCalled();
     expect(handleVllmSelection).not.toHaveBeenCalled();
     expect(handleRemoteProviderSelection).toHaveBeenCalledOnce();

src/lib/onboard/setup-nim-flow.ts

@@ -299,16 +299,19 @@ function assertVllmGpuProviderSelection(
   recoveredFromSandbox: boolean,
   deps: Pick<
     SetupNimFlowDeps,
-    "abortNonInteractive" | "error" | "exitProcess" | "isNonInteractive"
+    "abortNonInteractive" | "error" | "exitProcess" | "isNonInteractive" | "vllmPort"
   >,
 ): void {
   const requestedDevice = String(process.env.NEMOCLAW_VLLM_GPU_DEVICE ?? "").trim();
   const resumedManagedVllm = recoveredFromSandbox && selected.key === "vllm";
   if (!requestedDevice || selected.key === "install-vllm" || resumedManagedVllm) return;
 
   const message =
-    `--vllm-gpu-device applies only when NemoClaw installs managed vLLM; ` +
-    `the selected provider is '${selected.key}'.`;
+    selected.key === "vllm"
+      ? `vLLM is already running on localhost:${deps.vllmPort}, so --vllm-gpu-device cannot change its GPU. ` +
+        `Omit --vllm-gpu-device to reuse that server. To select a different GPU, stop the existing server, then rerun managed onboarding.`
+      : `--vllm-gpu-device applies only when NemoClaw installs managed vLLM; ` +
+        `the selected provider is '${selected.key}'.`;
   deps.error(`  ${message}`);
   if (deps.isNonInteractive()) deps.abortNonInteractive(message);
   deps.exitProcess(1);
@@ -613,11 +616,15 @@ async function handleEndpointProviderSelection(input: {
 function vllmPortConflictMessage(
   platform: InferenceProviderHostGpu["platform"],
   port: number,
+  hasGpuSelection: boolean,
 ): string {
   if (platform === "n1x") {
     return `The N1x Deferred preview requires managed vLLM, but vLLM is already running on localhost:${port}. Stop the existing server, then rerun with NEMOCLAW_PROVIDER=install-vllm.`;
   }
-  return "vLLM is already running on this host. Select Local vLLM, or stop the existing server before selecting the managed install path.";
+  const reuseAction = hasGpuSelection
+    ? "Omit --vllm-gpu-device and select Local vLLM to reuse it."
+    : "Select Local vLLM to reuse it.";
+  return `vLLM is already running on localhost:${port}. ${reuseAction} To change its GPU or port, stop the existing server before rerunning managed onboarding.`;
 }
 
 /**
@@ -1221,7 +1228,13 @@ export function createSetupNim(
             continue selectionLoop;
           }
           if (vllmRunning) {
-            const message = vllmPortConflictMessage(gpu?.platform, deps.vllmPort);
+            const hasGpuSelection =
+              String(process.env.NEMOCLAW_VLLM_GPU_DEVICE ?? "").trim() !== "";
+            const message = vllmPortConflictMessage(
+              gpu?.platform,
+              deps.vllmPort,
+              hasGpuSelection,
+            );
             deps.error(`  ${message}`);
             if (deps.isNonInteractive()) {
               deps.abortNonInteractive(message);

src/lib/onboard/vllm-menu.test.ts

@@ -99,7 +99,7 @@ describe("buildVllmMenuEntries", () => {
     assert.equal(entries[0].label, "Start vLLM (DGX Station)");
   });
 
-  it("labels only the N1x managed install entry as a Deferred preview (#8574)", () => {
+  it("keeps the Deferred label scoped to the pre-admission N1x managed entry (#8574)", () => {
     const install = buildVllmMenuEntries({
       vllmRunning: false,
       vllmProfile: { name: "N1x" },
@@ -119,6 +119,9 @@ describe("buildVllmMenuEntries", () => {
       log: () => {},
     });
 
+    // N1x readiness rejects the running-server state without explicit managed
+    // intent. If this lower-level helper sees that state in isolation, it must
+    // not mislabel an operator-managed server as the Deferred managed preview.
     assert.equal(install[0].label, "Install vLLM (N1x) [Deferred preview]");
     assert.equal(running[0].label, "Local vLLM (localhost:8000) — running");
     assert.doesNotMatch(running[0].label, /Deferred preview/);
@@ -209,6 +212,25 @@ describe("buildVllmMenuEntries", () => {
     assert.match(logs[0], /selecting the running instance/);
   });
 
+  it("preserves managed install intent when a running server conflicts with GPU selection", () => {
+    const logs: string[] = [];
+    const entries = buildVllmMenuEntries({
+      vllmRunning: true,
+      vllmProfile: { name: "DGX Station" },
+      experimental: false,
+      platform: "station",
+      hasVllmImage: true,
+      env: {
+        NEMOCLAW_PROVIDER: "install-vllm",
+        NEMOCLAW_VLLM_GPU_DEVICE: "2",
+      },
+      log: (message) => logs.push(message),
+    });
+
+    assert.equal(entries[0].key, "install-vllm");
+    assert.deepEqual(logs, []);
+  });
+
   it("does not log the override note when the user did not request install-vllm", () => {
     const logs: string[] = [];
     buildVllmMenuEntries({

src/lib/onboard/vllm-menu.ts

@@ -21,8 +21,9 @@
  * available for this host." message. It also lets the caller surface managed
  * vLLM by default for known DGX platforms while generic Linux stays gated, and
  * logs a note when running-vLLM takes precedence over the env-var opt-in. N1x
- * keeps the managed selection because its readiness exception is limited to
- * the managed-vLLM preview.
+ * and explicit managed GPU selection keep the managed selection so the
+ * provider flow can report the running-server conflict without changing the
+ * user's intent.
  */
 
 import { VLLM_PORT } from "../core/ports";
@@ -66,8 +67,11 @@ export function buildVllmMenuEntries(opts: BuildVllmMenuOptions): VllmMenuEntry[
   const env = opts.env ?? process.env;
   const userChoseManagedVllm =
     (env.NEMOCLAW_PROVIDER || "").trim().toLowerCase() === MANAGED_VLLM_PROVIDER_KEY;
-  const keepN1xManagedPreview = userChoseManagedVllm && opts.platform === "n1x";
-  if (opts.vllmRunning && !keepN1xManagedPreview) {
+  const hasManagedVllmGpuSelection =
+    String(env.NEMOCLAW_VLLM_GPU_DEVICE ?? "").trim() !== "";
+  const preserveManagedVllmIntent =
+    userChoseManagedVllm && (opts.platform === "n1x" || hasManagedVllmGpuSelection);
+  if (opts.vllmRunning && !preserveManagedVllmIntent) {
     if (userChoseManagedVllm) {
       log(
         `  Note: NEMOCLAW_PROVIDER=install-vllm requested, but vLLM is already running on localhost:${VLLM_PORT} — selecting the running instance.`,