fix(plan-usage): make the usage chip per-device, not synced

The plan-usage header chip (5h/7d %) was a SYNCED setting, so enabling
it on desktop turned it on for mobile too — even though the user never
enabled it there. Make the chip's DISPLAY purely per-device (default
OFF) like the response viewer / skin, while keeping telemetry COLLECTION
server-side.

Three leak sources fixed:
- server.ts renderIndexHtml force-revealed the chip from the synced
  value (pre-paint), pushing the desktop choice onto every device.
  Removed — the chip now ships hidden and the client reveals it
  per-device via applyHeaderVisibilitySettings.
- settings-ui.js load-merge let the server value win, writing desktop's
  `true` into the (separate) mobile settings blob. showPlanUsageLimits
  is now a displayKey AND is dropped from the server payload on load, so
  a stale server value is never seeded into a device that didn't enable
  it. It's also stripped from the save payload so a mobile "off" can't
  clobber the server.
- Collection was gated on the same synced flag. Decoupled via a new
  `statusLineTelemetry` ACTION field (schema + system-routes): sent on
  ENABLE only and never persisted, so the exporter is injected when a
  device turns the chip on but is never yanked when another device has
  it off (it's shared across sibling sessions). Session-create already
  reads the per-device blob, so that path was already correct.

One-time migration clears a stale synced `true` from the mobile blob so
existing mobile installs default to OFF without a manual toggle.

Verified end-to-end on an isolated server: with showPlanUsageLimits=true
persisted, the rendered HTML ships the chip hidden; a fresh browser
context (mobile case) keeps it hidden while a context that explicitly
enabled it shows it; the PUT accepts statusLineTelemetry and does not
persist it. tsc + frontend-syntax + system-routes/index tests green.

Co-Authored-By: Claude Opus 4.8 (1M context) <noreply@anthropic.com>

src/web/public/settings-ui.js

@@ -1515,12 +1515,25 @@ Object.assign(CodemanApp.prototype, {
     // Apply keyboard bar mode
     KeyboardAccessoryBar.setMode(settings.extendedKeyboardBar ? 'extended' : 'simple');
 
-    // Save to server (includes notification prefs for cross-browser persistence)
-    // Strip device-specific keys — localEchoEnabled/cjkInputEnabled are per-platform
-    const { localEchoEnabled: _leo, cjkInputEnabled: _cjk, extendedKeyboardBar: _ekb, skin: _skin, ...serverSettings } = settings;
+    // Save to server (includes notification prefs for cross-browser persistence).
+    // Strip device-specific DISPLAY keys so they never sync across devices —
+    // localEcho/cjk/extendedKeyboard/skin are per-platform, and showPlanUsageLimits
+    // is per-device too (desktop can show the usage chip while mobile stays hidden).
+    // Telemetry COLLECTION is requested out-of-band via statusLineTelemetry (sent on
+    // ENABLE only, so a device with the chip OFF never strips the exporter that
+    // another device's chip depends on — see system-routes settings handler).
+    const {
+      localEchoEnabled: _leo,
+      cjkInputEnabled: _cjk,
+      extendedKeyboardBar: _ekb,
+      skin: _skin,
+      showPlanUsageLimits: _pul,
+      ...serverSettings
+    } = settings;
     try {
       const res = await this._apiPut('/api/settings', {
         ...serverSettings,
+        ...(settings.showPlanUsageLimits ? { statusLineTelemetry: true } : {}),
         notificationPreferences: notifPrefsToSave,
         voiceSettings,
       });
@@ -1972,6 +1985,25 @@ Object.assign(CodemanApp.prototype, {
   },
 
   async loadAppSettingsFromServer(settingsPromise = null) {
+    // One-time migration: showPlanUsageLimits became a per-device display setting.
+    // Before this, it synced from the server, so the (separate) mobile settings blob
+    // may carry a stale `true` the user never enabled on this device. Clear it once
+    // so mobile defaults to OFF; the desktop blob is untouched and keeps its value.
+    try {
+      if (
+        MobileDetection.getDeviceType() === 'mobile' &&
+        !localStorage.getItem('codeman:planUsagePerDeviceMigrated')
+      ) {
+        const s = this.loadAppSettingsFromStorage();
+        if (s && s.showPlanUsageLimits) {
+          s.showPlanUsageLimits = false;
+          this.saveAppSettingsToStorage(s);
+        }
+        localStorage.setItem('codeman:planUsagePerDeviceMigrated', '1');
+      }
+    } catch {
+      /* best-effort migration */
+    }
     try {
       const settings = settingsPromise ? await settingsPromise : await fetch('/api/settings').then(r => r.ok ? r.json() : null).then(env => env?.success === true ? env.data : env);
       if (settings) {
@@ -1986,8 +2018,14 @@ Object.assign(CodemanApp.prototype, {
           'showLifecycleLog', 'showResponseViewer',
           'showMonitor', 'showProjectInsights', 'showFileBrowser', 'showSubagents',
           'subagentActiveTabOnly', 'tabTwoRows', 'localEchoEnabled', 'cjkInputEnabled', 'extendedKeyboardBar',
-          'skin',
+          'skin', 'showPlanUsageLimits',
         ]);
+        // The plan-usage chip is a PER-DEVICE display setting (default OFF): desktop
+        // can show it while mobile stays hidden. It used to sync, so an older
+        // server.json may still carry `true` — drop it so the server value is NEVER
+        // seeded into a device that didn't explicitly enable it (collection is handled
+        // separately via the statusLineTelemetry action, not this display flag).
+        delete appSettings.showPlanUsageLimits;
         // Merge settings: non-display keys always sync from server,
         // display keys only seed from server when localStorage has no value
         // (prevents cross-device overwrite while fixing settings re-enabling on fresh loads)

src/web/routes/system-routes.ts

@@ -531,7 +531,10 @@ export function registerSystemRoutes(
       } catch {
         /* ignore */
       }
-      const merged = { ...existing, ...settings };
+      // statusLineTelemetry is an ACTION field (reconcile the plan-usage exporter),
+      // not a stored setting — strip it before persisting so settings.json stays clean.
+      const { statusLineTelemetry, ...settingsToStore } = settings;
+      const merged = { ...existing, ...settingsToStore };
       await fs.writeFile(SETTINGS_PATH, JSON.stringify(merged, null, 2));
 
       // Handle subagent tracking toggle dynamically
@@ -547,19 +550,20 @@ export function registerSystemRoutes(
         }
       });
 
-      // Plan-usage chip (App Settings → Display → "Plan Usage Limits"): reconcile
-      // the statusLine exporter across all ACTIVE Claude sessions' working dirs the
-      // moment the setting is toggled — server-side and authoritative, so it works
-      // immediately for every user/session without depending on any client's synced
-      // state or on creating a new session. Enable injects; disable removes (ours
-      // only, marker-guarded). Each dir handled once.
-      if ('showPlanUsageLimits' in settings) {
-        const enabled = settings.showPlanUsageLimits === true;
+      // Plan-usage chip: its DISPLAY is per-device (client-side, see settings-ui.js).
+      // Telemetry COLLECTION is server-side and enable-sticky — when a client turns
+      // the chip ON it sends statusLineTelemetry:true and we (re)inject our exporter
+      // into every ACTIVE Claude session's working dir so the live % starts flowing
+      // immediately (no new session needed). We deliberately never auto-REMOVE here:
+      // the exporter is benign/print-through and a per-repo settings.local.json is
+      // shared by sibling sessions, so one device's "off" must not yank the exporter
+      // another device's chip depends on. Each dir handled once.
+      if (statusLineTelemetry === true) {
         const dirs = new Set<string>();
         for (const session of ctx.sessions.values()) {
           if (session.mode === 'claude' && session.workingDir) dirs.add(session.workingDir);
         }
-        await Promise.all([...dirs].map((dir) => applyStatusLineConfig(dir, enabled).catch(() => {})));
+        await Promise.all([...dirs].map((dir) => applyStatusLineConfig(dir, true).catch(() => {})));
       }
 
       // Handle tunnel toggle dynamically

src/web/schemas.ts

@@ -369,6 +369,12 @@ export const SettingsUpdateSchema = z
     showSubagents: z.boolean().optional(),
     showMultiMonitorButton: z.boolean().optional(),
     showPlanUsageLimits: z.boolean().optional(),
+    // Action field (NOT persisted as a setting): when true, (re)injects the
+    // plan-usage statusLine exporter into active Claude sessions so live usage %
+    // starts flowing. Sent on ENABLE only — the chip's DISPLAY is per-device
+    // (client-side), but telemetry COLLECTION is server-side, so the per-device
+    // toggle signals it out-of-band here rather than via showPlanUsageLimits.
+    statusLineTelemetry: z.boolean().optional(),
     // Input
     gestureControlEnabled: z.boolean().optional(),
     // Claude CLI settings

src/web/server.ts

@@ -1147,14 +1147,11 @@ export class WebServer extends EventEmitter {
     if (settings.showMultiMonitorButton === true) {
       html = html.replace(' btn-multimonitor--hidden', '');
     }
-    // Plan-usage chip: same pattern. Ships with `header-plan-usage--hidden` (App
-    // Settings → Display → "Plan Usage Limits", default off); strip it server-side
-    // when enabled so the chip doesn't flash hidden on every reload before the
-    // client's applyHeaderVisibilitySettings runs. showPlanUsageLimits is a synced
-    // (non-display) setting, so readSettings sees the persisted value here.
-    if (settings.showPlanUsageLimits === true) {
-      html = html.replace(' header-plan-usage--hidden', '');
-    }
+    // Plan-usage chip: ships hidden (`header-plan-usage--hidden`) and is revealed
+    // PER-DEVICE by the client (settings-ui.js applyHeaderVisibilitySettings). It
+    // used to be server-revealed from a synced setting, but that leaked the desktop
+    // choice onto mobile — display is now per-device only (like the response viewer).
+    // Telemetry collection stays server-side via the statusLineTelemetry action.
     // Detached single-session ("solo") window: inject the target session id so
     // the client can enter solo mode even if a (network-first) service worker
     // later serves a cached shell. The client primarily detects solo mode from