fix: tray main-thread message loop, numpy <2.0 pin, installer config copy

- Rewrite tray to run on main thread (pystray owns message loop, uvicorn
  in background thread) — fixes unresponsive confirmation dialogs
- Use native Windows MessageBoxW instead of tkinter (embedded Python
  has no tkinter)
- Pin numpy <2.0 to fix soundcard's numpy.fromstring (removed in 2.0)
- Strip transitive numpy 2.x wheels in build script
- Installer copies config.example.yaml as config.yaml on fresh install
- Suppress noisy screen_brightness_control warnings

build-dist-windows.sh

@@ -74,17 +74,24 @@ WIN_DEPS=(
 # Visualizer dependencies
 VIS_DEPS=(
     "soundcard>=0.4.0"
-    "numpy>=1.24.0"
+    "numpy>=1.24.0,<2.0"
 )
 
 ALL_DEPS=("${CORE_DEPS[@]}" "${WIN_DEPS[@]}" "${VIS_DEPS[@]}")
 
 for dep in "${ALL_DEPS[@]}"; do
-    pip download --quiet --dest "$WHEEL_DIR" \
+    pip download --quiet --no-cache-dir --dest "$WHEEL_DIR" \
         --platform win_amd64 --python-version "${PYTHON_SHORT}" \
         --implementation cp --only-binary :all: \
         "$dep" 2>/dev/null || \
-    pip download --quiet --dest "$WHEEL_DIR" "$dep"
+    pip download --quiet --no-cache-dir --dest "$WHEEL_DIR" \
+        --python-version "${PYTHON_SHORT}" \
+        "$dep"
+done
+
+# Remove numpy 2.x wheels pulled as transitive deps (soundcard requires <2.0)
+for f in "$WHEEL_DIR"/numpy-2*; do
+    [ -f "$f" ] && echo "Removing incompatible: $(basename "$f")" && rm "$f"
 done
 
 # Install wheels into site-packages

installer.nsi

@@ -73,6 +73,10 @@ Section "!Core (required)" SecCore
     ; Copy entire distribution
     File /r "dist\media-server\*.*"
 
+    ; Create config.yaml from example if it doesn't already exist (preserve user config on upgrade)
+    IfFileExists "$INSTDIR\config.yaml" +2
+    CopyFiles /SILENT "$INSTDIR\config.example.yaml" "$INSTDIR\config.yaml"
+
     ; Create uninstaller
     WriteUninstaller "$INSTDIR\uninstall.exe"
 

media_server/main.py

@@ -51,6 +51,9 @@ def setup_logging():
         handlers=[handler],
     )
 
+    # Suppress noisy third-party loggers
+    logging.getLogger("screen_brightness_control").setLevel(logging.ERROR)
+
 
 @asynccontextmanager
 async def lifespan(app: FastAPI):
@@ -240,23 +243,47 @@ def main():
             print("\nAuthentication is DISABLED (no tokens configured)")
         return
 
-    # Start system tray icon (unless disabled)
+    from .tray import PYSTRAY_AVAILABLE, TrayManager
-    tray_icon = None
-    if not args.no_tray:
-        from .tray import start_tray
 
-        tray_icon = start_tray(args.host, args.port)
+    use_tray = PYSTRAY_AVAILABLE and not args.no_tray
 
-    try:
+    if use_tray:
+        import asyncio
+        import threading
+
+        # Run uvicorn in a background thread so tray owns the main thread message loop
+        uv_config = uvicorn.Config(
+            "media_server.main:app",
+            host=args.host,
+            port=args.port,
+            log_level=settings.log_level.lower(),
+        )
+        server = uvicorn.Server(uv_config)
+
+        def run_server():
+            loop = asyncio.new_event_loop()
+            asyncio.set_event_loop(loop)
+            loop.run_until_complete(server.serve())
+
+        server_thread = threading.Thread(target=run_server, daemon=True)
+        server_thread.start()
+
+        # Tray on main thread (blocking)
+        tray = TrayManager(
+            port=args.port,
+            on_exit=lambda: setattr(server, "should_exit", True),
+        )
+        tray.run()
+
+        # Tray exited — wait for server to finish graceful shutdown
+        server_thread.join(timeout=10)
+    else:
         uvicorn.run(
             "media_server.main:app",
             host=args.host,
             port=args.port,
             reload=False,
         )
-    finally:
-        if tray_icon is not None:
-            tray_icon.stop()
 
 
 if __name__ == "__main__":

media_server/tray.py

@@ -1,13 +1,13 @@
 """System tray icon for Media Server."""
 
+import ctypes
 import io
 import logging
 import os
-import signal
-import subprocess
 import sys
-import threading
 import webbrowser
+from pathlib import Path
+from typing import Callable
 
 from PIL import Image, ImageDraw
 
@@ -16,28 +16,27 @@ logger = logging.getLogger(__name__)
 # pystray is optional — tray silently disabled when missing
 try:
     import pystray
+
+    PYSTRAY_AVAILABLE = True
 except ImportError:
     pystray = None
+    PYSTRAY_AVAILABLE = False
 
-# tkinter is optional — used for confirmation dialogs
+
-try:
+# Windows-native confirmation (no tkinter needed)
-    import tkinter as tk
+_MB_YESNO = 0x04
-    from tkinter import messagebox
+_MB_ICONQUESTION = 0x20
-except ImportError:
+_MB_TOPMOST = 0x40000
-    tk = None
+_MB_SETFOREGROUND = 0x10000
-    messagebox = None
+_IDYES = 6
 
 
 def _confirm(title: str, message: str) -> bool:
-    """Show a Yes/No confirmation dialog. Returns True if user clicks Yes."""
+    """Show a Yes/No dialog using native Windows MessageBox."""
-    if messagebox is None:
+    result = ctypes.windll.user32.MessageBoxW(
-        return True  # No tkinter — skip confirmation
+        0, message, title, _MB_YESNO | _MB_ICONQUESTION | _MB_TOPMOST | _MB_SETFOREGROUND
-    root = tk.Tk()
+    )
-    root.withdraw()
+    return result == _IDYES
-    root.attributes("-topmost", True)
-    result = messagebox.askyesno(title, message, parent=root)
-    root.destroy()
-    return result
 
 
 def _create_icon_image(size: int = 64) -> Image.Image:
@@ -66,15 +65,24 @@ def _create_icon_image(size: int = 64) -> Image.Image:
 
 
 def _load_icon_image() -> Image.Image:
-    """Load the SVG app icon, falling back to a generated image."""
+    """Load the ICO/SVG app icon, falling back to a generated image."""
+    icons_dir = Path(__file__).parent / "static" / "icons"
+
+    # Try .ico first (best for Windows tray)
+    ico_path = icons_dir / "icon.ico"
+    if ico_path.exists():
+        try:
+            return Image.open(ico_path)
+        except Exception:
+            pass
+
+    # Try SVG via cairosvg
     try:
         import cairosvg
 
-        svg_path = os.path.join(
+        svg_path = icons_dir / "icon.svg"
-            os.path.dirname(__file__), "static", "icons", "icon.svg"
+        if svg_path.exists():
-        )
+            png_data = cairosvg.svg2png(url=str(svg_path), output_width=64, output_height=64)
-        if os.path.exists(svg_path):
-            png_data = cairosvg.svg2png(url=svg_path, output_width=64, output_height=64)
             return Image.open(io.BytesIO(png_data))
     except Exception:
         pass
@@ -82,53 +90,57 @@ def _load_icon_image() -> Image.Image:
     return _create_icon_image()
 
 
-def start_tray(host: str, port: int) -> "pystray.Icon | None":
+class TrayManager:
-    """Start system tray icon in a background thread.
+    """Manages the system tray icon and its context menu.
 
-    Returns the Icon instance (call icon.stop() to remove), or None if
+    Call ``run()`` on the **main thread** — it blocks until ``stop()``
-    pystray is not installed.
+    is called (from any thread) or the user picks *Shutdown* from the menu.
     """
-    if pystray is None:
-        logger.info("pystray not installed — tray icon disabled")
-        return None
 
-    url = f"http://{'localhost' if host == '0.0.0.0' else host}:{port}"
+    def __init__(self, port: int, on_exit: Callable[[], None]) -> None:
+        if not PYSTRAY_AVAILABLE:
+            raise ImportError("pystray is required for system tray support")
 
-    def on_show_ui(_icon, _item):
+        self._port = port
-        webbrowser.open(url)
+        self._on_exit = on_exit
-
-    def on_restart(_icon, _item):
-        if not _confirm("Restart Media Server", "Are you sure you want to restart the server?"):
-            return
-        logger.info("Restart requested from tray")
-        _icon.stop()
-        # Re-launch the same process, then exit current
-        subprocess.Popen([sys.executable] + sys.argv)
-        os.kill(os.getpid(), signal.SIGINT)
-
-    def on_exit(_icon, _item):
-        if not _confirm("Exit Media Server", "Are you sure you want to shut down the server?"):
-            return
-        logger.info("Exit requested from tray")
-        _icon.stop()
-        os.kill(os.getpid(), signal.SIGINT)
 
         menu = pystray.Menu(
-        pystray.MenuItem("Show UI", on_show_ui, default=True),
+            pystray.MenuItem("Show UI", self._show_ui, default=True),
             pystray.Menu.SEPARATOR,
-        pystray.MenuItem("Restart", on_restart),
+            pystray.MenuItem("Restart", self._restart),
-        pystray.MenuItem("Shutdown", on_exit),
+            pystray.MenuItem("Shutdown", self._shutdown),
         )
 
-    icon = pystray.Icon(
+        self._icon = pystray.Icon(
             name="media-server",
             icon=_load_icon_image(),
             title="Media Server",
             menu=menu,
         )
 
-    thread = threading.Thread(target=icon.run, daemon=True)
+    def _show_ui(self, icon: "pystray.Icon", item: "pystray.MenuItem") -> None:
-    thread.start()
+        webbrowser.open(f"http://localhost:{self._port}")
-    logger.info("System tray icon started")
 
-    return icon
+    def _restart(self, icon: "pystray.Icon", item: "pystray.MenuItem") -> None:
+        if not _confirm("Media Server", "Restart the server?"):
+            return
+        logger.info("Restart requested from tray")
+        self._icon.stop()
+        self._on_exit()
+        os.environ["MEDIA_SERVER_RESTART"] = "1"
+        os.execv(sys.executable, [sys.executable] + sys.argv)
+
+    def _shutdown(self, icon: "pystray.Icon", item: "pystray.MenuItem") -> None:
+        if not _confirm("Media Server", "Shut down the server?"):
+            return
+        logger.info("Shutdown requested from tray")
+        self._on_exit()
+        self._icon.stop()
+
+    def run(self) -> None:
+        """Block the calling thread running the tray message loop."""
+        self._icon.run()
+
+    def stop(self) -> None:
+        """Stop the tray icon from any thread."""
+        self._icon.stop()

pyproject.toml

@@ -46,7 +46,7 @@ windows = [
 ]
 visualizer = [
     "soundcard>=0.4.0",
-    "numpy>=1.24.0",
+    "numpy>=1.24.0,<2.0",
 ]
 dev = [
     "pytest>=7.0",