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Not sure how to reproduce it. So when I open the needle editor and use the combo box to select needles the error occurs?

Looks like a permission problem and hence packaging/deployment issue.

There is a warn in the code:

Jan 24 13:49:34 openqa openqa[11963]: /var/lib/openqa/share/tests/sle/products/sle/needles/firefox-gnomeshell-installed-20151026.json is not in a subdir of /var/lib/openqa/share/tests/sle-12-SP1 at /usr/share/openqa/script/../lib/OpenQA/WebAPI/Controller/File.pm line 47.

the problem seems to be that the absolute dir is compared - but towards the not expanded tests directory, which is a symlink to sle

The only reason I can think of why these symlinks exist is that they pointed to opensuse before - and were changed to sle only later. But having sle-$VERSION symlink to sle doesn't make sense :(

E.g. these make sense:

drwxr-xr-x 9 geekotest nogroup 4096 10. Jan 22:45 sle-11-SP3
lrwxrwxrwx 1 root      root      10 11. Dez 2014  sle-11-SP4-Alpha -> sle-11-SP3

But the needle in database will be sle-11-SP3 - and the tests will be SP4. So this will eat the needle permissions

And all casp tests are affected too: https://openqa.suse.de/tests/727946#step/boot_to_desktop/1

Seems like Oliver already tried to fix it some time ago: https://github.com/os-autoinst/openQA/commit/2797bcffa5e9681db44e9d1a67eb0759aa7e85f6
Maybe this fix never worked or further commits broke it again.