fix: persist onboarding_completed for CLI-configured users on first chat_ready (#922)

* fix: persist onboarding_completed for CLI-configured users on first chat_ready (v0.50.179, #921)

Co-authored-by: bsgdigital

* fix(onboarding): don't 500 the status endpoint if save_settings fails

The #921 persist call `save_settings({"onboarding_completed": True})` in
get_onboarding_status() raises if the settings.json write fails
(read-only filesystem, disk full, permission error). That turns every
/api/onboarding/status call into a 500 until the disk is writable,
which is much worse UX than losing the persistence-across-restart guard.

Wrapped in try/except so persistence becomes best-effort. The function
still sets settings["onboarding_completed"] = True in memory on success,
and `completed` reflects `config_auto_completed` on this request either
way, so the user sees the right state even when the write fails — only
the next-restart protection degrades.

Added regression test that patches save_settings to raise OSError and
asserts the endpoint still returns completed=True without raising.

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>

---------

Co-authored-by: nesquena-hermes <nesquena-hermes@users.noreply.github.com>
Co-authored-by: Nathan Esquenazi <nesquena@gmail.com>
Co-authored-by: Claude Opus 4.7 (1M context) <noreply@anthropic.com>

CHANGELOG.md

@@ -29,6 +29,11 @@
   workspace subtree) and never enumerate blocked system roots. (`api/routes.py`,
   `api/workspace.py`, `static/panels.js`, `static/style.css`) (partial for #616)
 
+## [v0.50.179] — 2026-04-23
+
+### Fixed
+- **Onboarding wizard clobbering CLI users' config after server restart** — CLI-configured users (who set up via `hermes model` / `hermes auth`) had no `onboarding_completed` flag in `settings.json`. After a git branch switch or server restart, `verify_hermes_imports()` could momentarily return `imports_ok=False`, making `chat_ready=False` and causing the wizard to reappear with a destructive dropdown default (openrouter). Fixed by writing `onboarding_completed: True` to `settings.json` the first time `config_auto_completed` evaluates to `True`, so the flag survives future transient import failures. (`api/onboarding.py`) Co-authored by @bsgdigital.
+
 ## [v0.50.177] — 2026-04-23
 
 ### Fixed

api/onboarding.py

@@ -435,6 +435,25 @@ def get_onboarding_status() -> dict:
     config_exists = Path(_get_config_path()).exists()
     config_auto_completed = config_exists and bool(runtime.get("chat_ready"))
 
+    # Persist the flag so it survives future transient import failures (e.g. after
+    # a git branch switch in the hermes-agent repo).  Without this, a CLI-configured
+    # user who never ran the wizard has no onboarding_completed flag — any momentary
+    # imports_ok=False during restart makes chat_ready=False, config_auto_completed=False,
+    # and the wizard reappears with a broken dropdown that clobbers their config.
+    #
+    # Best-effort: if save_settings raises (read-only FS, disk full, permission error),
+    # log and continue.  The `config_auto_completed` branch of `completed=` below still
+    # returns True for this request, so the user sees the correct state — only the
+    # persistence-across-restart guarantee is degraded.  Raising here would turn every
+    # /api/onboarding/status call into a 500 until disk was writable, which is worse UX
+    # than losing the next-restart protection.
+    if config_auto_completed and not settings.get("onboarding_completed"):
+        try:
+            save_settings({"onboarding_completed": True})
+            settings["onboarding_completed"] = True
+        except Exception:
+            logger.debug("Failed to persist onboarding_completed", exc_info=True)
+
     return {
         "completed": bool(settings.get("onboarding_completed")) or auto_completed or config_auto_completed,
         "settings": {

tests/test_onboarding_existing_config.py

@@ -116,6 +116,50 @@ class TestOnboardingGate:
         assert "config_exists" in result["system"]
         assert result["system"]["config_exists"] is True
 
+    def test_persist_failure_does_not_break_status_endpoint(self):
+        """save_settings() failure (read-only FS, disk full) must not turn the
+        status endpoint into a 500.  The persistence-across-restart guarantee
+        degrades but `completed` still reflects the live `config_auto_completed`
+        signal so the user isn't blocked from using the UI.
+        """
+        import api.onboarding as mod
+        settings = {"onboarding_completed": False}
+        runtime = {
+            "chat_ready": True,
+            "provider_configured": True,
+            "provider_ready": True,
+            "setup_state": "ready",
+            "provider_note": "test",
+            "current_provider": "openrouter",
+            "current_model": "anthropic/claude-sonnet-4.6",
+            "current_base_url": None,
+            "env_path": "/tmp/.hermes_test/.env",
+        }
+        fake_config_path = pathlib.Path("/tmp/_test_config.yaml")
+
+        with (
+            mock.patch.object(mod, "load_settings", return_value=settings),
+            mock.patch.object(mod, "get_config", return_value={}),
+            mock.patch.object(mod, "verify_hermes_imports", return_value=(True, [], {})),
+            mock.patch.object(mod, "_status_from_runtime", return_value=runtime),
+            mock.patch.object(mod, "load_workspaces", return_value=[]),
+            mock.patch.object(mod, "get_last_workspace", return_value=None),
+            mock.patch.object(mod, "get_available_models", return_value=[]),
+            mock.patch.object(mod, "_get_config_path", return_value=fake_config_path),
+            mock.patch.object(pathlib.Path, "exists", return_value=True),
+            mock.patch.object(
+                mod, "save_settings", side_effect=OSError("read-only filesystem")
+            ),
+        ):
+            # Must not raise — persistence failure is best-effort.
+            result = mod.get_onboarding_status()
+
+        # completed still reflects the live signal via config_auto_completed
+        assert result["completed"] is True, (
+            "Status endpoint must still return completed=True via the live "
+            "config_auto_completed signal when persistence fails"
+        )
+
 
 class TestApplyOnboardingSetupGuard:
     """Fix #2: apply_onboarding_setup must not silently overwrite config.yaml."""
@@ -303,9 +347,10 @@ class TestOnboardingGateIntegration:
         # Write a fake API key so provider_ready (and thus chat_ready) fires
         # — but only when hermes_cli imports are available
         data, _ = _http_get("/api/onboarding/status")
+        try:
             if data["system"]["hermes_found"] and data["system"]["imports_ok"]:
                 (hermes_home / ".env").write_text(
-                "OPENROUTER_API_KEY=test-existing-key\n", encoding="utf-8"
+                    "OPENROUTER_API_KEY=test-e...\n", encoding="utf-8"
                 )
                 data, status = _http_get("/api/onboarding/status")
                 assert status == 200
@@ -316,7 +361,13 @@ class TestOnboardingGateIntegration:
                 # Agent not installed: chat_ready is always False, so wizard still
                 # fires — that is the correct behaviour (can't verify readiness).
                 assert data["completed"] is False
-
+        finally:
+            # Clean up: the auto-persist in get_onboarding_status() (#921) writes
+            # onboarding_completed=True to settings.json when config_auto_completed fires.
+            # Reset to avoid contaminating subsequent tests.
+            (hermes_home / "config.yaml").unlink(missing_ok=True)
+            (hermes_home / ".env").unlink(missing_ok=True)
+            _http_post("/api/settings", {"onboarding_completed": False})
     @_needs_yaml
     def test_setup_blocked_for_existing_config(self):
         """POST /api/onboarding/setup must return config_exists error if config.yaml exists."""
@@ -366,3 +417,7 @@ class TestOnboardingGateIntegration:
         assert data.get("error") != "config_exists", (
             "confirm_overwrite=True must bypass the guard."
         )
+        # Clean up so onboarding_completed=True left by this test's setup call
+        # does not contaminate subsequent tests (#921 test isolation).
+        (hermes_home / "config.yaml").unlink(missing_ok=True)
+        _http_post("/api/settings", {"onboarding_completed": False})