fix(dashboard): cap gateway health probe timeout

hermes_cli/web_server.py

@@ -1372,14 +1372,29 @@ def _apply_main_model_assignment(
 
 
 _GATEWAY_HEALTH_URL = os.getenv("GATEWAY_HEALTH_URL")
+_GATEWAY_HEALTH_TIMEOUT_MAX = 1.0
+_GATEWAY_HEALTH_ROUTE_TIMEOUT = 1.0
 try:
-    _GATEWAY_HEALTH_TIMEOUT = float(os.getenv("GATEWAY_HEALTH_TIMEOUT", "3"))
+    _GATEWAY_HEALTH_TIMEOUT = float(os.getenv("GATEWAY_HEALTH_TIMEOUT", "1"))
 except (ValueError, TypeError):
     _log.warning(
-        "Invalid GATEWAY_HEALTH_TIMEOUT value %r — using default 3.0s",
+        "Invalid GATEWAY_HEALTH_TIMEOUT value %r — using default 1.0s",
         os.getenv("GATEWAY_HEALTH_TIMEOUT"),
     )
-    _GATEWAY_HEALTH_TIMEOUT = 3.0
+    _GATEWAY_HEALTH_TIMEOUT = 1.0
+if _GATEWAY_HEALTH_TIMEOUT <= 0:
+    _log.warning(
+        "Invalid non-positive GATEWAY_HEALTH_TIMEOUT value %.3fs — using default 1.0s",
+        _GATEWAY_HEALTH_TIMEOUT,
+    )
+    _GATEWAY_HEALTH_TIMEOUT = 1.0
+elif _GATEWAY_HEALTH_TIMEOUT > _GATEWAY_HEALTH_TIMEOUT_MAX:
+    _log.warning(
+        "Capping GATEWAY_HEALTH_TIMEOUT %.3fs to %.3fs for dashboard liveness probes",
+        _GATEWAY_HEALTH_TIMEOUT,
+        _GATEWAY_HEALTH_TIMEOUT_MAX,
+    )
+    _GATEWAY_HEALTH_TIMEOUT = _GATEWAY_HEALTH_TIMEOUT_MAX
 
 _STATUS_ACTIVE_SESSIONS_TIMEOUT = 0.75
 
@@ -2823,9 +2838,17 @@ async def get_status(profile: Optional[str] = None):
 
         if not gateway_running and _GATEWAY_HEALTH_URL:
             loop = asyncio.get_running_loop()
-            alive, remote_health_body = await loop.run_in_executor(
-                None, _probe_gateway_health
-            )
+            try:
+                alive, remote_health_body = await asyncio.wait_for(
+                    loop.run_in_executor(None, _probe_gateway_health),
+                    timeout=_GATEWAY_HEALTH_ROUTE_TIMEOUT,
+                )
+            except TimeoutError:
+                _log.warning(
+                    "/api/status gateway health probe exceeded %.2fs; using local status",
+                    _GATEWAY_HEALTH_ROUTE_TIMEOUT,
+                )
+                alive, remote_health_body = False, None
             if alive:
                 gateway_running = True
                 # PID from the remote container (display only — not locally valid)

tests/hermes_cli/test_web_server.py

@@ -5,6 +5,7 @@ import os
 import json
 import shutil
 import sys
+import threading
 from pathlib import Path
 from types import SimpleNamespace
 from unittest.mock import patch, MagicMock
@@ -6851,6 +6852,26 @@ class TestProbeGatewayHealth:
         assert alive is False
         assert body is None
 
+    def test_probe_uses_configured_short_timeout(self, monkeypatch):
+        """The HTTP probe must not fall through to the OS TCP timeout."""
+        import hermes_cli.web_server as ws
+
+        monkeypatch.setattr(ws, "_GATEWAY_HEALTH_URL", "http://gw:8642")
+        monkeypatch.setattr(ws, "_GATEWAY_HEALTH_TIMEOUT", 0.75)
+        timeouts = []
+
+        def mock_urlopen(req, **kwargs):
+            timeouts.append(kwargs.get("timeout"))
+            raise TimeoutError("mock timeout")
+
+        monkeypatch.setattr(ws.urllib.request, "urlopen", mock_urlopen)
+
+        alive, body = ws._probe_gateway_health()
+
+        assert alive is False
+        assert body is None
+        assert timeouts == [0.75, 0.75]
+
     def test_normalizes_url_with_health_suffix(self, monkeypatch):
         """If the user sets the URL to include /health, it's stripped to base."""
         import hermes_cli.web_server as ws
@@ -6973,6 +6994,29 @@ class TestStatusRemoteGateway:
         assert data["gateway_state"] == "running"
         assert data["gateway_health_url"] == "http://gw:8642"
 
+    def test_status_bounds_the_complete_remote_probe(self, monkeypatch):
+        """Two serial HTTP attempts cannot consume more than the route budget."""
+        import hermes_cli.web_server as ws
+
+        probe_started = threading.Event()
+
+        def slow_probe():
+            probe_started.set()
+            threading.Event().wait(timeout=0.1)
+            return True, {"status": "ok", "pid": 999}
+
+        monkeypatch.setattr(ws, "get_running_pid_cached", lambda: None)
+        monkeypatch.setattr(ws, "read_runtime_status", lambda: None)
+        monkeypatch.setattr(ws, "_GATEWAY_HEALTH_URL", "http://gw:8642")
+        monkeypatch.setattr(ws, "_GATEWAY_HEALTH_ROUTE_TIMEOUT", 0.02)
+        monkeypatch.setattr(ws, "_probe_gateway_health", slow_probe)
+
+        resp = self.client.get("/api/status")
+
+        assert probe_started.is_set()
+        assert resp.status_code == 200
+        assert resp.json()["gateway_running"] is False
+
     def test_status_remote_probe_not_attempted_when_local_pid_found(self, monkeypatch):
         """When local PID check succeeds, the remote probe is never called."""
         import hermes_cli.web_server as ws