fix: warn and clear stale OPENAI_BASE_URL on provider switch (#5161)

agent/auxiliary_client.py

@@ -59,6 +59,9 @@ from hermes_constants import OPENROUTER_BASE_URL
 
 logger = logging.getLogger(__name__)
 
+# Module-level flag: only warn once per process about stale OPENAI_BASE_URL.
+_stale_base_url_warned = False
+
 _PROVIDER_ALIASES = {
     "google": "gemini",
     "google-gemini": "gemini",
@@ -1133,9 +1136,28 @@ def _resolve_auto() -> Tuple[Optional[OpenAI], Optional[str]]:
          provider they already have credentials for — no OpenRouter key needed.
       2. OpenRouter → Nous → custom → Codex → API-key providers (original chain).
     """
-    global auxiliary_is_nous
+    global auxiliary_is_nous, _stale_base_url_warned
     auxiliary_is_nous = False  # Reset — _try_nous() will set True if it wins
 
+    # ── Warn once if OPENAI_BASE_URL is set but config.yaml uses a named
+    #    provider (not 'custom').  This catches the common "env poisoning"
+    #    scenario where a user switches providers via `hermes model` but the
+    #    old OPENAI_BASE_URL lingers in ~/.hermes/.env. ──
+    if not _stale_base_url_warned:
+        _env_base = os.getenv("OPENAI_BASE_URL", "").strip()
+        _cfg_provider = _read_main_provider()
+        if (_env_base and _cfg_provider
+                and _cfg_provider != "custom"
+                and not _cfg_provider.startswith("custom:")):
+            logger.warning(
+                "OPENAI_BASE_URL is set (%s) but model.provider is '%s'. "
+                "Auxiliary clients may route to the wrong endpoint. "
+                "Run: hermes model to reconfigure, or remove "
+                "OPENAI_BASE_URL from ~/.hermes/.env",
+                _env_base, _cfg_provider,
+            )
+            _stale_base_url_warned = True
+
     # ── Step 1: non-aggregator main provider → use main model directly ──
     main_provider = _read_main_provider()
     main_model = _read_main_model()

hermes_cli/main.py

@@ -1080,6 +1080,42 @@ def select_provider_and_model(args=None):
     elif selected_provider in ("gemini", "zai", "minimax", "minimax-cn", "kilocode", "opencode-zen", "opencode-go", "ai-gateway", "alibaba", "huggingface"):
         _model_flow_api_key_provider(config, selected_provider, current_model)
 
+    # ── Post-switch cleanup: clear stale OPENAI_BASE_URL ──────────────
+    # When the user switches to a named provider (anything except "custom"),
+    # a leftover OPENAI_BASE_URL in ~/.hermes/.env can poison auxiliary
+    # clients that use provider:auto. Clear it proactively.  (#5161)
+    if selected_provider not in ("custom", "cancel", "remove-custom") \
+            and not selected_provider.startswith("custom:"):
+        _clear_stale_openai_base_url()
+
+
+def _clear_stale_openai_base_url():
+    """Remove OPENAI_BASE_URL from ~/.hermes/.env if the active provider is not 'custom'.
+
+    After a provider switch, a leftover OPENAI_BASE_URL causes auxiliary
+    clients (compression, vision, delegation) with provider:auto to route
+    requests to the old custom endpoint instead of the newly selected
+    provider.  See issue #5161.
+    """
+    from hermes_cli.config import get_env_value, save_env_value, load_config
+
+    cfg = load_config()
+    model_cfg = cfg.get("model", {})
+    if isinstance(model_cfg, dict):
+        provider = (model_cfg.get("provider") or "").strip().lower()
+    else:
+        provider = ""
+
+    if provider == "custom" or not provider:
+        return  # custom provider legitimately uses OPENAI_BASE_URL
+
+    stale_url = get_env_value("OPENAI_BASE_URL")
+    if stale_url:
+        save_env_value("OPENAI_BASE_URL", "")
+        print(f"Cleared stale OPENAI_BASE_URL from .env (was: {stale_url[:40]}...)"
+              if len(stale_url) > 40
+              else f"Cleared stale OPENAI_BASE_URL from .env (was: {stale_url})")
+
 
 def _prompt_provider_choice(choices, *, default=0):
     """Show provider selection menu with curses arrow-key navigation.

tests/agent/test_auxiliary_client.py

@@ -1,6 +1,7 @@
 """Tests for agent.auxiliary_client resolution chain, provider overrides, and model overrides."""
 
 import json
+import logging
 import os
 from pathlib import Path
 from unittest.mock import patch, MagicMock, AsyncMock
@@ -1472,3 +1473,90 @@ class TestAsyncCallLlmFallback:
 
         assert result is fb_response
         mock_fb.assert_called_once_with("auto", "compression", reason="connection error")
+class TestStaleBaseUrlWarning:
+    """_resolve_auto() warns when OPENAI_BASE_URL conflicts with config provider (#5161)."""
+
+    def test_warns_when_openai_base_url_set_with_named_provider(self, monkeypatch, caplog):
+        """Warning fires when OPENAI_BASE_URL is set but provider is a named provider."""
+        import agent.auxiliary_client as mod
+        # Reset the module-level flag so the warning fires
+        monkeypatch.setattr(mod, "_stale_base_url_warned", False)
+        monkeypatch.setenv("OPENAI_BASE_URL", "http://localhost:11434/v1")
+        monkeypatch.setenv("OPENROUTER_API_KEY", "sk-or-test")
+
+        with patch("agent.auxiliary_client._read_main_provider", return_value="openrouter"), \
+             patch("agent.auxiliary_client._read_main_model", return_value="google/gemini-flash"), \
+             caplog.at_level(logging.WARNING, logger="agent.auxiliary_client"):
+            _resolve_auto()
+
+        assert any("OPENAI_BASE_URL is set" in rec.message for rec in caplog.records), \
+            "Expected a warning about stale OPENAI_BASE_URL"
+        assert mod._stale_base_url_warned is True
+
+    def test_no_warning_when_provider_is_custom(self, monkeypatch, caplog):
+        """No warning when the provider is 'custom' — OPENAI_BASE_URL is expected."""
+        import agent.auxiliary_client as mod
+        monkeypatch.setattr(mod, "_stale_base_url_warned", False)
+        monkeypatch.setenv("OPENAI_BASE_URL", "http://localhost:11434/v1")
+        monkeypatch.setenv("OPENAI_API_KEY", "test-key")
+
+        with patch("agent.auxiliary_client._read_main_provider", return_value="custom"), \
+             patch("agent.auxiliary_client._read_main_model", return_value="llama3"), \
+             patch("agent.auxiliary_client._resolve_custom_runtime",
+                   return_value=("http://localhost:11434/v1", "test-key", None)), \
+             patch("agent.auxiliary_client.OpenAI") as mock_openai, \
+             caplog.at_level(logging.WARNING, logger="agent.auxiliary_client"):
+            mock_openai.return_value = MagicMock()
+            _resolve_auto()
+
+        assert not any("OPENAI_BASE_URL is set" in rec.message for rec in caplog.records), \
+            "Should NOT warn when provider is 'custom'"
+
+    def test_no_warning_when_provider_is_named_custom(self, monkeypatch, caplog):
+        """No warning when the provider is 'custom:myname' — base_url comes from config."""
+        import agent.auxiliary_client as mod
+        monkeypatch.setattr(mod, "_stale_base_url_warned", False)
+        monkeypatch.setenv("OPENAI_BASE_URL", "http://localhost:11434/v1")
+        monkeypatch.setenv("OPENAI_API_KEY", "test-key")
+
+        with patch("agent.auxiliary_client._read_main_provider", return_value="custom:ollama-local"), \
+             patch("agent.auxiliary_client._read_main_model", return_value="llama3"), \
+             patch("agent.auxiliary_client.resolve_provider_client",
+                   return_value=(MagicMock(), "llama3")), \
+             caplog.at_level(logging.WARNING, logger="agent.auxiliary_client"):
+            _resolve_auto()
+
+        assert not any("OPENAI_BASE_URL is set" in rec.message for rec in caplog.records), \
+            "Should NOT warn when provider is 'custom:*'"
+
+    def test_no_warning_when_openai_base_url_not_set(self, monkeypatch, caplog):
+        """No warning when OPENAI_BASE_URL is absent."""
+        import agent.auxiliary_client as mod
+        monkeypatch.setattr(mod, "_stale_base_url_warned", False)
+        monkeypatch.delenv("OPENAI_BASE_URL", raising=False)
+        monkeypatch.setenv("OPENROUTER_API_KEY", "sk-or-test")
+
+        with patch("agent.auxiliary_client._read_main_provider", return_value="openrouter"), \
+             patch("agent.auxiliary_client._read_main_model", return_value="google/gemini-flash"), \
+             caplog.at_level(logging.WARNING, logger="agent.auxiliary_client"):
+            _resolve_auto()
+
+        assert not any("OPENAI_BASE_URL is set" in rec.message for rec in caplog.records), \
+            "Should NOT warn when OPENAI_BASE_URL is not set"
+
+    def test_warning_only_fires_once(self, monkeypatch, caplog):
+        """Warning is suppressed after the first invocation."""
+        import agent.auxiliary_client as mod
+        monkeypatch.setattr(mod, "_stale_base_url_warned", False)
+        monkeypatch.setenv("OPENAI_BASE_URL", "http://localhost:11434/v1")
+        monkeypatch.setenv("OPENROUTER_API_KEY", "sk-or-test")
+
+        with patch("agent.auxiliary_client._read_main_provider", return_value="openrouter"), \
+             patch("agent.auxiliary_client._read_main_model", return_value="google/gemini-flash"), \
+             caplog.at_level(logging.WARNING, logger="agent.auxiliary_client"):
+            _resolve_auto()
+            caplog.clear()
+            _resolve_auto()
+
+        assert not any("OPENAI_BASE_URL is set" in rec.message for rec in caplog.records), \
+            "Warning should not fire a second time"

tests/hermes_cli/test_clear_stale_base_url.py

@@ -0,0 +1,75 @@
+"""Tests for _clear_stale_openai_base_url() cleanup after provider switch (#5161)."""
+
+from __future__ import annotations
+
+from unittest.mock import patch
+
+from hermes_cli.config import load_config, save_config, save_env_value, get_env_value
+
+
+def _write_provider(provider: str, model: str = "test-model"):
+    """Helper: write a provider + model to config.yaml."""
+    cfg = load_config()
+    model_cfg = cfg.get("model", {})
+    if not isinstance(model_cfg, dict):
+        model_cfg = {}
+    model_cfg["provider"] = provider
+    model_cfg["default"] = model
+    cfg["model"] = model_cfg
+    save_config(cfg)
+
+
+class TestClearStaleOpenaiBaseUrl:
+    """_clear_stale_openai_base_url() removes OPENAI_BASE_URL when provider is not custom."""
+
+    def test_clears_when_provider_is_named(self, monkeypatch):
+        """OPENAI_BASE_URL is cleared when config provider is a named provider."""
+        from hermes_cli.main import _clear_stale_openai_base_url
+
+        _write_provider("openrouter")
+        save_env_value("OPENAI_BASE_URL", "http://localhost:11434/v1")
+
+        _clear_stale_openai_base_url()
+
+        result = get_env_value("OPENAI_BASE_URL")
+        assert not result, f"Expected OPENAI_BASE_URL to be cleared, got: {result!r}"
+
+    def test_preserves_when_provider_is_custom(self, monkeypatch):
+        """OPENAI_BASE_URL is NOT cleared when config provider is 'custom'."""
+        from hermes_cli.main import _clear_stale_openai_base_url
+
+        _write_provider("custom")
+        save_env_value("OPENAI_BASE_URL", "http://localhost:11434/v1")
+
+        _clear_stale_openai_base_url()
+
+        result = get_env_value("OPENAI_BASE_URL")
+        assert result == "http://localhost:11434/v1", \
+            f"Expected OPENAI_BASE_URL to be preserved, got: {result!r}"
+
+    def test_noop_when_no_openai_base_url(self, monkeypatch):
+        """No error when OPENAI_BASE_URL is not set."""
+        from hermes_cli.main import _clear_stale_openai_base_url
+
+        _write_provider("openrouter")
+        # Ensure it's not set
+        save_env_value("OPENAI_BASE_URL", "")
+        monkeypatch.delenv("OPENAI_BASE_URL", raising=False)
+
+        # Should not raise
+        _clear_stale_openai_base_url()
+
+    def test_noop_when_provider_empty(self, monkeypatch):
+        """No cleanup when provider is not set in config."""
+        from hermes_cli.main import _clear_stale_openai_base_url
+
+        cfg = load_config()
+        cfg.pop("model", None)
+        save_config(cfg)
+        save_env_value("OPENAI_BASE_URL", "http://localhost:11434/v1")
+
+        _clear_stale_openai_base_url()
+
+        result = get_env_value("OPENAI_BASE_URL")
+        assert result == "http://localhost:11434/v1", \
+            "Should not clear when provider is not configured"