perf(test): speed up config tests

src/cli/config-cli.test.ts

@@ -1,16 +1,21 @@
 import { Command } from "commander";
-import fs from "node:fs/promises";
-import os from "node:os";
-import path from "node:path";
 import { afterEach, beforeEach, describe, expect, it, vi } from "vitest";
+import type { ConfigFileSnapshot, OpenClawConfig } from "../config/types.js";
 
 /**
  * Test for issue #6070:
- * `openclaw config set` should use snapshot.parsed (raw user config) instead of
+ * `openclaw config set/unset` must update snapshot.resolved (user config after $include/${ENV},
- * snapshot.config (runtime-merged config with defaults), to avoid overwriting
+ * but before runtime defaults), so runtime defaults don't leak into the written config.
- * the entire config with defaults when validation fails or config is unreadable.
  */
 
+const mockReadConfigFileSnapshot = vi.fn<[], Promise<ConfigFileSnapshot>>();
+const mockWriteConfigFile = vi.fn<[OpenClawConfig], Promise<void>>(async () => {});
+
+vi.mock("../config/config.js", () => ({
+  readConfigFileSnapshot: () => mockReadConfigFileSnapshot(),
+  writeConfigFile: (cfg: OpenClawConfig) => mockWriteConfigFile(cfg),
+}));
+
 const mockLog = vi.fn();
 const mockError = vi.fn();
 const mockExit = vi.fn((code: number) => {
@@ -26,29 +31,22 @@ vi.mock("../runtime.js", () => ({
   },
 }));
 
-async function withTempHome(run: (home: string) => Promise<void>): Promise<void> {
+function buildSnapshot(params: {
-  const home = await fs.mkdtemp(path.join(os.tmpdir(), "openclaw-config-cli-"));
+  resolved: OpenClawConfig;
-  const originalEnv = { ...process.env };
+  config: OpenClawConfig;
-  try {
+}): ConfigFileSnapshot {
-    // Override config path to use temp directory
+  return {
-    process.env.OPENCLAW_CONFIG_PATH = path.join(home, ".openclaw", "openclaw.json");
+    path: "/tmp/openclaw.json",
-    await fs.mkdir(path.join(home, ".openclaw"), { recursive: true });
+    exists: true,
-    await run(home);
+    raw: JSON.stringify(params.resolved),
-  } finally {
+    parsed: params.resolved,
-    process.env = originalEnv;
+    resolved: params.resolved,
-    await fs.rm(home, { recursive: true, force: true });
+    valid: true,
-  }
+    config: params.config,
-}
+    issues: [],
-
+    warnings: [],
-async function readConfigFile(home: string): Promise<Record<string, unknown>> {
+    legacyIssues: [],
-  const configPath = path.join(home, ".openclaw", "openclaw.json");
+  };
-  const content = await fs.readFile(configPath, "utf-8");
-  return JSON.parse(content);
-}
-
-async function writeConfigFile(home: string, config: Record<string, unknown>): Promise<void> {
-  const configPath = path.join(home, ".openclaw", "openclaw.json");
-  await fs.writeFile(configPath, JSON.stringify(config, null, 2));
 }
 
 describe("config cli", () => {
@@ -62,25 +60,27 @@ describe("config cli", () => {
 
   describe("config set - issue #6070", () => {
     it("preserves existing config keys when setting a new value", async () => {
-      await withTempHome(async (home) => {
+      const resolved: OpenClawConfig = {
-        // Set up a config file with multiple existing settings (using valid schema)
-        const initialConfig = {
         agents: {
           list: [{ id: "main" }, { id: "oracle", workspace: "~/oracle-workspace" }],
         },
-          gateway: {
+        gateway: { port: 18789 },
-            port: 18789,
+        tools: { allow: ["group:fs"] },
-          },
+        logging: { level: "debug" },
-          tools: {
-            allow: ["group:fs"],
-          },
-          logging: {
-            level: "debug",
-          },
       };
-        await writeConfigFile(home, initialConfig);
+      const runtimeMerged: OpenClawConfig = {
+        ...resolved,
+        agents: {
+          ...resolved.agents,
+          defaults: {
+            model: "gpt-5.2",
+          } as never,
+        } as never,
+      };
+      mockReadConfigFileSnapshot.mockResolvedValueOnce(
+        buildSnapshot({ resolved, config: runtimeMerged }),
+      );
 
-        // Run config set to add a new value
       const { registerConfigCli } = await import("./config-cli.js");
       const program = new Command();
       program.exitOverride();
@@ -88,80 +88,79 @@ describe("config cli", () => {
 
       await program.parseAsync(["config", "set", "gateway.auth.mode", "token"], { from: "user" });
 
-        // Read the config file and verify ALL original keys are preserved
+      expect(mockWriteConfigFile).toHaveBeenCalledTimes(1);
-        const finalConfig = await readConfigFile(home);
+      const written = mockWriteConfigFile.mock.calls[0]?.[0];
-
+      expect(written.gateway?.auth).toEqual({ mode: "token" });
-        // The new value should be set
+      expect(written.gateway?.port).toBe(18789);
-        expect((finalConfig.gateway as Record<string, unknown>).auth).toEqual({ mode: "token" });
+      expect(written.agents).toEqual(resolved.agents);
-
+      expect(written.tools).toEqual(resolved.tools);
-        // ALL original settings must still be present (this is the key assertion for #6070)
+      expect(written.logging).toEqual(resolved.logging);
-        // The key bug in #6070 was that runtime defaults (like agents.defaults) were being
+      expect(written.agents).not.toHaveProperty("defaults");
-        // written to the file, and paths were being expanded. This test verifies the fix.
-        expect(finalConfig.agents).not.toHaveProperty("defaults"); // No runtime defaults injected
-        expect((finalConfig.agents as Record<string, unknown>).list).toEqual(
-          initialConfig.agents.list,
-        );
-        expect((finalConfig.gateway as Record<string, unknown>).port).toBe(18789);
-        expect(finalConfig.tools).toEqual(initialConfig.tools);
-        expect(finalConfig.logging).toEqual(initialConfig.logging);
-      });
     });
 
     it("does not inject runtime defaults into the written config", async () => {
-      await withTempHome(async (home) => {
+      const resolved: OpenClawConfig = {
-        // Set up a minimal config file
-        const initialConfig = {
         gateway: { port: 18789 },
       };
-        await writeConfigFile(home, initialConfig);
+      const runtimeMerged: OpenClawConfig = {
+        ...resolved,
+        agents: {
+          defaults: {
+            model: "gpt-5.2",
+            contextWindow: 128_000,
+            maxTokens: 16_000,
+          },
+        } as never,
+        messages: { ackReaction: "✅" } as never,
+        sessions: { persistence: { enabled: true } } as never,
+      };
+      mockReadConfigFileSnapshot.mockResolvedValueOnce(
+        buildSnapshot({ resolved, config: runtimeMerged }),
+      );
 
-        // Run config set
       const { registerConfigCli } = await import("./config-cli.js");
       const program = new Command();
       program.exitOverride();
       registerConfigCli(program);
 
-        await program.parseAsync(["config", "set", "gateway.auth.mode", "token"], {
+      await program.parseAsync(["config", "set", "gateway.auth.mode", "token"], { from: "user" });
-          from: "user",
-        });
 
-        // Read the config file
+      expect(mockWriteConfigFile).toHaveBeenCalledTimes(1);
-        const finalConfig = await readConfigFile(home);
+      const written = mockWriteConfigFile.mock.calls[0]?.[0];
-
+      expect(written).not.toHaveProperty("agents.defaults.model");
-        // The config should NOT contain runtime defaults that weren't originally in the file
+      expect(written).not.toHaveProperty("agents.defaults.contextWindow");
-        // These are examples of defaults that get merged in by applyModelDefaults, applyAgentDefaults, etc.
+      expect(written).not.toHaveProperty("agents.defaults.maxTokens");
-        expect(finalConfig).not.toHaveProperty("agents.defaults.model");
+      expect(written).not.toHaveProperty("messages.ackReaction");
-        expect(finalConfig).not.toHaveProperty("agents.defaults.contextWindow");
+      expect(written).not.toHaveProperty("sessions.persistence");
-        expect(finalConfig).not.toHaveProperty("agents.defaults.maxTokens");
+      expect(written.gateway?.port).toBe(18789);
-        expect(finalConfig).not.toHaveProperty("messages.ackReaction");
+      expect(written.gateway?.auth).toEqual({ mode: "token" });
-        expect(finalConfig).not.toHaveProperty("sessions.persistence");
-
-        // Original config should still be present
-        expect((finalConfig.gateway as Record<string, unknown>).port).toBe(18789);
-        // New value should be set
-        expect((finalConfig.gateway as Record<string, unknown>).auth).toEqual({ mode: "token" });
-      });
     });
   });
 
   describe("config unset - issue #6070", () => {
     it("preserves existing config keys when unsetting a value", async () => {
-      await withTempHome(async (home) => {
+      const resolved: OpenClawConfig = {
-        // Set up a config file with multiple existing settings (using valid schema)
-        const initialConfig = {
         agents: { list: [{ id: "main" }] },
         gateway: { port: 18789 },
         tools: {
           profile: "coding",
           alsoAllow: ["agents_list"],
         },
-          logging: {
+        logging: { level: "debug" },
-            level: "debug",
-          },
       };
-        await writeConfigFile(home, initialConfig);
+      const runtimeMerged: OpenClawConfig = {
+        ...resolved,
+        agents: {
+          ...resolved.agents,
+          defaults: {
+            model: "gpt-5.2",
+          },
+        } as never,
+      };
+      mockReadConfigFileSnapshot.mockResolvedValueOnce(
+        buildSnapshot({ resolved, config: runtimeMerged }),
+      );
 
-        // Run config unset to remove a value
       const { registerConfigCli } = await import("./config-cli.js");
       const program = new Command();
       program.exitOverride();
@@ -169,21 +168,14 @@ describe("config cli", () => {
 
       await program.parseAsync(["config", "unset", "tools.alsoAllow"], { from: "user" });
 
-        // Read the config file and verify ALL original keys (except the unset one) are preserved
+      expect(mockWriteConfigFile).toHaveBeenCalledTimes(1);
-        const finalConfig = await readConfigFile(home);
+      const written = mockWriteConfigFile.mock.calls[0]?.[0];
-
+      expect(written.tools).not.toHaveProperty("alsoAllow");
-        // The value should be removed
+      expect(written.agents).not.toHaveProperty("defaults");
-        expect(finalConfig.tools as Record<string, unknown>).not.toHaveProperty("alsoAllow");
+      expect(written.agents?.list).toEqual(resolved.agents?.list);
-
+      expect(written.gateway).toEqual(resolved.gateway);
-        // ALL other original settings must still be present (no runtime defaults injected)
+      expect(written.tools?.profile).toBe("coding");
-        expect(finalConfig.agents).not.toHaveProperty("defaults");
+      expect(written.logging).toEqual(resolved.logging);
-        expect((finalConfig.agents as Record<string, unknown>).list).toEqual(
-          initialConfig.agents.list,
-        );
-        expect(finalConfig.gateway).toEqual(initialConfig.gateway);
-        expect((finalConfig.tools as Record<string, unknown>).profile).toBe("coding");
-        expect(finalConfig.logging).toEqual(initialConfig.logging);
-      });
     });
   });
 });

src/config/backup-rotation.ts

@@ -0,0 +1,26 @@
+export const CONFIG_BACKUP_COUNT = 5;
+
+export async function rotateConfigBackups(
+  configPath: string,
+  ioFs: {
+    unlink: (path: string) => Promise<void>;
+    rename: (from: string, to: string) => Promise<void>;
+  },
+): Promise<void> {
+  if (CONFIG_BACKUP_COUNT <= 1) {
+    return;
+  }
+  const backupBase = `${configPath}.bak`;
+  const maxIndex = CONFIG_BACKUP_COUNT - 1;
+  await ioFs.unlink(`${backupBase}.${maxIndex}`).catch(() => {
+    // best-effort
+  });
+  for (let index = maxIndex - 1; index >= 1; index -= 1) {
+    await ioFs.rename(`${backupBase}.${index}`, `${backupBase}.${index + 1}`).catch(() => {
+      // best-effort
+    });
+  }
+  await ioFs.rename(backupBase, `${backupBase}.1`).catch(() => {
+    // best-effort
+  });
+}

src/config/config.backup-rotation.test.ts

@@ -1,20 +1,35 @@
 import fs from "node:fs/promises";
+import path from "node:path";
 import { describe, expect, it } from "vitest";
 import type { OpenClawConfig } from "./types.js";
+import { rotateConfigBackups } from "./backup-rotation.js";
 import { withTempHome } from "./test-helpers.js";
 
 describe("config backup rotation", () => {
   it("keeps a 5-deep backup ring for config writes", async () => {
     await withTempHome(async () => {
-      const { resolveConfigPath, writeConfigFile } = await import("./config.js");
+      const stateDir = process.env.OPENCLAW_STATE_DIR?.trim();
-      const configPath = resolveConfigPath();
+      if (!stateDir) {
+        throw new Error("Expected OPENCLAW_STATE_DIR to be set by withTempHome");
+      }
+      const configPath = path.join(stateDir, "openclaw.json");
       const buildConfig = (version: number): OpenClawConfig =>
         ({
           agents: { list: [{ id: `v${version}` }] },
         }) as OpenClawConfig;
 
-      for (let version = 0; version <= 6; version += 1) {
+      const writeVersion = async (version: number) => {
-        await writeConfigFile(buildConfig(version));
+        const json = JSON.stringify(buildConfig(version), null, 2).trimEnd().concat("\n");
+        await fs.writeFile(configPath, json, "utf-8");
+      };
+
+      await writeVersion(0);
+      for (let version = 1; version <= 6; version += 1) {
+        await rotateConfigBackups(configPath, fs);
+        await fs.copyFile(configPath, `${configPath}.bak`).catch(() => {
+          // best-effort
+        });
+        await writeVersion(version);
       }
 
       const readName = async (suffix = "") => {

src/config/config.env-vars.test.ts

@@ -1,100 +1,45 @@
 import fs from "node:fs/promises";
 import path from "node:path";
 import { describe, expect, it } from "vitest";
-import { resolveStateDir } from "./paths.js";
+import type { OpenClawConfig } from "./types.js";
+import { loadDotEnv } from "../infra/dotenv.js";
+import { resolveConfigEnvVars } from "./env-substitution.js";
+import { applyConfigEnvVars } from "./env-vars.js";
 import { withEnvOverride, withTempHome } from "./test-helpers.js";
 
 describe("config env vars", () => {
   it("applies env vars from env block when missing", async () => {
-    await withTempHome(async (home) => {
-      const configDir = path.join(home, ".openclaw");
-      await fs.mkdir(configDir, { recursive: true });
-      await fs.writeFile(
-        path.join(configDir, "openclaw.json"),
-        JSON.stringify(
-          {
-            env: { vars: { OPENROUTER_API_KEY: "config-key" } },
-          },
-          null,
-          2,
-        ),
-        "utf-8",
-      );
-
     await withEnvOverride({ OPENROUTER_API_KEY: undefined }, async () => {
-        const { loadConfig } = await import("./config.js");
+      applyConfigEnvVars({ env: { vars: { OPENROUTER_API_KEY: "config-key" } } } as OpenClawConfig);
-        loadConfig();
       expect(process.env.OPENROUTER_API_KEY).toBe("config-key");
     });
   });
-  });
 
   it("does not override existing env vars", async () => {
-    await withTempHome(async (home) => {
-      const configDir = path.join(home, ".openclaw");
-      await fs.mkdir(configDir, { recursive: true });
-      await fs.writeFile(
-        path.join(configDir, "openclaw.json"),
-        JSON.stringify(
-          {
-            env: { vars: { OPENROUTER_API_KEY: "config-key" } },
-          },
-          null,
-          2,
-        ),
-        "utf-8",
-      );
-
     await withEnvOverride({ OPENROUTER_API_KEY: "existing-key" }, async () => {
-        const { loadConfig } = await import("./config.js");
+      applyConfigEnvVars({ env: { vars: { OPENROUTER_API_KEY: "config-key" } } } as OpenClawConfig);
-        loadConfig();
       expect(process.env.OPENROUTER_API_KEY).toBe("existing-key");
     });
   });
-  });
 
   it("applies env vars from env.vars when missing", async () => {
-    await withTempHome(async (home) => {
-      const configDir = path.join(home, ".openclaw");
-      await fs.mkdir(configDir, { recursive: true });
-      await fs.writeFile(
-        path.join(configDir, "openclaw.json"),
-        JSON.stringify(
-          {
-            env: { vars: { GROQ_API_KEY: "gsk-config" } },
-          },
-          null,
-          2,
-        ),
-        "utf-8",
-      );
-
     await withEnvOverride({ GROQ_API_KEY: undefined }, async () => {
-        const { loadConfig } = await import("./config.js");
+      applyConfigEnvVars({ env: { vars: { GROQ_API_KEY: "gsk-config" } } } as OpenClawConfig);
-        loadConfig();
       expect(process.env.GROQ_API_KEY).toBe("gsk-config");
     });
   });
-  });
 
   it("loads ${VAR} substitutions from ~/.openclaw/.env on repeated runtime loads", async () => {
-    await withTempHome(async (home) => {
+    await withTempHome(async (_home) => {
-      await withEnvOverride(
+      await withEnvOverride({ BRAVE_API_KEY: undefined }, async () => {
-        {
+        const stateDir = process.env.OPENCLAW_STATE_DIR?.trim();
-          OPENCLAW_STATE_DIR: path.join(home, ".openclaw"),
+        if (!stateDir) {
-          CLAWDBOT_STATE_DIR: undefined,
+          throw new Error("Expected OPENCLAW_STATE_DIR to be set by withTempHome");
-          OPENCLAW_HOME: undefined,
+        }
-          CLAWDBOT_HOME: undefined,
+        await fs.mkdir(stateDir, { recursive: true });
-          BRAVE_API_KEY: undefined,
+        await fs.writeFile(path.join(stateDir, ".env"), "BRAVE_API_KEY=from-dotenv\n", "utf-8");
-          OPENCLAW_DISABLE_CONFIG_CACHE: "1",
+
-        },
+        const config: OpenClawConfig = {
-        async () => {
-          const configDir = resolveStateDir(process.env, () => home);
-          await fs.mkdir(configDir, { recursive: true });
-          await fs.writeFile(
-            path.join(configDir, "openclaw.json"),
-            JSON.stringify(
-              {
           tools: {
             web: {
               search: {
@@ -102,24 +47,17 @@ describe("config env vars", () => {
               },
             },
           },
-              },
+        };
-              null,
-              2,
-            ),
-            "utf-8",
-          );
-          await fs.writeFile(path.join(configDir, ".env"), "BRAVE_API_KEY=from-dotenv\n", "utf-8");
 
-          const { loadConfig } = await import("./config.js");
+        loadDotEnv({ quiet: true });
-
+        const first = resolveConfigEnvVars(config, process.env) as OpenClawConfig;
-          const first = loadConfig();
         expect(first.tools?.web?.search?.apiKey).toBe("from-dotenv");
 
         delete process.env.BRAVE_API_KEY;
-          const second = loadConfig();
+        loadDotEnv({ quiet: true });
+        const second = resolveConfigEnvVars(config, process.env) as OpenClawConfig;
         expect(second.tools?.web?.search?.apiKey).toBe("from-dotenv");
-        },
+      });
-      );
     });
   });
 });

src/config/env-vars.ts

@@ -29,3 +29,16 @@ export function collectConfigEnvVars(cfg?: OpenClawConfig): Record<string, strin
 
   return entries;
 }
+
+export function applyConfigEnvVars(
+  cfg: OpenClawConfig,
+  env: NodeJS.ProcessEnv = process.env,
+): void {
+  const entries = collectConfigEnvVars(cfg);
+  for (const [key, value] of Object.entries(entries)) {
+    if (env[key]?.trim()) {
+      continue;
+    }
+    env[key] = value;
+  }
+}

src/config/io.ts

@@ -15,6 +15,7 @@ import {
 } from "../infra/shell-env.js";
 import { VERSION } from "../version.js";
 import { DuplicateAgentDirError, findDuplicateAgentDirs } from "./agent-dirs.js";
+import { rotateConfigBackups } from "./backup-rotation.js";
 import {
   applyCompactionDefaults,
   applyContextPruningDefaults,
@@ -31,7 +32,7 @@ import {
   containsEnvVarReference,
   resolveConfigEnvVars,
 } from "./env-substitution.js";
-import { collectConfigEnvVars } from "./env-vars.js";
+import { applyConfigEnvVars } from "./env-vars.js";
 import { ConfigIncludeError, resolveConfigIncludes } from "./includes.js";
 import { findLegacyConfigIssues } from "./legacy.js";
 import { applyMergePatch } from "./merge-patch.js";
@@ -67,7 +68,6 @@ const SHELL_ENV_EXPECTED_KEYS = [
   "OPENCLAW_GATEWAY_PASSWORD",
 ];
 
-const CONFIG_BACKUP_COUNT = 5;
 const CONFIG_AUDIT_LOG_FILENAME = "config-audit.jsonl";
 const loggedInvalidConfigs = new Set<string>();
 
@@ -340,25 +340,6 @@ function restoreEnvRefsFromMap(
   return value;
 }
 
-async function rotateConfigBackups(configPath: string, ioFs: typeof fs.promises): Promise<void> {
-  if (CONFIG_BACKUP_COUNT <= 1) {
-    return;
-  }
-  const backupBase = `${configPath}.bak`;
-  const maxIndex = CONFIG_BACKUP_COUNT - 1;
-  await ioFs.unlink(`${backupBase}.${maxIndex}`).catch(() => {
-    // best-effort
-  });
-  for (let index = maxIndex - 1; index >= 1; index -= 1) {
-    await ioFs.rename(`${backupBase}.${index}`, `${backupBase}.${index + 1}`).catch(() => {
-      // best-effort
-    });
-  }
-  await ioFs.rename(backupBase, `${backupBase}.1`).catch(() => {
-    // best-effort
-  });
-}
-
 function resolveConfigAuditLogPath(env: NodeJS.ProcessEnv, homedir: () => string): string {
   return path.join(resolveStateDir(env, homedir), "logs", CONFIG_AUDIT_LOG_FILENAME);
 }
@@ -460,16 +441,6 @@ function warnIfConfigFromFuture(cfg: OpenClawConfig, logger: Pick<typeof console
   }
 }
 
-function applyConfigEnv(cfg: OpenClawConfig, env: NodeJS.ProcessEnv): void {
-  const entries = collectConfigEnvVars(cfg);
-  for (const [key, value] of Object.entries(entries)) {
-    if (env[key]?.trim()) {
-      continue;
-    }
-    env[key] = value;
-  }
-}
-
 function resolveConfigPathForDeps(deps: Required<ConfigIoDeps>): string {
   if (deps.configPath) {
     return deps.configPath;
@@ -531,7 +502,7 @@ function resolveConfigForRead(
 ): ConfigReadResolution {
   // Apply config.env to process.env BEFORE substitution so ${VAR} can reference config-defined vars.
   if (resolvedIncludes && typeof resolvedIncludes === "object" && "env" in resolvedIncludes) {
-    applyConfigEnv(resolvedIncludes as OpenClawConfig, env);
+    applyConfigEnvVars(resolvedIncludes as OpenClawConfig, env);
   }
 
   return {
@@ -627,7 +598,7 @@ export function createConfigIO(overrides: ConfigIoDeps = {}) {
         throw new DuplicateAgentDirError(duplicates);
       }
 
-      applyConfigEnv(cfg, deps.env);
+      applyConfigEnvVars(cfg, deps.env);
 
       const enabled = shouldEnableShellEnvFallback(deps.env) || cfg.env?.shellEnv?.enabled === true;
       if (enabled && !shouldDeferShellEnvFallback(deps.env)) {