fix: run RecoveryManager before early-exit commands and improve config handling

Fixes #214 - Fresh install fails with 'Config not found' when running
ccs config before RecoveryManager runs.

Changes:
- Move RecoveryManager.recoverAll() before all early-exit commands in ccs.ts
- Fix loadConfigSafe() to return empty config instead of throwing in legacy mode
- Add getActiveConfigPath() for mode-aware config path resolution
- Rename cliproxy getConfigPath() to getCliproxyConfigPath() to avoid confusion
- Update help-command.ts to show correct config path based on mode

This ensures all commands benefit from auto-recovery on fresh installs,
and gracefully handles missing config files in all code paths.

src/ccs.ts

@@ -291,6 +291,18 @@ async function main(): Promise<void> {
     await autoMigrate();
   }
 
+  // Auto-recovery for missing configuration (BEFORE any early-exit commands)
+  // This ensures ALL commands benefit from auto-recovery, not just profile-switching flow
+  // Recovery is safe to run early - it only creates missing files with safe defaults
+  const RecoveryManagerModule = await import('./management/recovery-manager');
+  const RecoveryManager = RecoveryManagerModule.default;
+  const recovery = new RecoveryManager();
+  const recovered = recovery.recoverAll();
+
+  if (recovered) {
+    recovery.showRecoveryHints();
+  }
+
   // Special case: version command (check BEFORE profile detection)
   if (firstArg === 'version' || firstArg === '--version' || firstArg === '-v') {
     handleVersionCommand();
@@ -455,16 +467,6 @@ async function main(): Promise<void> {
     return;
   }
 
-  // Auto-recovery for missing configuration
-  const RecoveryManagerModule = await import('./management/recovery-manager');
-  const RecoveryManager = RecoveryManagerModule.default;
-  const recovery = new RecoveryManager();
-  const recovered = recovery.recoverAll();
-
-  if (recovered) {
-    recovery.showRecoveryHints();
-  }
-
   // First-time install: offer setup wizard for interactive users
   // Check independently of recovery status (user may have empty config.yaml)
   // Skip if headless, CI, or non-TTY environment

src/cliproxy/config-generator.ts

@@ -129,9 +129,10 @@ export function getConfigPathForPort(port: number): string {
 }
 
 /**
- * Get config file path (default port)
+ * Get CLIProxy config file path (default port)
+ * Named distinctly from config-manager's getConfigPath to avoid confusion.
  */
-export function getConfigPath(): string {
+export function getCliproxyConfigPath(): string {
   return getConfigPathForPort(CLIPROXY_DEFAULT_PORT);
 }
 
@@ -377,7 +378,7 @@ export function regenerateConfig(port: number = CLIPROXY_DEFAULT_PORT): string {
  * @returns true if config should be regenerated
  */
 export function configNeedsRegeneration(): boolean {
-  const configPath = getConfigPath();
+  const configPath = getCliproxyConfigPath();
   if (!fs.existsSync(configPath)) {
     return false; // Will be created on first use
   }

src/cliproxy/index.ts

@@ -65,7 +65,7 @@ export {
   getCliproxyDir,
   getProviderAuthDir,
   getAuthDir,
-  getConfigPath,
+  getCliproxyConfigPath,
   getBinDir,
   configExists,
   deleteConfig,

src/cliproxy/openai-compat-manager.ts

@@ -7,7 +7,7 @@
 
 import * as fs from 'fs';
 import * as yaml from 'js-yaml';
-import { getConfigPath } from './config-generator';
+import { getCliproxyConfigPath } from './config-generator';
 
 /** Model alias configuration */
 export interface OpenAICompatModel {
@@ -48,7 +48,7 @@ interface ConfigYaml {
  * Load current config.yaml
  */
 function loadConfig(): ConfigYaml {
-  const configPath = getConfigPath();
+  const configPath = getCliproxyConfigPath();
   if (!fs.existsSync(configPath)) {
     return {};
   }
@@ -65,7 +65,7 @@ function loadConfig(): ConfigYaml {
  * Save config.yaml with proper formatting
  */
 function saveConfig(config: ConfigYaml): void {
-  const configPath = getConfigPath();
+  const configPath = getCliproxyConfigPath();
   const content = yaml.dump(config, {
     lineWidth: -1, // Disable line wrapping
     quotingType: '"',

src/commands/help-command.ts

@@ -1,6 +1,7 @@
 import * as fs from 'fs';
 import * as path from 'path';
 import { initUI, box, color, dim, sectionHeader, subheader } from '../utils/ui';
+import { isUnifiedMode } from '../config/unified-config-loader';
 
 // Get version from package.json (same as version-command.ts)
 const VERSION = JSON.parse(
@@ -234,7 +235,7 @@ Run ${color('ccs config', 'command')} for web dashboard`.trim();
 
   // Configuration
   printConfigSection('Configuration', [
-    ['Config File:', '~/.ccs/config.json'],
+    ['Config File:', isUnifiedMode() ? '~/.ccs/config.yaml' : '~/.ccs/config.json'],
     ['Profiles:', '~/.ccs/profiles.json'],
     ['Instances:', '~/.ccs/instances/'],
     ['Settings:', '~/.ccs/*.settings.json'],

src/management/checks/cliproxy-check.ts

@@ -8,7 +8,7 @@ import {
   isCLIProxyInstalled,
   getCLIProxyPath,
   getAllAuthStatus,
-  getConfigPath,
+  getCliproxyConfigPath,
   getInstalledCliproxyVersion,
   CLIPROXY_DEFAULT_PORT,
   configNeedsRegeneration,
@@ -60,7 +60,7 @@ export class CLIProxyConfigChecker implements IHealthChecker {
 
   run(results: HealthCheck): void {
     const spinner = ora('Checking CLIProxy config').start();
-    const configPath = getConfigPath();
+    const configPath = getCliproxyConfigPath();
 
     if (fs.existsSync(configPath)) {
       // Check if config needs regeneration (version mismatch or missing features)

src/utils/config-manager.ts

@@ -27,12 +27,26 @@ export function getCcsDir(): string {
 }
 
 /**
- * Get config file path
+ * Get config file path (legacy JSON path)
+ * @deprecated Use getActiveConfigPath() for mode-aware config path
  */
 export function getConfigPath(): string {
   return process.env.CCS_CONFIG || path.join(getCcsHome(), '.ccs', 'config.json');
 }
 
+/**
+ * Get the active config file path based on current mode.
+ * Returns config.yaml in unified mode, config.json in legacy mode.
+ * @returns Path to the active config file
+ */
+export function getActiveConfigPath(): string {
+  const ccsDir = getCcsDir();
+  if (isUnifiedMode()) {
+    return path.join(ccsDir, 'config.yaml');
+  }
+  return path.join(ccsDir, 'config.json');
+}
+
 /**
  * Load and validate config.json
  */
@@ -126,7 +140,8 @@ export function loadConfigSafe(): Config {
   const configPath = getConfigPath();
 
   if (!fs.existsSync(configPath)) {
-    throw new Error(`Config not found: ${configPath}`);
+    // Return empty config for graceful degradation (matches unified mode behavior)
+    return { profiles: {} };
   }
 
   const raw = fs.readFileSync(configPath, 'utf8');

src/web-server/health/cliproxy-checks.ts

@@ -9,7 +9,7 @@ import {
   isCLIProxyInstalled,
   getInstalledCliproxyVersion,
   getCLIProxyPath,
-  getConfigPath as getCliproxyConfigPath,
+  getCliproxyConfigPath,
   getAllAuthStatus,
   CLIPROXY_DEFAULT_PORT,
 } from '../../cliproxy';

src/web-server/routes/cliproxy-stats-routes.ts

@@ -14,7 +14,7 @@ import {
 } from '../../cliproxy/stats-fetcher';
 import {
   getCliproxyWritablePath,
-  getConfigPath,
+  getCliproxyConfigPath,
   getAuthDir,
 } from '../../cliproxy/config-generator';
 import { getProxyStatus as getProxyProcessStatus, stopProxy } from '../../cliproxy/session-tracker';
@@ -272,7 +272,7 @@ router.get('/error-logs/:name', async (req: Request, res: Response): Promise<voi
  */
 router.get('/config.yaml', async (_req: Request, res: Response): Promise<void> => {
   try {
-    const configPath = getConfigPath();
+    const configPath = getCliproxyConfigPath();
     if (!fs.existsSync(configPath)) {
       res.status(404).json({ error: 'Config file not found' });
       return;
@@ -299,7 +299,7 @@ router.put('/config.yaml', async (req: Request, res: Response): Promise<void> =>
       return;
     }
 
-    const configPath = getConfigPath();
+    const configPath = getCliproxyConfigPath();
 
     // Ensure parent directory exists
     const configDir = path.dirname(configPath);