fix(dashboard): support unified config.yaml in web server routes

Add loadConfigSafe() function that handles both unified (config.yaml) and
legacy (config.json) config formats. Uses throwable errors instead of
process.exit() so try/catch blocks work properly in web server routes.

Updated files to use loadConfigSafe():
- overview-routes.ts: Dashboard overview API
- route-helpers.ts: readConfigSafe() helper
- profile-reader.ts: API profile reading
- profile-writer.ts: API profile writing
- variant-config-adapter.ts: CLIProxy variant config

Fixes #206 (Problem 2: config.json not found when user has config.yaml)

src/api/services/profile-reader.ts

@@ -7,7 +7,7 @@
 
 import * as fs from 'fs';
 import * as path from 'path';
-import { getCcsDir, loadConfig } from '../../utils/config-manager';
+import { getCcsDir, loadConfigSafe } from '../../utils/config-manager';
 import { loadOrCreateUnifiedConfig, isUnifiedMode } from '../../config/unified-config-loader';
 import type { ApiProfileInfo, CliproxyVariantInfo, ApiListResult } from './profile-types';
 
@@ -20,7 +20,7 @@ export function apiProfileExists(name: string): boolean {
       const config = loadOrCreateUnifiedConfig();
       return name in config.profiles;
     }
-    const config = loadConfig();
+    const config = loadConfigSafe();
     return name in config.profiles;
   } catch {
     return false;
@@ -79,7 +79,7 @@ export function listApiProfiles(): ApiListResult {
       });
     }
   } else {
-    const config = loadConfig();
+    const config = loadConfigSafe();
     for (const [name, settingsPath] of Object.entries(config.profiles)) {
       // Skip 'default' profile - it's the user's native Claude settings
       if (name === 'default' && (settingsPath as string).includes('.claude/settings.json')) {
@@ -116,7 +116,7 @@ export function getApiProfileNames(): string[] {
     const config = loadOrCreateUnifiedConfig();
     return Object.keys(config.profiles);
   }
-  const config = loadConfig();
+  const config = loadConfigSafe();
   return Object.keys(config.profiles);
 }
 

src/api/services/profile-writer.ts

@@ -5,7 +5,7 @@
 import * as fs from 'fs';
 import * as os from 'os';
 import * as path from 'path';
-import { getCcsDir, getConfigPath, loadConfig } from '../../utils/config-manager';
+import { getCcsDir, getConfigPath, loadConfigSafe } from '../../utils/config-manager';
 import { expandPath } from '../../utils/helpers';
 import {
   loadOrCreateUnifiedConfig,
@@ -166,7 +166,7 @@ function removeApiProfileUnified(name: string): void {
 
 /** Remove API profile from legacy config */
 function removeApiProfileLegacy(name: string): void {
-  const config = loadConfig();
+  const config = loadConfigSafe();
   delete config.profiles[name];
 
   const configPath = getConfigPath();

src/cliproxy/services/variant-config-adapter.ts

@@ -5,7 +5,7 @@
  */
 
 import * as fs from 'fs';
-import { getConfigPath, loadConfig } from '../../utils/config-manager';
+import { getConfigPath, loadConfigSafe } from '../../utils/config-manager';
 import { CLIProxyProvider } from '../types';
 import {
   loadOrCreateUnifiedConfig,
@@ -38,7 +38,7 @@ export function variantExistsInConfig(name: string): boolean {
       const config = loadOrCreateUnifiedConfig();
       return !!(config.cliproxy?.variants && name in config.cliproxy.variants);
     }
-    const config = loadConfig();
+    const config = loadConfigSafe();
     return !!(config.cliproxy && name in config.cliproxy);
   } catch {
     return false;
@@ -94,7 +94,7 @@ export function listVariantsFromConfig(): Record<string, VariantConfig> {
       return result;
     }
 
-    const config = loadConfig();
+    const config = loadConfigSafe();
     const variants = config.cliproxy || {};
     const result: Record<string, VariantConfig> = {};
     for (const name of Object.keys(variants)) {

src/types/index.ts

@@ -12,6 +12,7 @@ export type {
   EnvValue,
   ProfileMetadata,
   ProfilesRegistry,
+  CLIProxyVariantsConfig,
 } from './config';
 export { isConfig, isSettings } from './config';
 

src/utils/config-manager.ts

@@ -1,7 +1,7 @@
 import * as fs from 'fs';
 import * as path from 'path';
 import * as os from 'os';
-import { Config, isConfig, Settings, isSettings } from '../types';
+import { Config, isConfig, Settings, isSettings, CLIProxyVariantsConfig } from '../types';
 import { expandPath, error } from './helpers';
 import { info } from './ui';
 import { isUnifiedMode, loadOrCreateUnifiedConfig } from '../config/unified-config-loader';
@@ -82,6 +82,63 @@ export function readConfig(): Config {
   return loadConfig();
 }
 
+/**
+ * Load config safely with unified mode support.
+ * Returns Config with profiles from unified config.yaml or legacy config.json.
+ * Throws on error (catchable) instead of process.exit.
+ * Use this in web server routes where try/catch is needed.
+ */
+export function loadConfigSafe(): Config {
+  // Unified mode: extract profiles from config.yaml
+  if (isUnifiedMode()) {
+    const unifiedConfig = loadOrCreateUnifiedConfig();
+
+    // Convert unified profiles to legacy format for compatibility
+    const profiles: Record<string, string> = {};
+    for (const [name, profile] of Object.entries(unifiedConfig.profiles)) {
+      if (profile.settings) {
+        profiles[name] = profile.settings;
+      }
+    }
+
+    // Convert unified cliproxy variants to legacy format
+    let cliproxy: CLIProxyVariantsConfig | undefined;
+    if (unifiedConfig.cliproxy?.variants) {
+      cliproxy = {};
+      for (const [name, variant] of Object.entries(unifiedConfig.cliproxy.variants)) {
+        cliproxy[name] = {
+          // Cast provider - unified has more providers than legacy type
+          provider: variant.provider as 'gemini' | 'codex' | 'agy' | 'qwen',
+          settings: variant.settings || '',
+          account: variant.account,
+          port: variant.port,
+        };
+      }
+    }
+
+    return {
+      profiles,
+      cliproxy,
+    };
+  }
+
+  // Legacy mode: read config.json
+  const configPath = getConfigPath();
+
+  if (!fs.existsSync(configPath)) {
+    throw new Error(`Config not found: ${configPath}`);
+  }
+
+  const raw = fs.readFileSync(configPath, 'utf8');
+  const parsed: unknown = JSON.parse(raw);
+
+  if (!isConfig(parsed)) {
+    throw new Error(`Invalid config format: ${configPath}`);
+  }
+
+  return parsed;
+}
+
 /**
  * Get settings path for profile.
  * In unified mode (config.yaml exists), reads from config.yaml first,

src/web-server/overview-routes.ts

@@ -5,7 +5,7 @@
  */
 
 import { Router, Request, Response } from 'express';
-import { loadConfig } from '../utils/config-manager';
+import { loadConfigSafe } from '../utils/config-manager';
 import { runHealthChecks } from './health-service';
 import { getAllAuthStatus, initializeAccounts } from '../cliproxy/auth-handler';
 import { getVersion } from '../utils/version';
@@ -18,7 +18,7 @@ export const overviewRoutes = Router();
  */
 overviewRoutes.get('/', async (_req: Request, res: Response) => {
   try {
-    const config = loadConfig();
+    const config = loadConfigSafe();
 
     const profileCount = Object.keys(config.profiles).length;
     const cliproxyVariantCount = Object.keys(config.cliproxy || {}).length;

src/web-server/routes/route-helpers.ts

@@ -4,7 +4,7 @@
 
 import * as fs from 'fs';
 import * as path from 'path';
-import { getCcsDir, getConfigPath, loadConfig, loadSettings } from '../../utils/config-manager';
+import { getCcsDir, getConfigPath, loadConfigSafe, loadSettings } from '../../utils/config-manager';
 import { expandPath } from '../../utils/helpers';
 import type { Config, Settings } from '../../types/config';
 
@@ -17,11 +17,12 @@ export interface ModelMapping {
 }
 
 /**
- * Read config safely with fallback
+ * Read config safely with fallback.
+ * Uses loadConfigSafe which supports both unified (config.yaml) and legacy (config.json).
  */
 export function readConfigSafe(): Config {
   try {
-    return loadConfig();
+    return loadConfigSafe();
   } catch {
     return { profiles: {} };
   }