fix(onboard): ignore stale provider recovery on fresh

src/lib/onboard.ts

@@ -3925,6 +3925,7 @@ async function setupNim(
   gpu: ReturnType<typeof nim.detectGpu>,
   sandboxName: string | null = null,
   agent: AgentDefinition | null = null,
+  recoverProvider = true,
 ): Promise<{
   model: string | null;
   provider: string;
@@ -3972,13 +3973,12 @@ async function setupNim(
     ollamaInstallMenu,
     gpuNimCapable,
   } = providerHostState;
-  const requestedProvider = getNonInteractiveProvider();
+  const requestedProvider = getNonInteractiveProvider() || (recoverProvider ? null : "build");
   const requestedModel = isNonInteractive()
     ? getNonInteractiveModel(requestedProvider || "build")
     : null;
   const agentProviderOptions = getAgentInferenceProviderOptions(agent);
 
-  // Model Router: complexity-based routing via blueprint config.
   const blueprintRouterCfg = loadBlueprintProfile("routed");
   const { options, hermesProviderAvailable } = buildInferenceProviderMenu({
     remoteProviderConfig: REMOTE_PROVIDER_CONFIG,

src/lib/onboard/machine/core-flow-phases.test.ts

@@ -203,6 +203,29 @@ describe("core onboard flow phases", () => {
     expect(Array.isArray(result.result)).toBe(true);
   });
 
+  it("passes fresh context through to provider setup recovery policy", async () => {
+    const setupNim = vi.fn(async () => ({
+      model: "nvidia/test",
+      provider: "nim",
+      endpointUrl: "https://example.test/v1",
+      credentialEnv: "NVIDIA_INFERENCE_API_KEY",
+      hermesAuthMethod: null,
+      hermesToolGateways: [],
+      preferredInferenceApi: "chat",
+      nimContainer: null,
+    }));
+    const [providerPhase] = createPhases({ providerDeps: { setupNim } });
+
+    await providerPhase.run(context({ fresh: true }));
+
+    expect(setupNim).toHaveBeenCalledWith(
+      { platform: "linux" },
+      "my-sandbox",
+      { name: "openclaw" },
+      false,
+    );
+  });
+
   it("uses normalized context Hermes tool gateways for provider inference resume", async () => {
     const setupInference = vi.fn(async () => ({ ok: true as const }));
     const [providerPhase] = createPhases({

src/lib/onboard/machine/core-flow-phases.ts

@@ -57,6 +57,7 @@ export function createCoreOnboardFlowPhases<
     async run(context) {
       const providerInferenceResult = await handleProviderInferenceState({
         resume: context.resume,
+        fresh: context.fresh,
         session: context.session,
         gpu: context.gpu,
         sandboxName: context.sandboxName,

src/lib/onboard/machine/handlers/provider-inference.test.ts

@@ -110,6 +110,7 @@ function baseOptions(
 ): ProviderInferenceStateOptions<Gpu, Agent, Host> {
   return {
     resume: false,
+    fresh: false,
     session,
     gpu: { type: "nvidia" },
     sandboxName: null,
@@ -143,7 +144,7 @@ describe("handleProviderInferenceState", () => {
     const result = await handleProviderInferenceState(baseOptions(deps));
 
     expect(calls.startStep).toHaveBeenNthCalledWith(1, "provider_selection");
-    expect(calls.setupNim).toHaveBeenCalledWith({ type: "nvidia" }, null, null);
+    expect(calls.setupNim).toHaveBeenCalledWith({ type: "nvidia" }, null, null, true);
     expect(calls.complete).toHaveBeenCalledWith(
       "provider_selection",
       expect.objectContaining({ provider: "nvidia-prod" }),
@@ -191,6 +192,18 @@ describe("handleProviderInferenceState", () => {
     ]);
   });
 
+  it("disables recorded provider recovery during fresh provider selection", async () => {
+    const { deps, calls } = createDeps();
+
+    await handleProviderInferenceState({
+      ...baseOptions(deps),
+      fresh: true,
+      sandboxName: "dcode-station",
+    });
+
+    expect(calls.setupNim).toHaveBeenCalledWith({ type: "nvidia" }, "dcode-station", null, false);
+  });
+
   it("clears non-NVIDIA provider credentials when inference setup fails", async () => {
     const setupNim = vi.fn(async () => ({
       ...baseSelection,

src/lib/onboard/machine/handlers/provider-inference.ts

@@ -23,6 +23,7 @@ export interface ProviderSelectionResult {
 
 export interface ProviderInferenceStateOptions<Gpu, Agent, Host> {
   resume: boolean;
+  fresh: boolean;
   session: Session | null;
   gpu: Gpu;
   sandboxName: string | null;
@@ -48,7 +49,12 @@ export interface ProviderInferenceStateOptions<Gpu, Agent, Host> {
   };
   deps: {
     normalizeHermesAuthMethod(value: string | null | undefined): string | null;
-    setupNim(gpu: Gpu, sandboxName: string | null, agent: Agent): Promise<ProviderSelectionResult>;
+    setupNim(
+      gpu: Gpu,
+      sandboxName: string | null,
+      agent: Agent,
+      allowRecordedProviderRecovery?: boolean,
+    ): Promise<ProviderSelectionResult>;
     setupInference(
       sandboxName: string | null,
       model: string,
@@ -167,6 +173,7 @@ function clearStagedCredentialEnv(
 
 export async function handleProviderInferenceState<Gpu, Agent, Host>({
   resume,
+  fresh,
   session,
   gpu,
   sandboxName,
@@ -246,7 +253,7 @@ export async function handleProviderInferenceState<Gpu, Agent, Host>({
       const selection = await withProviderSelectionTrace(
         sandboxName,
         (agent as { name?: string } | null)?.name,
-        () => deps.setupNim(gpu, sandboxName, agent),
+        () => deps.setupNim(gpu, sandboxName, agent, !fresh),
       );
       model = selection.model;
       provider = selection.provider;

test/onboard-resume-provider-recovery.test.ts

@@ -360,3 +360,123 @@ console.log(JSON.stringify({
     expect(payload.model).toBe("qwen2.5:14b");
   });
 });
+
+describe("setupNim provider recovery policy", () => {
+  it("ignores stale recorded providers when fresh setup disables provider recovery", () => {
+    const repoRoot = path.join(import.meta.dirname, "..");
+    const tmpDir = fs.mkdtempSync(path.join(os.tmpdir(), "nemoclaw-onboard-fresh-provider-"));
+    const fakeBin = path.join(tmpDir, "bin");
+    const scriptPath = path.join(tmpDir, "fresh-provider-recovery-check.js");
+    const onboardPath = JSON.stringify(path.join(repoRoot, "dist", "lib", "onboard.js"));
+    const sessionPath = JSON.stringify(
+      path.join(repoRoot, "dist", "lib", "state", "onboard-session.js"),
+    );
+    const registryPath = JSON.stringify(path.join(repoRoot, "dist", "lib", "state", "registry.js"));
+    const runnerPath = JSON.stringify(path.join(repoRoot, "dist", "lib", "runner.js"));
+
+    fs.mkdirSync(fakeBin, { recursive: true });
+    fs.writeFileSync(
+      path.join(fakeBin, "curl"),
+      `#!/usr/bin/env bash
+body='{"choices":[{"message":{"role":"assistant","content":"OK"}}]}'
+status="200"
+outfile=""
+while [ "$#" -gt 0 ]; do
+  case "$1" in
+    -o) outfile="$2"; shift 2 ;;
+    *) shift ;;
+  esac
+done
+printf '%s' "$body" > "$outfile"
+printf '%s' "$status"
+`,
+      { mode: 0o755 },
+    );
+
+    const script = String.raw`
+const fs = require("fs");
+const path = require("path");
+const Module = require("module");
+const runner = require(${runnerPath});
+const registry = require(${registryPath});
+const onboardSession = require(${sessionPath});
+
+runner.runCapture = () => "";
+registry.getSandbox = () => null;
+registry.listSandboxes = () => ({ sandboxes: [], defaultSandbox: null });
+onboardSession.loadSession = () => ({
+  sandboxName: "dcode-station",
+  provider: "ollama-local",
+  model: "llama3.1",
+});
+
+const onboardFile = ${onboardPath};
+const source = fs.readFileSync(onboardFile, "utf-8");
+const injected = source + "\nmodule.exports.__setNonInteractive = (value) => { NON_INTERACTIVE = value; };";
+const onboardModule = new Module(onboardFile, module);
+onboardModule.filename = onboardFile;
+onboardModule.paths = Module._nodeModulePaths(path.dirname(onboardFile));
+onboardModule._compile(injected, onboardFile);
+
+const { setupNim, __setNonInteractive } = onboardModule.exports;
+
+(async () => {
+  for (const key of [
+    "NEMOCLAW_PROVIDER",
+    "NEMOCLAW_PROVIDER_KEY",
+    "OPENAI_API_KEY",
+    "ANTHROPIC_API_KEY",
+    "GEMINI_API_KEY",
+    "COMPATIBLE_API_KEY",
+    "COMPATIBLE_ANTHROPIC_API_KEY",
+  ]) {
+    delete process.env[key];
+  }
+  process.env.NVIDIA_INFERENCE_API_KEY = "nvapi-test";
+  process.env.NEMOCLAW_MODEL = "nvidia/test-model";
+  __setNonInteractive(true);
+  const originalLog = console.log;
+  const originalError = console.error;
+  const lines = [];
+  console.log = (...args) => lines.push(args.join(" "));
+  console.error = (...args) => lines.push(args.join(" "));
+  try {
+    const result = await setupNim(null, "dcode-station", null, false);
+    originalLog(JSON.stringify({ result, lines }));
+  } finally {
+    console.log = originalLog;
+    console.error = originalError;
+  }
+})().catch((error) => {
+  console.error(error);
+  process.exit(1);
+});
+`;
+    fs.writeFileSync(scriptPath, script);
+
+    const result = spawnSync(process.execPath, [scriptPath], {
+      cwd: repoRoot,
+      encoding: "utf-8",
+      env: {
+        ...process.env,
+        HOME: tmpDir,
+        PATH: `${fakeBin}:${process.env.PATH || ""}`,
+        NEMOCLAW_TEST_NO_SLEEP: "1",
+      },
+    });
+
+    if (result.status !== 0) {
+      throw new Error(result.stderr || result.stdout);
+    }
+    const payload = JSON.parse(result.stdout.trim());
+    expect(payload.result.provider).toBe("nvidia-prod");
+    expect(payload.result.model).toBe("nvidia/test-model");
+    expect(payload.result.preferredInferenceApi).toBe("openai-completions");
+    expect(
+      payload.lines.some((line: string) => line.includes("[non-interactive] Provider: build")),
+    ).toBe(true);
+    expect(payload.lines.every((line: string) => !line.includes("recovered from sandbox"))).toBe(
+      true,
+    );
+  });
+});