fix: filter out 429 rate limit errors from API error telemetry

packages/types/src/telemetry.ts

@@ -276,15 +276,75 @@ export const EXPECTED_API_ERROR_CODES = new Set([
 	429, // Rate limit - expected when hitting API limits
 ])
 
+/**
+ * Patterns in error messages that indicate expected errors (rate limits, etc.)
+ * These are checked when no numeric error code is available.
+ */
+const EXPECTED_ERROR_MESSAGE_PATTERNS = [
+	/^429\b/, // Message starts with "429"
+	/rate limit/i, // Contains "rate limit" (case insensitive)
+]
+
+/**
+ * Interface for SDK errors that have HTTP status information.
+ * OpenAI SDK errors (APIError, AuthenticationError, RateLimitError, etc.)
+ * all extend this interface with a numeric status property.
+ */
+interface SdkErrorWithStatus {
+	status: number
+	code?: number | string
+	message: string
+}
+
+/**
+ * Type guard to check if an error object is an SDK error with status property.
+ * OpenAI SDK errors (APIError and subclasses) have: status, code, message properties.
+ */
+function isSdkErrorWithStatus(error: unknown): error is SdkErrorWithStatus {
+	return (
+		typeof error === "object" &&
+		error !== null &&
+		"status" in error &&
+		typeof (error as SdkErrorWithStatus).status === "number"
+	)
+}
+
+/**
+ * Extracts the HTTP status code from an error object.
+ * Supports SDK errors that have a status property (e.g., OpenAI APIError).
+ * @param error - The error to extract status from
+ * @returns The status code if available, undefined otherwise
+ */
+export function getErrorStatusCode(error: unknown): number | undefined {
+	if (isSdkErrorWithStatus(error)) {
+		return error.status
+	}
+	return undefined
+}
+
 /**
  * Helper to check if an API error should be reported to telemetry.
- * Filters out expected errors like rate limits.
+ * Filters out expected errors like rate limits by checking both error codes and messages.
  * @param errorCode - The HTTP error code (if available)
+ * @param errorMessage - The error message (if available)
  * @returns true if the error should be reported, false if it should be filtered out
  */
-export function shouldReportApiErrorToTelemetry(errorCode?: number): boolean {
-	if (errorCode === undefined) return true
-	return !EXPECTED_API_ERROR_CODES.has(errorCode)
+export function shouldReportApiErrorToTelemetry(errorCode?: number, errorMessage?: string): boolean {
+	// Check numeric error code
+	if (errorCode !== undefined && EXPECTED_API_ERROR_CODES.has(errorCode)) {
+		return false
+	}
+
+	// Check error message for expected patterns (e.g., "429 Rate limit exceeded")
+	if (errorMessage) {
+		for (const pattern of EXPECTED_ERROR_MESSAGE_PATTERNS) {
+			if (pattern.test(errorMessage)) {
+				return false
+			}
+		}
+	}
+
+	return true
 }
 
 /**

src/api/providers/__tests__/openrouter.spec.ts

@@ -321,6 +321,50 @@ describe("OpenRouterHandler", () => {
 			})
 		})
 
+		it("does NOT capture telemetry for SDK exceptions with status 429", async () => {
+			const handler = new OpenRouterHandler(mockOptions)
+			const error = new Error("Rate limit exceeded: free-models-per-day") as any
+			error.status = 429
+			const mockCreate = vitest.fn().mockRejectedValue(error)
+			;(OpenAI as any).prototype.chat = {
+				completions: { create: mockCreate },
+			} as any
+
+			const generator = handler.createMessage("test", [])
+			await expect(generator.next()).rejects.toThrow("Rate limit exceeded")
+
+			// Verify telemetry was NOT captured for rate limit errors
+			expect(mockCaptureException).not.toHaveBeenCalled()
+		})
+
+		it("does NOT capture telemetry for SDK exceptions with 429 in message (fallback)", async () => {
+			const handler = new OpenRouterHandler(mockOptions)
+			const mockCreate = vitest.fn().mockRejectedValue(new Error("429 Rate limit exceeded: free-models-per-day"))
+			;(OpenAI as any).prototype.chat = {
+				completions: { create: mockCreate },
+			} as any
+
+			const generator = handler.createMessage("test", [])
+			await expect(generator.next()).rejects.toThrow("429 Rate limit exceeded")
+
+			// Verify telemetry was NOT captured for rate limit errors (via message parsing)
+			expect(mockCaptureException).not.toHaveBeenCalled()
+		})
+
+		it("does NOT capture telemetry for SDK exceptions containing 'rate limit'", async () => {
+			const handler = new OpenRouterHandler(mockOptions)
+			const mockCreate = vitest.fn().mockRejectedValue(new Error("Request failed due to rate limit"))
+			;(OpenAI as any).prototype.chat = {
+				completions: { create: mockCreate },
+			} as any
+
+			const generator = handler.createMessage("test", [])
+			await expect(generator.next()).rejects.toThrow("rate limit")
+
+			// Verify telemetry was NOT captured for rate limit errors
+			expect(mockCaptureException).not.toHaveBeenCalled()
+		})
+
 		it("does NOT capture telemetry for 429 rate limit errors", async () => {
 			const handler = new OpenRouterHandler(mockOptions)
 			const mockStream = {
@@ -483,6 +527,47 @@ describe("OpenRouterHandler", () => {
 			})
 		})
 
+		it("does NOT capture telemetry for SDK exceptions with status 429", async () => {
+			const handler = new OpenRouterHandler(mockOptions)
+			const error = new Error("Rate limit exceeded: free-models-per-day") as any
+			error.status = 429
+			const mockCreate = vitest.fn().mockRejectedValue(error)
+			;(OpenAI as any).prototype.chat = {
+				completions: { create: mockCreate },
+			} as any
+
+			await expect(handler.completePrompt("test prompt")).rejects.toThrow("Rate limit exceeded")
+
+			// Verify telemetry was NOT captured for rate limit errors
+			expect(mockCaptureException).not.toHaveBeenCalled()
+		})
+
+		it("does NOT capture telemetry for SDK exceptions with 429 in message (fallback)", async () => {
+			const handler = new OpenRouterHandler(mockOptions)
+			const mockCreate = vitest.fn().mockRejectedValue(new Error("429 Rate limit exceeded: free-models-per-day"))
+			;(OpenAI as any).prototype.chat = {
+				completions: { create: mockCreate },
+			} as any
+
+			await expect(handler.completePrompt("test prompt")).rejects.toThrow("429 Rate limit exceeded")
+
+			// Verify telemetry was NOT captured for rate limit errors (via message parsing)
+			expect(mockCaptureException).not.toHaveBeenCalled()
+		})
+
+		it("does NOT capture telemetry for SDK exceptions containing 'rate limit'", async () => {
+			const handler = new OpenRouterHandler(mockOptions)
+			const mockCreate = vitest.fn().mockRejectedValue(new Error("Request failed due to rate limit"))
+			;(OpenAI as any).prototype.chat = {
+				completions: { create: mockCreate },
+			} as any
+
+			await expect(handler.completePrompt("test prompt")).rejects.toThrow("rate limit")
+
+			// Verify telemetry was NOT captured for rate limit errors
+			expect(mockCaptureException).not.toHaveBeenCalled()
+		})
+
 		it("does NOT capture telemetry for 429 rate limit errors", async () => {
 			const handler = new OpenRouterHandler(mockOptions)
 			const mockError = {

src/api/providers/openrouter.ts

@@ -8,6 +8,7 @@ import {
 	OPEN_ROUTER_PROMPT_CACHING_MODELS,
 	DEEP_SEEK_DEFAULT_TEMPERATURE,
 	shouldReportApiErrorToTelemetry,
+	getErrorStatusCode,
 	ApiProviderError,
 } from "@roo-code/types"
 import { TelemetryService } from "@roo-code/telemetry"
@@ -227,15 +228,14 @@ export class OpenRouterHandler extends BaseProvider implements SingleCompletionH
 		try {
 			stream = await this.client.chat.completions.create(completionParams, requestOptions)
 		} catch (error) {
-			TelemetryService.instance.captureException(
-				new ApiProviderError(
-					error instanceof Error ? error.message : String(error),
-					this.providerName,
-					modelId,
-					"createMessage",
-				),
-				{ provider: this.providerName, modelId, operation: "createMessage" },
-			)
+			const errorMessage = error instanceof Error ? error.message : String(error)
+			const errorStatus = getErrorStatusCode(error)
+			if (shouldReportApiErrorToTelemetry(errorStatus, errorMessage)) {
+				TelemetryService.instance.captureException(
+					new ApiProviderError(errorMessage, this.providerName, modelId, "createMessage", errorStatus),
+					{ provider: this.providerName, modelId, operation: "createMessage", errorCode: errorStatus },
+				)
+			}
 			throw handleOpenAIError(error, this.providerName)
 		}
 
@@ -260,7 +260,7 @@ export class OpenRouterHandler extends BaseProvider implements SingleCompletionH
 			if ("error" in chunk) {
 				const error = chunk.error as { message?: string; code?: number }
 				console.error(`OpenRouter API Error: ${error?.code} - ${error?.message}`)
-				if (shouldReportApiErrorToTelemetry(error?.code)) {
+				if (shouldReportApiErrorToTelemetry(error?.code, error?.message)) {
 					TelemetryService.instance.captureException(
 						new ApiProviderError(
 							error?.message ?? "Unknown error",
@@ -466,21 +466,20 @@ export class OpenRouterHandler extends BaseProvider implements SingleCompletionH
 		try {
 			response = await this.client.chat.completions.create(completionParams, requestOptions)
 		} catch (error) {
-			TelemetryService.instance.captureException(
-				new ApiProviderError(
-					error instanceof Error ? error.message : String(error),
-					this.providerName,
-					modelId,
-					"completePrompt",
-				),
-				{ provider: this.providerName, modelId, operation: "completePrompt" },
-			)
+			const errorMessage = error instanceof Error ? error.message : String(error)
+			const errorStatus = getErrorStatusCode(error)
+			if (shouldReportApiErrorToTelemetry(errorStatus, errorMessage)) {
+				TelemetryService.instance.captureException(
+					new ApiProviderError(errorMessage, this.providerName, modelId, "completePrompt", errorStatus),
+					{ provider: this.providerName, modelId, operation: "completePrompt", errorCode: errorStatus },
+				)
+			}
 			throw handleOpenAIError(error, this.providerName)
 		}
 
 		if ("error" in response) {
 			const error = response.error as { message?: string; code?: number }
-			if (shouldReportApiErrorToTelemetry(error?.code)) {
+			if (shouldReportApiErrorToTelemetry(error?.code, error?.message)) {
 				TelemetryService.instance.captureException(
 					new ApiProviderError(
 						error?.message ?? "Unknown error",