fix: respect auth cooldown with auth.order

CHANGELOG.md

@@ -7,6 +7,7 @@
 - Commands: accept /models as an alias for /model.
 - Debugging: add raw model stream logging flags and document gateway watch mode.
 - Agent: add claude-cli/opus-4.5 runner via Claude CLI with resume support (tools disabled).
+- Auth: respect cooldown tracking even with explicit `auth.order` (avoid repeatedly trying known-bad keys). — thanks @steipete
 - CLI: move `clawdbot message` to subcommands (`message send|poll|…`), fold Discord/Slack/Telegram/WhatsApp tools into `message`, and require `--provider` unless only one provider is configured.
 - CLI: improve `logs` output (pretty/plain/JSONL), add gateway unreachable hint, and document logging.
 - WhatsApp: route queued replies to the original sender instead of the bot's own number. (#534) — thanks @mcinteerj

src/agents/auth-profiles.test.ts

@@ -130,6 +130,27 @@ describe("resolveAuthProfileOrder", () => {
     expect(order).toEqual(["anthropic:work", "anthropic:default"]);
   });
 
+  it("pushes cooldown profiles to the end even with configured order", () => {
+    const now = Date.now();
+    const order = resolveAuthProfileOrder({
+      cfg: {
+        auth: {
+          order: { anthropic: ["anthropic:default", "anthropic:work"] },
+          profiles: cfg.auth.profiles,
+        },
+      },
+      store: {
+        ...store,
+        usageStats: {
+          "anthropic:default": { cooldownUntil: now + 60_000 },
+          "anthropic:work": { lastUsed: 1 },
+        },
+      },
+      provider: "anthropic",
+    });
+    expect(order).toEqual(["anthropic:work", "anthropic:default"]);
+  });
+
   it("normalizes z.ai aliases in auth.order", () => {
     const order = resolveAuthProfileOrder({
       cfg: {

src/agents/auth-profiles.ts

@@ -897,14 +897,37 @@ export function resolveAuthProfileOrder(params: {
 
   // If user specified explicit order in config, respect it exactly
   if (configuredOrder && configuredOrder.length > 0) {
-    // Still put preferredProfile first if specified
-    if (preferredProfile && deduped.includes(preferredProfile)) {
-      return [
-        preferredProfile,
-        ...deduped.filter((e) => e !== preferredProfile),
-      ];
+    // ...but still respect cooldown tracking to avoid repeatedly selecting a
+    // known-bad/rate-limited key as the first candidate.
+    const now = Date.now();
+    const available: string[] = [];
+    const inCooldown: Array<{ profileId: string; cooldownUntil: number }> = [];
+
+    for (const profileId of deduped) {
+      const cooldownUntil = store.usageStats?.[profileId]?.cooldownUntil;
+      if (
+        typeof cooldownUntil === "number" &&
+        Number.isFinite(cooldownUntil) &&
+        cooldownUntil > 0 &&
+        now < cooldownUntil
+      ) {
+        inCooldown.push({ profileId, cooldownUntil });
+      } else {
+        available.push(profileId);
+      }
     }
-    return deduped;
+
+    const cooldownSorted = inCooldown
+      .sort((a, b) => a.cooldownUntil - b.cooldownUntil)
+      .map((entry) => entry.profileId);
+
+    const ordered = [...available, ...cooldownSorted];
+
+    // Still put preferredProfile first if specified
+    if (preferredProfile && ordered.includes(preferredProfile)) {
+      return [preferredProfile, ...ordered.filter((e) => e !== preferredProfile)];
+    }
+    return ordered;
   }
 
   // Otherwise, use round-robin: sort by lastUsed (oldest first)