fix(setup): merge plist/systemd env vars instead of overwriting

setup.mjs previously wrote the launchd plist and the Linux systemd unit
with writeFileSync(path, NEW_TEMPLATE_STRING), which silently dropped any
user-customised env vars (CLAUDE_HEARTBEAT_INTERVAL, CLAUDE_CACHE_TTL,
etc.) on every re-setup or upgrade. This change introduces
scripts/lib/plist-merge.mjs which preserves keys present only in the
existing file and lets the template's known keys win. Linux variant uses
the same logic against Environment=KEY=VALUE lines.

Tests added in test-features.mjs cover preserve / override / first-install
for both formats.

No cli.js citation needed: this is OCP-internal installer behaviour with
no corresponding cli.js operation.

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>

scripts/lib/plist-merge.mjs

@@ -0,0 +1,80 @@
+// scripts/lib/plist-merge.mjs
+//
+// Preserves user-customised env vars when setup.mjs rewrites the unit file.
+//
+// Rule:
+//   - keys present in NEW template → template value wins (template is source of truth)
+//   - keys ONLY in EXISTING (not in template) → preserved verbatim
+//
+// No new dependencies — regex-based, plist <key>X</key><string>Y</string> shape
+// is stable enough for our hand-written templates in setup.mjs.
+
+const PLIST_KV_RE = /<key>([^<]+)<\/key>\s*<string>([^<]*)<\/string>/g;
+
+export function parsePlistEnv(plistContent) {
+  if (!plistContent) return {};
+  // Restrict to the EnvironmentVariables dict to avoid catching Label, etc.
+  const envBlock = plistContent.match(/<key>EnvironmentVariables<\/key>\s*<dict>([\s\S]*?)<\/dict>/);
+  if (!envBlock) return {};
+  const out = {};
+  let m;
+  PLIST_KV_RE.lastIndex = 0;
+  while ((m = PLIST_KV_RE.exec(envBlock[1])) !== null) {
+    out[m[1]] = m[2];
+  }
+  return out;
+}
+
+export function mergePlistEnv(existing, template) {
+  if (!existing) return template;
+  const existingEnv = parsePlistEnv(existing);
+  const templateEnv = parsePlistEnv(template);
+  const KNOWN = new Set(Object.keys(templateEnv));
+
+  const preserved = {};
+  for (const [k, v] of Object.entries(existingEnv)) {
+    if (!KNOWN.has(k)) preserved[k] = v;
+  }
+  if (Object.keys(preserved).length === 0) return template;
+
+  const lines = Object.entries(preserved)
+    .map(([k, v]) => `    <key>${k}</key>\n    <string>${v}</string>`)
+    .join("\n");
+
+  // Inject before the closing </dict> of EnvironmentVariables
+  return template.replace(
+    /(<key>EnvironmentVariables<\/key>\s*<dict>[\s\S]*?)(\n\s*<\/dict>)/,
+    `$1\n${lines}$2`
+  );
+}
+
+const SYSTEMD_KV_RE = /^Environment=([^=]+)=(.*)$/gm;
+
+export function parseSystemdEnv(serviceContent) {
+  if (!serviceContent) return {};
+  const out = {};
+  let m;
+  SYSTEMD_KV_RE.lastIndex = 0;
+  while ((m = SYSTEMD_KV_RE.exec(serviceContent)) !== null) {
+    out[m[1]] = m[2];
+  }
+  return out;
+}
+
+export function mergeSystemdEnv(existing, template) {
+  if (!existing) return template;
+  const existingEnv = parseSystemdEnv(existing);
+  const templateEnv = parseSystemdEnv(template);
+  const KNOWN = new Set(Object.keys(templateEnv));
+
+  const preservedLines = Object.entries(existingEnv)
+    .filter(([k]) => !KNOWN.has(k))
+    .map(([k, v]) => `Environment=${k}=${v}`);
+  if (preservedLines.length === 0) return template;
+
+  // Inject after the last existing Environment= line in the template
+  return template.replace(
+    /(^Environment=[^\n]+\n)((?!Environment=).*$)/ms,
+    `$1${preservedLines.join("\n")}\n$2`
+  );
+}

setup.mjs

@@ -13,6 +13,7 @@
  *   5. Optionally starts the proxy
  */
 import { readFileSync, writeFileSync, existsSync, mkdirSync, unlinkSync, readdirSync, chmodSync } from "node:fs";
+import { mergePlistEnv, mergeSystemdEnv } from "./scripts/lib/plist-merge.mjs";
 import { execSync } from "node:child_process";
 import { join, dirname } from "node:path";
 import { homedir } from "node:os";
@@ -424,9 +425,15 @@ if (!DRY_RUN) {
 </plist>
 `;
 
-    writeFileSync(plistPath, plistXml);
+    const existingPlist = existsSync(plistPath) ? readFileSync(plistPath, "utf8") : null;
+    const finalPlistXml = mergePlistEnv(existingPlist, plistXml);
+    writeFileSync(plistPath, finalPlistXml);
     chmodSync(plistPath, 0o600);
-    log(`Plist written: ${plistPath} (mode 600)`);
+    if (existingPlist && finalPlistXml !== plistXml) {
+      log(`Plist written: ${plistPath} (mode 600, preserved user env vars)`);
+    } else {
+      log(`Plist written: ${plistPath} (mode 600)`);
+    }
 
     // Bootout first (in case it was already loaded) then bootstrap
     try { execSync(`launchctl bootout gui/$(id -u) "${plistPath}" 2>/dev/null`); } catch { /* ignore */ }
@@ -459,9 +466,15 @@ StandardError=append:${logPath}
 WantedBy=default.target
 `;
 
-    writeFileSync(servicePath, serviceUnit);
+    const existingService = existsSync(servicePath) ? readFileSync(servicePath, "utf8") : null;
+    const finalServiceUnit = mergeSystemdEnv(existingService, serviceUnit);
+    writeFileSync(servicePath, finalServiceUnit);
     chmodSync(servicePath, 0o600);
-    log(`Service file written: ${servicePath} (mode 600)`);
+    if (existingService && finalServiceUnit !== serviceUnit) {
+      log(`Service file written: ${servicePath} (mode 600, preserved user env vars)`);
+    } else {
+      log(`Service file written: ${servicePath} (mode 600)`);
+    }
 
     execSync(`systemctl --user daemon-reload`);
     execSync(`systemctl --user enable ocp-proxy`);

test-features.mjs

@@ -454,6 +454,116 @@ async function runSingleflightTests() {
 
 await runSingleflightTests();
 
+// ── Plist Env Merge Tests ──
+import { mergePlistEnv, mergeSystemdEnv } from "./scripts/lib/plist-merge.mjs";
+
+console.log("\nPlist env merge:");
+
+const SAMPLE_TEMPLATE_PLIST = `<?xml version="1.0" encoding="UTF-8"?>
+<!DOCTYPE plist PUBLIC "-//Apple//DTD PLIST 1.0//EN" "http://www.apple.com/DTDs/PropertyList-1.0.dtd">
+<plist version="1.0">
+<dict>
+  <key>Label</key>
+  <string>dev.ocp.proxy</string>
+  <key>EnvironmentVariables</key>
+  <dict>
+    <key>CLAUDE_PROXY_PORT</key>
+    <string>3478</string>
+    <key>CLAUDE_BIND</key>
+    <string>127.0.0.1</string>
+    <key>CLAUDE_AUTH_MODE</key>
+    <string>multi</string>
+  </dict>
+</dict>
+</plist>`;
+
+const SAMPLE_EXISTING_PLIST = `<?xml version="1.0" encoding="UTF-8"?>
+<!DOCTYPE plist PUBLIC "-//Apple//DTD PLIST 1.0//EN" "http://www.apple.com/DTDs/PropertyList-1.0.dtd">
+<plist version="1.0">
+<dict>
+  <key>Label</key>
+  <string>dev.ocp.proxy</string>
+  <key>EnvironmentVariables</key>
+  <dict>
+    <key>CLAUDE_PROXY_PORT</key>
+    <string>3456</string>
+    <key>CLAUDE_BIND</key>
+    <string>127.0.0.1</string>
+    <key>CLAUDE_AUTH_MODE</key>
+    <string>none</string>
+    <key>CLAUDE_HEARTBEAT_INTERVAL</key>
+    <string>2000</string>
+    <key>CLAUDE_CACHE_TTL</key>
+    <string>600</string>
+  </dict>
+</dict>
+</plist>`;
+
+test("mergePlistEnv preserves unknown user keys", () => {
+  const merged = mergePlistEnv(SAMPLE_EXISTING_PLIST, SAMPLE_TEMPLATE_PLIST);
+  assert.match(merged, /<key>CLAUDE_HEARTBEAT_INTERVAL<\/key>\s*<string>2000<\/string>/);
+  assert.match(merged, /<key>CLAUDE_CACHE_TTL<\/key>\s*<string>600<\/string>/);
+});
+
+test("mergePlistEnv overrides known template keys", () => {
+  const merged = mergePlistEnv(SAMPLE_EXISTING_PLIST, SAMPLE_TEMPLATE_PLIST);
+  assert.match(merged, /<key>CLAUDE_PROXY_PORT<\/key>\s*<string>3478<\/string>/);
+  assert.match(merged, /<key>CLAUDE_AUTH_MODE<\/key>\s*<string>multi<\/string>/);
+});
+
+test("mergePlistEnv first-install returns template unchanged when existing is null", () => {
+  const merged = mergePlistEnv(null, SAMPLE_TEMPLATE_PLIST);
+  assert.equal(merged, SAMPLE_TEMPLATE_PLIST);
+});
+
+test("mergePlistEnv first-install returns template unchanged when existing is empty", () => {
+  const merged = mergePlistEnv("", SAMPLE_TEMPLATE_PLIST);
+  assert.equal(merged, SAMPLE_TEMPLATE_PLIST);
+});
+
+const SAMPLE_TEMPLATE_SYSTEMD = `[Unit]
+Description=OCP — Open Claude Proxy
+After=network.target
+
+[Service]
+ExecStart=/usr/bin/node /home/u/ocp/server.mjs
+Environment=CLAUDE_PROXY_PORT=3478
+Environment=CLAUDE_BIND=127.0.0.1
+Environment=CLAUDE_AUTH_MODE=multi
+Restart=always
+`;
+
+const SAMPLE_EXISTING_SYSTEMD = `[Unit]
+Description=OCP — Open Claude Proxy
+After=network.target
+
+[Service]
+ExecStart=/usr/bin/node /home/u/ocp/server.mjs
+Environment=CLAUDE_PROXY_PORT=3456
+Environment=CLAUDE_BIND=127.0.0.1
+Environment=CLAUDE_AUTH_MODE=none
+Environment=CLAUDE_HEARTBEAT_INTERVAL=2000
+Environment=CLAUDE_CACHE_TTL=600
+Restart=always
+`;
+
+test("mergeSystemdEnv preserves unknown user Environment lines", () => {
+  const merged = mergeSystemdEnv(SAMPLE_EXISTING_SYSTEMD, SAMPLE_TEMPLATE_SYSTEMD);
+  assert.match(merged, /Environment=CLAUDE_HEARTBEAT_INTERVAL=2000/);
+  assert.match(merged, /Environment=CLAUDE_CACHE_TTL=600/);
+});
+
+test("mergeSystemdEnv overrides known template keys", () => {
+  const merged = mergeSystemdEnv(SAMPLE_EXISTING_SYSTEMD, SAMPLE_TEMPLATE_SYSTEMD);
+  assert.match(merged, /Environment=CLAUDE_PROXY_PORT=3478/);
+  assert.match(merged, /Environment=CLAUDE_AUTH_MODE=multi/);
+});
+
+test("mergeSystemdEnv first-install returns template unchanged", () => {
+  assert.equal(mergeSystemdEnv(null, SAMPLE_TEMPLATE_SYSTEMD), SAMPLE_TEMPLATE_SYSTEMD);
+  assert.equal(mergeSystemdEnv("", SAMPLE_TEMPLATE_SYSTEMD), SAMPLE_TEMPLATE_SYSTEMD);
+});
+
 // ── Cleanup ──
 closeDb();