I’ve had this issue come and go for the last few months. Not sure what the problem is as sometimes it loads the key from my secrets.yaml file, and other times it doesn’t.
I haven’t noticed the sabnzbd.conf file being created, but then again I haven’t looked for it either.
I’m having the same issue. Each time I start hassio I’m forced to enter the API key even though it’s been specified under the sabnzbd component. The file sabnzbd.conf (which is created if it does not already exist) contains the API Key in json.
The only time it happens now is if it can’t connect to SABnzbd, generally if I’ve put that PC to sleep, but then waking it up, I have to manually enter in the api key as it didn’t connect and thinks it’s wrong. Rebooting HA fixes this until it happens again.
I ran into this but the cause was actually my SABnzbd machine which had rebooted and hadn’t started up SABnzbd. A failed API request will prompt for API Key. It could be a timing issue if SABnzbd is starting up along with Hass.
Launched SABnzbd and restarted Hass and it’s all fine.