## Why
Customer `k.sand@ksand.dk` reported never receiving wash certificates for completed bookings. Two methods contained silent early-return guards so the actual reason was unobservable from container logs:
- `order_bookings_o::sendWashCertificateToCustomer()` — 5 silent returns
- `email::sendWashCertificateEmailToCustomer()` — 1 silent return
The most likely root cause: `email_notifications_enabled` defaults to `0` in the schema and `users.add()` does not set it on insert, so newly imported customers have notifications off until toggled. `wantsEmailNotifications()` then returns false and the email silently skips.
## What changed
### Original commit (`0ead5de5`)
- `objects/order_bookings_o.php` — all 5 silent early-returns now log via new `logWashCertificateSkip()` helper (Redis stream `module=email / action=WASH_CERT_SKIP` + `error_log('[wash-cert-skip] …')`).
- `classes/email.php` — silent `hasTransaction()` return in `sendWashCertificateEmailToCustomer()` now logs too.
- `objects/bookings_o.php` — emits `WASH_CERT_SKIP` (legacy_no_wash_certificate_email) when `washCertificateEmail` is empty; no behavioural change.
- **New** `routes/washCertificateDebugRoute.php` — `GET /debug/wash-certificates/diagnose?customer_number=&from=&to=` (404 in prod via $DEBUG; superuser-auth otherwise) replays the decision tree and reports `blocking_reason` per booking.
### Follow-up commit (`46a59e4e`) — silent-failure sweep
**PART A — silent returns / silent errors (10 fixes):**
- `email::sendEmailMailerSend()` — blacklisted-recipient skip now logs with context.
- `email::sendNewCustomerRegistrationNotifications()` — empty-email skip + per-recipient try/catch with error_log (was unprotected; a single MailerSend error broke the loop).
- `bookings_new_o::generateWashCertificate()` — wrapped `sendWashCertificateEmail()` in try/catch with error_log and re-throw (same pattern as the k.sand fix).
- `users_o::getCustomerName()` — replaced catch-and-swallow with structured error_log.
- `users_o::getCustomerEcocomicData()` — same.
- `bookingsRoute.php` — added booking-id context to 4 × `$response->error('Booking not found', 404)` calls.
**PART B — cron paths (10 files):** Added error_log breadcrumb + try/catch to `CheckUnfulfilledBookings`, `ClearAllUsersEconomicCustomerDetails`, `ClearAllUsersEconomicCustomerDiscounts`, `RunXLVaskModuleCron`, `SyncBookings`, `SyncEconomicInvoiceStatus`, `SyncLogs`, `BackfillEconomicV2History`, `EnsureXLVaskAutomationSchema`, and 3 functions in `Cron.php`. Each uses a distinct `[cron-…]` prefix for grep-ability.
**PART C — real bugs (2 fixed):**
1. `email::sendEmailMailerSend()` attachment `array_map` — the previous exception message emitted a binary blob because `$attachment[0]` was already overwritten by `file_get_contents()`. Now captures $path first.
2. `bookings_new_o::generateWashCertificate()` — booking persisted as `completed` before email was sent, with no try/catch. Fixed (see PART A).
## How to verify
1. Deploy to staging.
2. Hit `/debug/wash-certificates/diagnose?customer_number=<k.sand's customer_number>` as a superuser — the response lists every booking's `blocking_reason`.
3. Tail container logs for `[wash-cert-skip]`, `[email-skip]`, `[cron-…]`, and Redis stream `module=email` action `WASH_CERT_SKIP` to see real-world skips going forward.
## Follow-ups (out of scope)
- Schema migration to default `email_notifications_enabled` to `1` and backfill non-empty-email customers.
- Move `error_log` to a proper PSR-3 logger.
## Risk
- Logging only + new debug endpoint (404-gated in prod). No behavioural change for any path that previously sent mail successfully. `php -l` could not be run in the original sandbox; please verify on your CI box before deploying.
🤖 Generated with [OpenClaw](https://openclaw.ai)
Jeppe B