fix(apns): add diagnostic dump on PEM parse failure (v1.4.47.3)

v1.4.47.2 normalisation didn't recover the production PEM. Emit a structured diagnostic on the existing parse-failure branch (counts + sha256_prefix, no secret bytes) so the operator can compare the in-container shape against the source .p8.

CHANGELOG.md

@@ -1,5 +1,27 @@
 # Changelog
 
+## [1.4.47.3] — 2026-05-22 — APNs PEM diagnostic dump on parse failure
+
+v1.4.47.2 added defensive PEM normalisation but the production env-var was still rejected at `crypto.createPrivateKey` with `error:1E08010C:DECODER routines::unsupported`. The base64 body itself appears to be corrupted somewhere along the Coolify → docker-compose → `process.env` path; normalising the wrapping cannot recover it.
+
+This release adds a one-line diagnostic dump on parse failure so the operator can compare the in-container shape against the source `.p8`:
+
+```
+APNs key did not parse as PEM: <err> [diag raw_len=… norm_len=…
+  escaped_newlines=… real_newlines=… begin_markers=… end_markers=…
+  base64_chars=… other_chars=… sha256_prefix=…]
+```
+
+No secret bytes leave the warning — only character-class counts, structural marker counts, and a 16-char SHA-256 prefix that the operator can compare against `shasum -a 256 AuthKey_*.p8` locally.
+
+### Changed
+
+- `src/lib/notifications/senders/apns.ts:loadApnsConfig` — on the existing `crypto.createPrivateKey` failure branch, emit a structured diagnostic warning. Channel disable behaviour unchanged.
+
+### Risk
+
+Zero. Behaviour-preserving — only the warning message gets richer when the parse already fails.
+
 ## [1.4.47.2] — 2026-05-22 — APNs JWT signing repair (defensive PEM normalisation)
 
 Same-day follow-up to v1.4.47.1. Coolify runtime logs surfaced

package.json

@@ -1,6 +1,6 @@
 {
   "name": "healthlog",
-  "version": "1.4.47.2",
+  "version": "1.4.47.3",
   "description": "Self-hosted personal-health-tracking PWA with Withings integration, AI insights, and doctor-report PDF export.",
   "license": "AGPL-3.0-only",
   "homepage": "https://healthlog.dev",

src/lib/notifications/senders/apns.ts

@@ -21,7 +21,7 @@
  * separately — that's what the library is for, and pinning a single
  * token to the process lifetime would expire ~50 minutes after boot.
  */
-import { createPrivateKey } from "node:crypto";
+import { createHash, createPrivateKey } from "node:crypto";
 import { readFileSync } from "node:fs";
 
 import apn from "@parse/node-apn";
@@ -219,7 +219,29 @@ export function loadApnsConfig(): ApnsConfig | null {
       }
     } catch (err) {
       const message = err instanceof Error ? err.message : "parse_failed";
-      getEvent()?.addWarning(`APNs key did not parse as PEM: ${message}`);
+      // v1.4.47.3 — diagnostic dump on parse failure so operators can
+      // tell whether the env-var arrived in the expected shape.
+      // Logs nothing sensitive: only lengths, character-class counts,
+      // and a SHA-256 prefix of the normalised body. Never the key bytes.
+      const sha256 = createHash("sha256").update(signingKey).digest("hex");
+      const escapedNewlineCount = (inlineKey.match(/\\n/g) || []).length;
+      const realNewlineCount = (signingKey.match(/\n/g) || []).length;
+      const beginCount = (signingKey.match(/-----BEGIN/g) || []).length;
+      const endCount = (signingKey.match(/-----END/g) || []).length;
+      const base64Chars = (signingKey.match(/[A-Za-z0-9+/=]/g) || []).length;
+      const otherChars =
+        signingKey.length -
+        base64Chars -
+        realNewlineCount -
+        (signingKey.match(/[-\s]/g) || []).length;
+      getEvent()?.addWarning(
+        `APNs key did not parse as PEM: ${message} ` +
+          `[diag raw_len=${inlineKey.length} norm_len=${signingKey.length} ` +
+          `escaped_newlines=${escapedNewlineCount} real_newlines=${realNewlineCount} ` +
+          `begin_markers=${beginCount} end_markers=${endCount} ` +
+          `base64_chars=${base64Chars} other_chars=${otherChars} ` +
+          `sha256_prefix=${sha256.slice(0, 16)}]`,
+      );
       cachedConfig = null;
       return null;
     }