Prevent queue loss during app updates

- Increase quit timeout from 900ms to 5000ms to ensure pending saves complete
- Add persistNowSync() called before update install to flush queue to disk
- Remove blockAllPersistence from shutdown save condition — shutdown must
  always persist to prevent data loss across restarts
- Add temp file recovery as last resort when both primary and backup
  session files are corrupted

Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>

src/main/app-controller.ts

@@ -354,6 +354,9 @@ export class AppController {
     if (this.manager.isSessionRunning()) {
       this.manager.stop();
     }
+    // Flush any pending async saves BEFORE the update process starts.
+    // This ensures the queue is fully persisted to disk so it survives the restart.
+    this.manager.persistNowSync();
 
     const cacheAgeMs = Date.now() - this.lastUpdateCheckAt;
     const cached = this.lastUpdateCheck && !this.lastUpdateCheck.error && cacheAgeMs <= 10 * 60 * 1000

src/main/download-manager.ts

@@ -4696,9 +4696,12 @@ export class DownloadManager extends EventEmitter {
     this.pacedStartReservationByItem.clear();
     this.nonResumableActive = 0;
     this.session.summaryText = "";
-    // Persist synchronously on shutdown to guarantee data is written before process exits
+    // Persist synchronously on shutdown to guarantee data is written before process exits.
-    // Skip if a backup was just imported — the restored session on disk must not be overwritten
+    // Only skip if a backup was just imported (skipShutdownPersist) — the restored session
-    if (!this.skipShutdownPersist && !this.blockAllPersistence) {
+    // on disk must not be overwritten.  blockAllPersistence is intentionally NOT checked
+    // here: it guards async/periodic saves during runtime, but shutdown must always persist
+    // to prevent queue loss across restarts/updates.
+    if (!this.skipShutdownPersist) {
       const pkgCount = Object.keys(this.session.packages).length;
       const itemCount = Object.keys(this.session.items).length;
       logger.info(`Shutdown-Save: ${pkgCount} Pakete, ${itemCount} Items`);
@@ -5030,6 +5033,18 @@ export class DownloadManager extends EventEmitter {
     }
   }
 
+  /** Synchronous persist — guarantees state is on disk before returning.
+   *  Used before update installs to prevent queue loss. */
+  public persistNowSync(): void {
+    this.clearPersistTimer();
+    const pkgCount = Object.keys(this.session.packages).length;
+    const itemCount = Object.keys(this.session.items).length;
+    logger.info(`Pre-Update Sync-Save: ${pkgCount} Pakete, ${itemCount} Items`);
+    this.foldRuntimeIntoSettings(nowMs());
+    saveSession(this.storagePaths, this.session);
+    saveSettings(this.storagePaths, this.settings);
+  }
+
   private emitState(force = false): void {
     const now = nowMs();
     const MIN_FORCE_GAP_MS = 120;

src/main/main.ts

@@ -257,7 +257,7 @@ function registerIpcHandlers(): void {
     if (result.started) {
       updateQuitTimer = setTimeout(() => {
         app.quit();
-      }, 900);
+      }, 5000);
     }
     return result;
   });

src/main/storage.ts

@@ -881,7 +881,25 @@ export function loadSession(paths: StoragePaths): SessionState {
     return backup;
   }
 
-  logger.error("Session konnte nicht geladen werden (auch Backup fehlgeschlagen)");
+  // Last resort: try to recover from temp files left by interrupted writes
+  for (const kind of ["sync", "async"] as const) {
+    const tmpPath = sessionTempPath(paths.sessionFile, kind);
+    if (fs.existsSync(tmpPath)) {
+      const tmpSession = readSessionFile(tmpPath);
+      if (tmpSession && Object.keys(tmpSession.packages).length > 0) {
+        logger.warn(`Session aus temporaerer Datei wiederhergestellt: ${tmpPath} (${Object.keys(tmpSession.packages).length} Pakete)`);
+        try {
+          const payload = JSON.stringify({ ...tmpSession, updatedAt: Date.now() });
+          fs.writeFileSync(paths.sessionFile, payload, "utf8");
+        } catch {
+          // ignore restore write failure
+        }
+        return tmpSession;
+      }
+    }
+  }
+
+  logger.error("Session konnte nicht geladen werden (Primary, Backup und Temp-Dateien fehlgeschlagen)");
   return emptySession();
 }