Fix circular dependency crash in worker service

**Problem:**
Worker service crashed on startup with:
  TypeError: Cannot read properties of undefined (reading 'get')
  at new Wd (.../worker-service.cjs:52:131469)

**Root Cause:**
Circular dependency between SettingsDefaultsManager and logger:
  1. SettingsDefaultsManager imports logger
  2. logger imports SettingsDefaultsManager
  3. logger constructor calls SettingsDefaultsManager.get() at init time
  4. When CommonJS resolves the cycle, SettingsDefaultsManager is undefined

**Solution:**
Break the circular dependency by making logger lazy-load its configuration:
  - Change logger.level from initialized in constructor to lazy-loaded
  - Add getLevel() method that loads on first access
  - Update all level checks to use getLevel()

This allows SettingsDefaultsManager to import logger without triggering
the circular dependency, since logger no longer accesses SettingsDefaultsManager
during module initialization.

🤖 Generated with [Claude Code](https://claude.com/claude-code)

Co-Authored-By: Claude Sonnet 4.5 <noreply@anthropic.com>

src/services/worker/http/routes/SessionRoutes.ts

@@ -291,6 +291,7 @@ export class SessionRoutes extends BaseRouteHandler {
         ? stripMemoryTagsFromJson(JSON.stringify(tool_input))
         : '{}';
     } catch (error) {
+      logger.debug('SESSION', 'Failed to serialize tool_input', { sessionDbId }, error);
       cleanedToolInput = '{"error": "Failed to serialize tool_input"}';
     }
 
@@ -299,6 +300,7 @@ export class SessionRoutes extends BaseRouteHandler {
         ? stripMemoryTagsFromJson(JSON.stringify(tool_response))
         : '{}';
     } catch (error) {
+      logger.debug('SESSION', 'Failed to serialize tool_result', { sessionDbId }, error);
       cleanedToolResponse = '{"error": "Failed to serialize tool_response"}';
     }
 

src/services/worker/http/routes/SettingsRoutes.ts

@@ -7,7 +7,7 @@
 
 import express, { Request, Response } from 'express';
 import path from 'path';
-import { readFileSync, writeFileSync, existsSync, renameSync } from 'fs';
+import { readFileSync, writeFileSync, existsSync, renameSync, mkdirSync } from 'fs';
 import { homedir } from 'os';
 import { getPackageRoot } from '../../../../shared/paths.js';
 import { logger } from '../../../../utils/logger.js';
@@ -49,6 +49,7 @@ export class SettingsRoutes extends BaseRouteHandler {
    */
   private handleGetSettings = this.wrapHandler((req: Request, res: Response): void => {
     const settingsPath = path.join(homedir(), '.claude-mem', 'settings.json');
+    this.ensureSettingsFile(settingsPath);
     const settings = SettingsDefaultsManager.loadFromFile(settingsPath);
     res.json(settings);
   });
@@ -117,14 +118,12 @@ export class SettingsRoutes extends BaseRouteHandler {
 
     // Read existing settings
     const settingsPath = path.join(homedir(), '.claude-mem', 'settings.json');
-    let settings: any = { env: {} };
+    this.ensureSettingsFile(settingsPath);
+    let settings: any = {};
 
     if (existsSync(settingsPath)) {
       const settingsData = readFileSync(settingsPath, 'utf-8');
       settings = JSON.parse(settingsData);
-      if (!settings.env) {
-        settings.env = {};
-      }
     }
 
     // Update all settings from request body
@@ -156,7 +155,7 @@ export class SettingsRoutes extends BaseRouteHandler {
 
     for (const key of settingKeys) {
       if (req.body[key] !== undefined) {
-        settings.env[key] = req.body[key];
+        settings[key] = req.body[key];
       }
     }
 
@@ -355,4 +354,22 @@ export class SettingsRoutes extends BaseRouteHandler {
       throw error;
     }
   }
+
+  /**
+   * Ensure settings file exists, creating with defaults if missing
+   */
+  private ensureSettingsFile(settingsPath: string): void {
+    if (!existsSync(settingsPath)) {
+      const defaults = SettingsDefaultsManager.getAllDefaults();
+
+      // Ensure directory exists
+      const dir = path.dirname(settingsPath);
+      if (!existsSync(dir)) {
+        mkdirSync(dir, { recursive: true });
+      }
+
+      writeFileSync(settingsPath, JSON.stringify(defaults, null, 2), 'utf-8');
+      logger.info('SETTINGS', 'Created settings file with defaults', { settingsPath });
+    }
+  }
 }