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nb - same template - different civi version stopped it working?
Would you be able to update to the latest 0.6.0 beta? Lots of changes have been made since the Helmut release.If you can post a sample of the HTML being rendered that would help determining what's going on. Just FYI, the most typical cause of 500 errors on simple documents is a table cell larger than a single page.We'll take a look at the xdebug.txt when we get a chance to see if there's anything of note.
DOMPDF 0.6.0 will return the working HTML document as a string if you call $dompdf->output_html().