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after Magento upgrade from v1.9.1.0 to v1.9.2.0 mails stopped sending. In system.log I see an error HRADERS ALREDY SENT. However, this message appear when I press Add to cart button, but users' checkout process goes smoothly. Moreover, I see successful orders in the dashboard where it is said that customer is notified and status order - pending. Thus, I am not sure whether this issue causes problem with email.

In addition, I have a list of files in system.log that are loaded and probably have white space or BOM and I checked them but found nothing. The list contains 334 files, so it is possible that I miss something. Is there a way to find a file that causes Headers error ?

Also, I checked if I can send email just using mail() from "simple" php - it works.

How to start solving problem with emails. I read that I should select crone.php in cPanel, and I did it. How to know whether emails are not being formed or could not be sent?

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First thing you should check is exception.log to see if there is anything that can help there.

In the Magento 1.9.2 upgrade they have added a mail queue system for some of the emails that get sent. The account success email is sent immediately:

$mailer->setSender(Mage::getStoreConfig($sender, $storeId));
$mailer->setStoreId($storeId);
$mailer->setTemplateId(Mage::getStoreConfig($template, $storeId));
$mailer->setTemplateParams($templateParams);
$mailer->send();

However emails such as the order invoice order is added to the mail queue and is sent on cron:

$emailQueue = Mage::getModel('core/email_queue');
$emailQueue->setEntityId($this->getId())
            ->setEntityType(self::ENTITY)
            ->setEventType(self::EMAIL_EVENT_NAME_NEW_ORDER)
            ->setIsForceCheck(!$forceMode);
$mailer->setQueue($emailQueue)->send();

You should should have your cron setup to run around every 5 minutes. See magento cron your should also look at installing AOE_Scheduler to help manage your cron tasks

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  • exception.log is not created. However, I have just found that emails were created in database. By the way, cron is configured. I will dig towards the cron.
    – user2027175
    Jul 31, 2015 at 14:12
  • Well, I found that I should add a string to cron.php $isShellDisabled = true;. Now my cron.php is called from cPanel.
    – user2027175
    Aug 2, 2015 at 6:57
  • Did this get your emails working?
    – rob3000
    Aug 3, 2015 at 0:51
  • Yes, I did and now mails are sent. However, it still needs tuning, because my cPanel sent me a notification once with an error: Fatal error: Call to a member function load() on a non-object in app/code/core/Mage/ProductAlert/Model/Observer.php on line 135. But, I will observe it.
    – user2027175
    Aug 3, 2015 at 18:46

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