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I have informed our host to adjust the SUHOSIN settings. And now they have given me the phpinfo and asked me which particular thing we want to set.
The Module is the WF-downloads and Permission Settings. There are now 7 groups to access files esp publications. The groups/users are set to access different volumes depending on their subscription. So there will be more groups added, at least once a year. As for the files to be accessed, well we have now 22 volumes at 4 issues each and 10-20 articles per issue. Added to these are the other files for announcement and the like. We did not have problems before but we changed hosts and so encountered this time only.
May I ask then what particular aspect of SUHOSIN setting? Now the suhosin.post.max_vars is set at 200 for both local and master value.