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When the email config passed to sendHTMLEmailWithError differs from the manager's persisted config (a test send with edited but unsaved settings), build a fresh manager so stale Username, Password, AuthRequired, SMTPHost, SMTPPort, TLS, StartTLS, or Provider fields cannot leak into the SMTP exchange. The shared production manager is left untouched. Without this, a relay-mode test (port 25, no credentials) on a deployment that previously had authenticated SMTP saved would still attempt AUTH and fail with "AUTH not available" because the manager's old AuthRequired and credentials persisted (Fixes #1440). When the configs match, the existing reuse path is preserved so the production manager's rate limiter keeps working across grouped sends.