mailmerge ends prematurely w/o error

I have Word VBA code that basically:

opens a main doc
for each *.txt
opens it as a datasource
mailmerges it
saves it
Adobe ConvertToPDF
closes it
next

Sometimes, the mailmerge ends prematurely without merging all the records. No indication at all of any problem. These are 500-record datasources, the first record being the header info.

What really bothers me is that sometimes it works, sometimes it doesn't. Sometimes it'll do this on smaller datasource files too. It occurs on the mailmerge, not the ConverToPDF, sometimes on the first datasource.

Anyone experienced this? I'll be happy to supply more details if you want.

Word 2000, Windows XP SP2. Also reproduced with Word 2003.
.

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