OK, the issue you're having has nothing to do with mailmerge, but with the macro in your mailmerge main document.

The first executable line in your macro is:
Dialogs(wdDialogFilePrint).Show
Unless you cancel out of that, it prints your mailmerge main document. That explains why you're getting a file with the fieldnames being printed. In any event, you don't need that line, because the rest of the macro sends the actual mailmerge output to the printer.

Finally, given that you're using a macro to drive the process, there's no need for your mailmerge main document to be anything other than a normal document (i.e. one that wouldn't give the SQL prompt when you open it).

__________________
Cheers,
Paul Edstein
[Fmr MS MVP - Word]