Hi Lynda,
It's just possible that the reason why the dialog is displayed sometimes and
not others is simply because the data varies. Word does have to work quite
hard to guess what the delimiters might be, even when it's usually as plain
as day to a human being. (One of the problems it has is that Word does not
assume that you are using a particular character encoding for your file - as
the data gets more complicated it may guess wrongly, and as far as I know
there is no simple way to tell Word to assume the same encoding every time).
However, the key factor here seems much more likely to be an automated
update applied around a month ago, as you obviously suspect.
It's dificult to know how to proceed in this situation. I think I would
either contact Microsoft Technical Support (we are just volunteers here),
create an incident (precisely how to do that depends on whether you have an
agreement with them, and of course they have all sorts of rules about
charging v. free incidents), and take it from there. Or, if you are able to
restore to previous versions, take one machine back in time and see if you
can identify which change seems to have introduced the problem. But even
then there is little option but to contact Technical Support to have a
resolution unless you can exclude the specific update that creates the
problem.
If you happen to have a copy of Excel 2007 around, I would try Graham's idea
of opening the .csv in Excel and seeing what happens, because the 2007
version does support far more columns (and I have just verified that you can
open and save .csv files with more than 255 columns in that version.
However, even if you had any intention of doing so, moving to Office 2007
would not currently be a solution to your merge problem, because there is
still no way to get more than 255 columns from Excel 2007 in a merge.
Sorry I couldn't find a way through, but if you do find a solution via
Technical Support it would be appreciated if you could post back.
Peter Jamieson