Error 5854 - String parameter too long when merging Word Document caused by replace code trying to populate too much data.

Error 5854 in Document Production

The issue is that the application is trying to populate a replace field (RF) with a value in excess of 255 characters long. Microsoft Word imposes a limit when creating replace field values.

You should be able to see which RF is causing the problem in the document production wizard. The way to avoid this error is to reduce the length of the text that is being inserted.