Was there ever a definitive answer to this? I am having a similar problem. If I delete the NZEMAIL.CFG file and then go back into TAS-K and leave all defaults, I can add a signature and all is fine. But if I change the subject line or the body of the email at all, it will NOT generate the PDF file. I am setting it to use all default paths which is:
 
c:\ists\pdfs\
 
default subject line is: "evo~erp email"
default Body: "This has an attachment of an EVO~ERP %DTYPE%.
 
When I edit this at all, no pdf is generated. If I leave it at default as above, it generates the pdf's fine. Any ideas why?
 
Thanks