Sounds like there may be a conflict or error with saving the PDF form.
. From the plugin’s EXPORT tab, are you able to EXPORT a PDF with the correct data merged to the PDF form?
. Have the flatten and email settings worked on your installation in the past, and just stopped for one field map?
Depending on your answers, we may need to take a look at your installation, but first please reply here with the above info and screenshots of;
. The EXPORT tab with the Form and Field Map selected and showing all the settings and at least the first mapped field.
. The Under the Hood tab.
Or, provide login details on this form and we’ll take a look and fix it faster, if possible.
We remain at your service.