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Thanks for the input, agree Windows may not be the problem, but that is one bit of software that is always updating. I also agree with your comment about Google search in fact that was how I found this site. The frustration is that it worked fine for a number of years.

Regret I don't have an answer, but I have the same problem with my Brother MFC-J6530DW. Same symptoms for years worked perfectly, now rejects envelopes with message paper size sent by PC is A4. Seems to suggest a Windows update or something has caused problem. I hope like you that some expert...