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solution for older Notes versions, too....try a different PDF printer.
I found Bullzip PDF printer years ago as a PDF alternative. Lately, I was able to find a document that the Excel VBA guys use to automate the printing. I adapted it for Lotus Documents in the UI with older Notes version.
The Bullzip drivers allows you to define an object with settings that suppresses the pop-up. If it is selected as the default printer, the uidoc.print(1) seems to work well. Otherwise, you will have to use later version of Notes to select the print driver (or use some external calls to W32 DLL for printer selections).
If helpful, the following seems to work well for me, if you install the Bullzip PDF printers and use it with Notes:
'...get uidoc...and set sFileName
Dim oPrinterSettings as variant
Dim oPrinterUtil as variant
Set oPrinterSettings = createobject("Bullzip.PdfSettings")
Set oPrinterUtil = createobject("Bullzip.PdfUtil")
solution for older Notes versions, too....try a different PDF printer.
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. . solution for older Notes versions, ... (~John Reniskiik... 17.Nov.11) 
