Enterprise Search - E10, not building all records

We have a custom enterprise search BAQ to lookup up the master pack #. I opened a support call because it was spotty with returning results. When I copy the query out of the BAQ and run it in SQL, all records come back fine so it isn’t a problem with joins or data.

Support found an issue with records truncating if over the paging size. I increased the page size from 200000 to 500000 and am still getting the same spotty results. I was told I probably need to limit the results more or keep increasing the page size.

I don’t quite understand the correlation between paging size and truncating the results I’m seeing - we’re indexing ~110k records, 20 columns but no memo fields.

Any one have a better idea on how to get this resolved? I don’t want to keep rebuilding indexes and increasing page sizes until something works - we keep adding records so I don’t know how long it would work. Is there limitations on paging size or what do I have to watch for hits to performance?

Thanks!
Jenn