Thanks for the reply, Barry.
The problem was, my manually placed zones did not substract the construction area (walls, columns) at all, or did not do that correctly.
We did resolve the situation (at least enough to get the area we needed). We had to change all walls to Reduce zone area only.
We had some walls set to Zone boundaries, and some to Reduce zone volume. The manually placed zone ignored the boundaries walls, but the Reduce zone volume walls messed up the calculations totally, with no apparent pattern to it.
I am using the Zone_Stamp_02_11e.gsm, since it gives me lots of display options without having to mess with GDL, as I have not learnt it yet.
I do know about the manual/automatic zones and I use this option as well as zone parameter changes regularely. I think the zone update should be automatic. In the AC9 I think I had a zone tool that did that, but it's long lost due to a computer crash and then upgrade.
ArchiCad 22, Sweden
Windows 10 Pro 64-bit
HP ZBook 15u / Intel Core i7 8:e gen. 8550U / 1.8 GHz (4 GHz) / 8 MB Cache
AMD Radeon Pro WX 3100 / Intel HD Graphics 620, 2 GB