Text Line Outside Extent and reuse module

I am trying to reuse a previous layout by using a module.  When I pick 10 components, I can place the reuse module on the new design without issue.  When I try to fully populate (over 500 components), I am consistently getting a "Text Line Outside Extent" issue and the 3-4 hours of work in associating components just simply disappears.  This has happened 3 times in a row.    Is there a limit on how many components a module can associate ?  Is there a preexisting location that I need to set before associating components ?   Is there something else that I am missing ?