Hello Brian,
1. It is possible that the queue size is larger than the count of documents, for a): Laserfiche full text search engine also index metadata, such as entry name, which also is calculated in queue size. You may also notice that the queue size will go up and down, it is because that LFS expands the document index request to metadata index requests and queue size is increased during index.
b). If you modify a document (which will trigger an index), queue size will be increased too.
2. In your case, from the info in your support case, you have ~25GB text documents and ~400GB electronic documents. Thus, it is possible that the lfqueueN.idx folders are consuming 500GB, since you have that size of text and electronic documents. You may need to reserve 700GB for the catalog.
For other users who don't have many electronic documents, you need to reserve: 4 * size of text documents, or 2.5 * size of text documents + 3 * size of lflink.idx in 9.2.0, for whole search folder(including lfqueueN.idx folders and idx files). E.g. if you have 25GB text documents and no electronic document, you need to reserve 4 * 25GB = 100 GB disk space.
3. It is consuming the disk space during index. After indexing finished, the disk space will be released. If it is still consuming disk space, you can restart Laserfiche full text search engine to free it.
Since electronic documents have large size, you can extract text pages from Client, this may save the disk space in Laserfiche full text search engine.
In the next minor release, you can filter extensions to not index specified types of electronic documents, such as video, which can save disk space in Laserfiche full text search engine too.