I do not think the DISTINCT is the issue --- I tried that to see what I would get but with or without it in SSMS the Select without the FOR XML clause returns 248 records. Once I add the FOR XML clause, it only give me 46 records and the xml file is not compeleted -- it just ends in the middle of one of the XML tags...

I also checked the field types/sizes. the larges ones are only char(50).... :unsure: