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While creating zones I notice that the postal code field has a character limit of 255 characters. Many of my county zip codes exceed that amount of characters. Has anyone else had that problem?

postal codes that exceed 255 characters? What planet is this on? Seriously how do you end up with a postal code > 255 chars?

I should have been more specific. Some of our county's have so many zip codes they exceed the 255 character limit for zones.

Have you tried using the wildcard feature to reduce the number of entries?

I'm familiar with it but it doesn't apply in my case.

maybe try changing the field definition, i.e., increase 2x or 3x? Don't know if it will work or not but might be worth a try.