Hi Stephen,
I haven't heard about your issue so far.
Of course there will be more lines in the report if you don't suppress zeros, but as the word says: All key figures are zero in these records, so they cannot affect the result lines.
If you compared the result row with suppression and without and it is still the same, but not matching the excel sum over all rows then it's really weired.
Is the AO result more or less than the excel sum?
Regards,
Martin
PS: You should compare the total sum with RSRT, too!