I'm using ACAD2011 and a HP DesignJet 500 plotter. We use PDF underlays of scanned charts, maps, etc in our cad plans and sometimes the PDFs will only partially plots even though the rest of the cad linework plots. We are using 2007 dwg file format to make files compatible with another program. I have monkeyed with the RASTERPERCENT and RASTERTHRESHHOLD variables but still same problem. Any Ideas?
When that happens next time, then as a test, plot to the same device but on a much smaller sheet size and see if the plot completes. Most likely it is a sign you've exceeded that device's ability to handle that quantity of information.