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Personally, I've never hit the 20 million limit, and it's pretty easy to figure out which county to use. I have Maps and Streets on my laptop, and it shows county names. I do an initial routing there, look at the counties, then pick those counties for download in Mapopolis. Works pretty well. There are also some ways to get maps of counties from some internet sources, but I've never used them.
For Routis it's both for limitations. You can only store on your machine what you have space to hold, and once you get the map there it has to load into memory. I think it dynamically gets parts from the card, as the maps are generally larger than the memory space I have available. Right now the map on my Axim (all of Virginia) is about 25 Mbytes. That fits in memory, but so does a map of 125 miles radius of my house, which is larger than the RAM I have available, so somehow Routis looks like it is dynamically reading the map.
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