Hi -- if all you've got is "In (function (npt = min(n + 2L, 2L * n), rhobeg = NA, rhoend = NA, : unused control arguments ignored." -- this is a warning, not an error. It can be ignored.
It is something about one of the external optimiser functions (optimx I think; BioGeoBEARS can choose one of several optimizers, which all are from external R packages), I've never taken the time to figure it out as it seems to run fine on defaults.
Re: the .Rdata files, if you mean the files saved by BioGeoBEARS script, these contain no information saving all the steps in the search, so the length of the search will not change the size of the .Rdata file. It's possible that some change from an old to new version of BioGeoBEARS might do so, or perhaps just an update of R; the "save" function that produces .Rdata files is from R base.
If the length of your search has changed, you can do a longer search if you want, e.g. by setting $use_optimx = "GenSA". Usually this makes no difference, the vast amount of most searches is spent optimizing the last few decimal points of the parameters, having no physical significance. On rare occasions or complex models with many parameters, it might make sense to do.
Cheers,
Nick