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Running out of disk space warning when there is plenty left

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I was using the Build 6151 (i.e., 6131 with the Hot Fix) to back up my HP laptop to a USB drive that had over 500 GB available space on it. My laptop's HD is 250 GB but of that less than 90 GB is used. Yet, in about 10 minutes into a full disk backup, a msg popped up warning me that I was running out of disk space. Fortunately it gave me the option to ignore it, which I did and after that the backup completed successfully, creating a 59 GB image file. I wonder why this warning msg is issued in such a situation. Even though I can ignore it, but such intervention pretty much prevents unattended backups.

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Possibly a temp drive issue - have you limited the space for the temp drive? I goofed the other night and put my temp drive on a 1.5GB RAM drive and everything was OK until I attempted to copy a file greater than 1.5GB and it failed with the out of space message.

I use the system-assigned temp drive that never gave me trouble before. Does ATI require a special temp drive assigned?

Hmmm. If you are doing a physical drive backup and it is therefore backing up an invisible boot partition, it is possible this is the problem. Volume shadow copy requires free space at least as large as the largest single file. If there is indeed a small boot partition, it can happen that there is not enough space for volume shadow copy to work - and you will get this error. I've had windows Image Backup fail on laptops for this reason.

Lot of if's I know and the suggestioned solution is using a partition editor to increase the size of the hidden partition. Probably not worth the effort..

cheers

Rod

As a matter of fact you're right about both a phys drive backup and a small boot partition because originally I was dual booting into the old Vista and the new Win7 till I finally made the old Vista partition a non-bootable data partition, using the MiniTool Partition Wizard. However, I backed up this config several times before this ATI version without any problems like this. Should I maybe try backups in the future by backing up both partitions (drives C: and D:) separately?