when I do a tape status /dev/rStp0 I get the following on a new tape and I have tried several:

Status : ready beginning-of-tape

soft errors : 0
hard errors: 2
underruns: 5

My BackupEdge has stopped backing up my system because it asks for a new volume yet my total system data is under 20 gigs and I'm using a 20/40 DDS4 drive. This has all worked fine until this monday.

I've seen the quite often. The drive itself is failing. Cleaning cartridges may not help

If you can, get the drive replaced either under sometype of warranty, or but a new one.

How often do you clean the tape drive?
Check the output from your Edge backups, write errors are usually recorded.
Consider changing your backup device to DVD, with compression you might get 20gb of data on a 4.7DVD, otherwise use the dual layer media, (9.4gb) its only disadvantage is that it is a one-write media.

Thank you guys for your responses. It seems I needed to clean the drive more than once. I just sat there inserting the cleaning tape, letting it eject, and doing it again. I did it about 7 times and now the backups work again. I think it's time for a new drive.

I have similar issues with one of two Compaq boxes running SCO.
I got hard errors but no under runs. I do get the end of medium errors too. I have a dat 4 tape drive that only needs one cleaning 2 or 3 times a week to get it to work. I am replacing my tapes now, even though my tapes are less than a year old. Maybe the tapes are buggering the drive. My drive has been replaced twice by HP.
sounds like you are not alone.
SkyyBugg

I too experience a bugged up DAT drive. My brand new IBM x3200 server is on its third DAT 72 drive (replaced twice so far.) The original drive was requesting a "cleaning" daily and during the backup. Most "warranty" replacement drives are almost always "reconditioned" units.