Success! First of all thanks for the /st0 hint. I changed it to /nst0. 
And the labelling seems to be the true source of the warnings! Changing 
"Check Lables" to no forces Bareos to assume they are Bareos Labels. (And 
not ANSI/IBM, which the autocheck apparently assumed) And now the backup 
runs without failure!

Still weird, that the Error message gets cut off. (It happened a couple 
more times during our correspondence)

Again, giant thanks for your support! I wouldn't have been able to fix this 
without you and I learned a lot about debugging Bareos and the Bareos 
config. 

Sebastian Sura schrieb am Montag, 26. Februar 2024 um 15:41:28 UTC+1:

> I think i know what the problem is now.  The trace is not needed anymore.  
> Thanks for your help in tracking this down.
>
> bareos thinks that your volumes use ansi/ibm labels but cannot read them 
> for some reason.
> Something is probably misconfigured in your installation.
> I see that you are using /dev/st0 as your drive path.  This is a big 
> problem. You need to ensure that you use the /dev/nst* path
> since bareos does not expect tapes to rewind on their own. If the tape 
> gets rewound and bareos does not notice that, then it
> will overwrite the previous data from that tape.
>
> Kind Regards
> Sebastian Sura
> Am 26.02.24 um 15:13 schrieb Leon Bartle:
>
> Yes it does! 
>
> bareos-sd (100): stored/ansi_label.cc:70-179 Read ansi label.
> bareos-sd (100): stored/ansi_label.cc:84-179 Read device got: ERR=Cannot 
> allocate memory
> bareos-sd (130): stored/label.cc:143-179 Big if statement in 
> ReadVolumeLabel
> bareos-sd (250): stored/block.cc:952-179 Full read in 
> ReadBlockFromDevice() len=64512
> bareos-sd (250): stored/block.cc:1012-179 Read device got 64512 bytes at 
> 0:0
> bareos-sd (250): stored/block.cc:1155-179 At end of read block
> bareos-sd (250): stored/block.cc:1168-179 Exit read_block read_len=64512 
> block_len=213
>
> I will send a censored trace asap if still needed.
>
> Sebastian Sura schrieb am Montag, 26. Februar 2024 um 11:32:12 UTC+1:
>
>> Could you check if the trace contains
>>
>>  Read device got: ERR=
>>
>> or if you are comfortable with it, you can also send the trace to this 
>> email address (sebasti...@bareos.com) and i can take a look myself.
>> Kind Regards
>>
>> Sebastian Sura
>> Am 23.02.24 um 15:54 schrieb Leon Bartle:
>>
>> My tapes are equipped with barcodes in the format 000001L8, which are 
>> imported to volumes via the barcode scanner. I am unsure of what "ANSI 
>> labels" means. 
>>
>> For some reason, now a bug is visible in the regular log: bareos-sd 
>> JobId 179: Error: stored/block.cc:1018 Read zero bytes at 651:0 on device 
>> "TapeStorage" (/dev/st0).
>>
>> The trace has no mention of "BootStrapRecord", "block too big" or 
>> "Writing second EOF failed". I am still sifting through the rest of it. 
>> Sebastian Sura schrieb am Freitag, 23. Februar 2024 um 11:59:05 UTC+1:
>>
>>> Do some of your volumes have ansi labels ?
>>>
>>> Could you try creating a trace (level > 250) on the sd while a job with 
>>> that error happens ?
>>> Such a trace can be created with `setdebug level=300 trace=1 
>>> storage=<storagename>` in bconsole.
>>> I am wondering if one of the following messages are in the trace:
>>>
>>> BootStrapRecord for reread; block too big for buffer.
>>>
>>> Writing second EOF failed.
>>>
>>> Kind Regards
>>>
>>> Sebastian Sura
>>> Am 23.02.24 um 11:28 schrieb Leon Bartle:
>>>
>>> Log from the message before is the output when viewing "messages".  
>>> Here is list joblog jobid=176:
>>>
>>> *list joblog jobid=176
>>>  2024-02-21 21:00:02 BAREOS_SERVER JobId 176: Start Backup JobId 176, 
>>> Job=CLIENT-server.2024-02-21_21.00.00_02
>>>  2024-02-21 21:00:02 BAREOS_SERVER JobId 176: Connected Storage daemon 
>>> at BAREOS_SERVER:9103, encryption: TLS_CHACHA20_POLY1305_SHA256 TLSv1.3
>>>  2024-02-21 21:00:02 BAREOS_SERVER JobId 176:  Encryption: 
>>> TLS_CHACHA20_POLY1305_SHA256 TLSv1.3
>>>  2024-02-21 21:00:02 BAREOS_SERVER JobId 176: Connected Client: 
>>> CLIENT-server at 172.21.51.110:9102, encryption: 
>>> TLS_CHACHA20_POLY1305_SHA256 TLSv1.3
>>>  2024-02-21 21:00:02 BAREOS_SERVER JobId 176:  Handshake: Immediate TLS
>>>  2024-02-21 21:00:02 BAREOS_SERVER JobId 176:  Encryption: 
>>> TLS_CHACHA20_POLY1305_SHA256 TLSv1.3
>>>  2024-02-21 21:00:03 CLIENT-server-fd JobId 176: shell command: run 
>>> ClientBeforeJob "service mariadb stop"
>>>  2024-02-21 21:00:03 CLIENT-server-fd JobId 176: ClientBeforeJob: 
>>> Redirecting to /bin/systemctl stop mariadb.service
>>>  2024-02-21 21:00:04 BAREOS_SERVER JobId 176: Using Device "TapeStorage" 
>>> to write.
>>>  2024-02-21 21:00:04 CLIENT-server-fd JobId 176: Connected Storage 
>>> daemon at BAREOS_SERVER:9103, encryption: TLS_CHACHA20_POLY1305_SHA256 
>>> TLSv1.3
>>>  2024-02-21 21:00:04 CLIENT-server-fd JobId 176:  Encryption: 
>>> TLS_CHACHA20_POLY1305_SHA256 TLSv1.3
>>>  2024-02-21 21:00:04 CLIENT-server-fd JobId 176: Extended attribute 
>>> support is enabled
>>>  2024-02-21 21:00:04 CLIENT-server-fd JobId 176: ACL support is enabled
>>>  2024-02-21 21:00:22 bareos-sd JobId 176: Error:  2024-02-21 21:00:22 
>>> bareos-sd JobId 176: Volume "000056L8" previously written, moving to end of 
>>> data.
>>>  2024-02-21 21:01:14 bareos-sd JobId 176: Ready to append to end of 
>>> Volume "000056L8" at file=609.
>>>  2024-02-21 21:01:14 CLIENT-server-fd JobId 176:      Disallowed 
>>> filesystem. Will not descend from / into /dev
>>>  2024-02-21 21:01:14 CLIENT-server-fd JobId 176:      Disallowed 
>>> filesystem. Will not descend from / into /run
>>>  2024-02-21 21:01:14 CLIENT-server-fd JobId 176:      Disallowed 
>>> filesystem. Will not descend from / into /sys
>>>  2024-02-21 21:01:15 CLIENT-server-fd JobId 176:      Disallowed 
>>> filesystem. Will not descend from / into /var/lib/nfs/rpc_pipefs
>>>  2024-02-21 21:05:38 CLIENT-server-fd JobId 176:      Disallowed 
>>> filesystem. Will not descend from / into /mnt/SLINUX
>>>  2024-02-21 21:05:39 CLIENT-server-fd JobId 176: shell command: run 
>>> ClientAfterJob "service mariadb start"
>>>  2024-02-21 21:05:39 bareos-sd JobId 176: Releasing device "TapeStorage" 
>>> (/dev/st0).
>>>  2024-02-21 21:05:39 CLIENT-server-fd JobId 176: ClientAfterJob: 
>>> Redirecting to /bin/systemctl start mariadb.service
>>>  2024-02-21 21:05:44 bareos-sd JobId 176: Elapsed time=00:04:30, 
>>> Transfer rate=76.21 M Bytes/second
>>>  2024-02-21 21:05:44 BAREOS_SERVER JobId 176: Insert of attributes batch 
>>> table with 109 entries start
>>>  2024-02-21 21:05:44 BAREOS_SERVER JobId 176: Insert of attributes batch 
>>> table done
>>>  2024-02-21 21:05:44 BAREOS_SERVER JobId 176: Bareos BAREOS_SERVER 
>>> 22.1.1~pre74.a2f4c9943 (15Aug23):
>>>   Build OS:               Debian GNU/Linux 11 (bullseye)
>>>   JobId:                  176
>>>   Job:                    CLIENT-server.2024-02-21_21.00.00_02
>>>   Backup Level:           Incremental, since=2024-02-21 11:11:03
>>>   Client:                 "CLIENT-server" 22.1.1~pre74.a2f4c9943 
>>> (15Aug23) Red Hat Enterprise Linux release 8.7 (Ootpa),redhat
>>>   FileSet:                "CLIENT" 2023-08-25 11:06:19
>>>   Pool:                   "Incremental" (From Job IncPool override)
>>>   Catalog:                "MyCatalog" (From Client resource)
>>>   Storage:                "Tape" (From Job resource)
>>>   Scheduled time:         21-Feb-2024 21:00:00
>>>   Start time:             21-Feb-2024 21:00:04
>>>   End time:               21-Feb-2024 21:05:44
>>>   Elapsed time:           5 mins 40 secs
>>>   Priority:               10
>>>   FD Files Written:       109
>>>   SD Files Written:       109
>>>   FD Bytes Written:       20,577,536,367 (20.57 GB)
>>>   SD Bytes Written:       20,577,549,139 (20.57 GB)
>>>   Rate:                   60522.2 KB/s
>>>   Software Compression:   None
>>>   VSS:                    no
>>>   Encryption:             no
>>>   Accurate:               no
>>>   Volume name(s):         000056L8
>>>   Volume Session Id:      3
>>>   Volume Session Time:    1708498060
>>>   Last Volume Bytes:      609,780,261,888 (609.7 GB)
>>>   Non-fatal FD errors:    0
>>>   SD Errors:              1
>>>   FD termination status:  OK
>>>   SD termination status:  OK
>>>   Bareos binary info:     Bareos community build (UNSUPPORTED): Get 
>>> professional support from https://www.bareos.com
>>>   Job triggered by:       Scheduler
>>>   Termination:            Backup OK -- with warnings
>>>
>>> The "Volume previously written"-Error happens with every Backup job, not 
>>> just this specific one.
>>>
>>> Sebastian Sura schrieb am Freitag, 23. Februar 2024 um 11:22:13 UTC+1:
>>>
>>>> Did you gather this log during the backup or did you use `list joblog 
>>>> jobid=176` ?
>>>>
>>>> In case you used the former, could you check if the message is there in 
>>>> the later ?
>>>> I think what happened is that the error message was not setup properly 
>>>> on the sd
>>>> and is missing its trailing newline.
>>>>
>>>> Kind regards
>>>>
>>>> Sebastian Sura
>>>> Am 22.02.24 um 09:08 schrieb Leon Bartle:
>>>>
>>>> (I am unsure of what happened to the last message, but here is a repost)
>>>> bareos-webui report (see attached)
>>>>
>>>> bareos-webui log excerpt  (see attached)
>>>> Note, that the line I colored yellow only exists in webui and not in 
>>>> the bconsole log.
>>>>
>>>> bconsole log:
>>>> 21-Feb 21:00 BAREOS_SERVER JobId 176: Start Backup JobId 176, 
>>>> Job=CLIENT-server.2024-02-21_21.00.00_02
>>>> 21-Feb 21:00 BAREOS_SERVER JobId 176: Connected Storage daemon at 
>>>> BAREOS_SERVER:9103, encryption: TLS_CHACHA20_POLY1305_SHA256 TLSv1.3
>>>> 21-Feb 21:00 BAREOS_SERVER JobId 176:  Encryption: 
>>>> TLS_CHACHA20_POLY1305_SHA256 TLSv1.3
>>>> 21-Feb 21:00 BAREOS_SERVER JobId 176: Connected Client: CLIENT-server 
>>>> at 172.21.51.110:9102, encryption: TLS_CHACHA20_POLY1305_SHA256 TLSv1.3
>>>> 21-Feb 21:00 BAREOS_SERVER JobId 176:  Handshake: Immediate TLS
>>>> 21-Feb 21:00 BAREOS_SERVER JobId 176:  Encryption: 
>>>> TLS_CHACHA20_POLY1305_SHA256 TLSv1.3
>>>> 21-Feb 21:00 CLIENT-server-fd JobId 176: shell command: run 
>>>> ClientBeforeJob "service mariadb stop"
>>>> 21-Feb 21:00 CLIENT-server-fd JobId 176: ClientBeforeJob: Redirecting 
>>>> to /bin/systemctl stop mariadb.service
>>>> 21-Feb 21:00 BAREOS_SERVER JobId 176: Using Device "TapeStorage" to 
>>>> write.
>>>> 21-Feb 21:00 CLIENT-server-fd JobId 176: Connected Storage daemon at 
>>>> BAREOS_SERVER:9103, encryption: TLS_CHACHA20_POLY1305_SHA256 TLSv1.3
>>>> 21-Feb 21:00 CLIENT-server-fd JobId 176:  Encryption: 
>>>> TLS_CHACHA20_POLY1305_SHA256 TLSv1.3
>>>> 21-Feb 21:00 CLIENT-server-fd JobId 176: Extended attribute support is 
>>>> enabled
>>>> 21-Feb 21:00 CLIENT-server-fd JobId 176: ACL support is enabled
>>>> 21-Feb 21:00 bareos-sd JobId 176: Error:
>>>> 21-Feb 21:01 bareos-sd JobId 176: Ready to append to end of Volume 
>>>> "VOLUME_NO" at file=609.
>>>> 21-Feb 21:01 CLIENT-server-fd JobId 176:      Disallowed filesystem. 
>>>> Will not descend from / into /dev
>>>> 21-Feb 21:01 CLIENT-server-fd JobId 176:      Disallowed filesystem. 
>>>> Will not descend from / into /run
>>>> 21-Feb 21:01 CLIENT-server-fd JobId 176:      Disallowed filesystem. 
>>>> Will not descend from / into /sys
>>>> 21-Feb 21:01 CLIENT-server-fd JobId 176:      Disallowed filesystem. 
>>>> Will not descend from / into /var/lib/nfs/rpc_pipefs
>>>> 21-Feb 21:05 CLIENT-server-fd JobId 176:      Disallowed filesystem. 
>>>> Will not descend from / into /mnt/SLINUX
>>>> 21-Feb 21:05 CLIENT-server-fd JobId 176: shell command: run 
>>>> ClientAfterJob "service mariadb start"
>>>> 21-Feb 21:05 bareos-sd JobId 176: Releasing device "TapeStorage" 
>>>> (/dev/st0).
>>>> 21-Feb 21:05 CLIENT-server-fd JobId 176: ClientAfterJob: Redirecting to 
>>>> /bin/systemctl start mariadb.service
>>>> 21-Feb 21:05 bareos-sd JobId 176: Elapsed time=00:04:30, Transfer 
>>>> rate=76.21 M Bytes/second
>>>> 21-Feb 21:05 BAREOS_SERVER JobId 176: Insert of attributes batch table 
>>>> with 109 entries start
>>>> 21-Feb 21:05 BAREOS_SERVER JobId 176: Insert of attributes batch table 
>>>> done
>>>> 21-Feb 21:05 BAREOS_SERVER JobId 176: Bareos BAREOS_SERVER 
>>>> 22.1.1~pre74.a2f4c9943 (15Aug23):
>>>>   Build OS:               Debian GNU/Linux 11 (bullseye)
>>>>   JobId:                  176
>>>>   Job:                    CLIENT-server.2024-02-21_21.00.00_02
>>>>   Backup Level:           Incremental, since=2024-02-21 11:11:03
>>>>   Client:                 "CLIENT-server" 22.1.1~pre74.a2f4c9943 
>>>> (15Aug23) Red Hat Enterprise Linux release 8.7 (Ootpa),redhat
>>>>   FileSet:                "CLIENT" 2023-08-25 11:06:19
>>>>   Pool:                   "Incremental" (From Job IncPool override)
>>>>   Catalog:                "MyCatalog" (From Client resource)
>>>>   Storage:                "Tape" (From Job resource)
>>>>   Scheduled time:         21-Feb-2024 21:00:00
>>>>   Start time:             21-Feb-2024 21:00:04
>>>>   End time:               21-Feb-2024 21:05:44
>>>>   Elapsed time:           5 mins 40 secs
>>>>   Priority:               10
>>>>   FD Files Written:       109
>>>>   SD Files Written:       109
>>>>   FD Bytes Written:       20,577,536,367 (20.57 GB)
>>>>   SD Bytes Written:       20,577,549,139 (20.57 GB)
>>>>   Rate:                   60522.2 KB/s
>>>>   Software Compression:   None
>>>>   VSS:                    no
>>>>   Encryption:             no
>>>>   Accurate:               no
>>>>   Volume name(s):         VOLUME_NO
>>>>   Volume Session Id:      3
>>>>   Volume Session Time:    1708498060
>>>>   Last Volume Bytes:      609,780,261,888 (609.7 GB)
>>>>   Non-fatal FD errors:    0
>>>>   SD Errors:              1
>>>>   FD termination status:  OK
>>>>   SD termination status:  OK
>>>>   Bareos binary info:     Bareos community build (UNSUPPORTED): Get 
>>>> professional support from https://www.bareos.com
>>>>   Job triggered by:       Scheduler
>>>>   Termination:            Backup OK -- with warnings
>>>>
>>>> Thanks for your help!
>>>>
>>>> Sebastian Sura schrieb am Mittwoch, 21. Februar 2024 um 15:24:57 UTC+1:
>>>>
>>>>> Can you post the joblog ?
>>>>>
>>>>> The messages that you quoted are not supposed to be errors but just 
>>>>> informational messages, it would be very weird if they caused your backup 
>>>>> to show up as "with warnings".
>>>>>
>>>>> Kind Regards
>>>>>
>>>>> Sebastian Sura
>>>>> Am 21.02.24 um 08:49 schrieb Leon Bartle:
>>>>>
>>>>> data.
>>>>> Ready to append to end of Volume " XXXXXX  " at file=80.
>>>>>
>>>>> This error does not seem to effect functionality in any way, because 
>>>>> the files are in perfect condition, restores are successful and the tapes 
>>>>> get written fully. Yet it downgrades the status to "Warning" and creates 
>>>>> this error. (As far as I understand it, this isn't even something bad, 
>>>>> that 
>>>>> a volume was written and we continue writing it.)
>>>>>
>>>>>    - Why is this caused?
>>>>>    - How can I move further with troubleshooting? 
>>>>>
>>>>> -- 
>>>>>  Sebastian Sura                  sebasti...@bareos.com
>>>>>  Bareos GmbH & Co. KG            Phone: +49 221 630693-0
>>>>>  https://www.bareos.com
>>>>>  Sitz der Gesellschaft: Köln | Amtsgericht Köln: HRA 29646
>>>>>  Komplementär: Bareos Verwaltungs-GmbH
>>>>>  Geschäftsführer: Stephan Dühr, Jörg Steffens, Philipp Storz
>>>>>
>>>>> -- 
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>>>>  
>>>> <https://groups.google.com/d/msgid/bareos-users/e4e8fafd-b2ad-4502-97e3-1ecdfc8644fbn%40googlegroups.com?utm_medium=email&utm_source=footer>
>>>> .
>>>>
>>>> -- 
>>>>  Sebastian Sura                  sebasti...@bareos.com
>>>>  Bareos GmbH & Co. KG            Phone: +49 221 630693-0
>>>>  https://www.bareos.com
>>>>  Sitz der Gesellschaft: Köln | Amtsgericht Köln: HRA 29646
>>>>  Komplementär: Bareos Verwaltungs-GmbH
>>>>  Geschäftsführer: Stephan Dühr, Jörg Steffens, Philipp Storz
>>>>
>>>> -- 
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>>> .
>>>
>>> -- 
>>>  Sebastian Sura                  sebasti...@bareos.com
>>>
>>>  Bareos GmbH & Co. KG            Phone: +49 221 630693-0
>>>  https://www.bareos.com
>>>  Sitz der Gesellschaft: Köln | Amtsgericht Köln: HRA 29646
>>>  Komplementär: Bareos Verwaltungs-GmbH
>>>  Geschäftsführer: Stephan Dühr, Jörg Steffens, Philipp Storz
>>>
>>> -- 
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>>  
>> <https://groups.google.com/d/msgid/bareos-users/757619a7-6080-426a-a43f-6e7a21eabe79n%40googlegroups.com?utm_medium=email&utm_source=footer>
>> .
>>
>> -- 
>>  Sebastian Sura                  sebasti...@bareos.com
>>  Bareos GmbH & Co. KG            Phone: +49 221 630693-0
>>  https://www.bareos.com
>>  Sitz der Gesellschaft: Köln | Amtsgericht Köln: HRA 29646
>>  Komplementär: Bareos Verwaltungs-GmbH
>>  Geschäftsführer: Stephan Dühr, Jörg Steffens, Philipp Storz
>>
>> -- 
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>  
> <https://groups.google.com/d/msgid/bareos-users/f0f5e745-7b0a-4d91-819e-418ebe9dfe13n%40googlegroups.com?utm_medium=email&utm_source=footer>
> .
>
> -- 
>  Sebastian Sura                  sebasti...@bareos.com
>  Bareos GmbH & Co. KG            Phone: +49 221 630693-0
>  https://www.bareos.com
>  Sitz der Gesellschaft: Köln | Amtsgericht Köln: HRA 29646
>  Komplementär: Bareos Verwaltungs-GmbH
>  Geschäftsführer: Stephan Dühr, Jörg Steffens, Philipp Storz
>
>

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