We've come across a really strange problem with Previous Versions. I wonder if anyone else has had a similar problem?
Briefly, Windows Server 2003, XP client. Loads of disk space on the server. Multiple volumes with all the previous versions held on a separate, non-shadow-copied volume (as per the recommendation).
After a period of a couple of weeks, we find we are unable to manipulate large files. For example, when trying to open an Outlook archive file of about 100MB+ we get an "unable to open..." error. Nothing specific to go on. We see similar errors when trying to move or copy other big files.
By chance, when we first spotted this, we deleted one Shadow Copy from the server, and the file copy, and Outlook archive worked. Surely a fluke, but no, this is the "fix" - delete one Previous Version, and the problem goes away for a while.
Does this sound familiar to anyone?