IDPA: ESXi Failure While Performing Upgrade: "Failed to Upgrade VSAN"

Summary: This KB article walks through the procedure to upgrade the VSAN disk format (ONDISK-FORMAT) manually in case ACM fails to upgrade VSAN.

This article applies to This article does not apply to This article is not tied to any specific product. Not all product versions are identified in this article.
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Symptoms

The message "Failed to to Upgrade VSAN" is seen in the "Hypervisor and Server Firmware" or "Compute node (ESXi)" upgrade section of the ACM upgrade UI:

Failed to Upgrade VSAN

Check errors in the "/data01/tmp/patch/logs/esxi-logs.log" file. The following command to upgrade VSAN On-disk format fails:

15/02/19 00:37:15 upgrade_vsan_disk_format() Executing command : rvc -a root@localos:Idpa_1234@192.168.100.101 -c \"vsan.disks_stats /192.168.100.101/DPappliance/computers/DPappliance-VSAN\" -c \"quit\"

upgrade UI

 

Cause

It is important to verify "Add disks to storage" option is set to manual and all disk groups are healthy before starting the version upgrade to avoid this issue.

 

Resolution

Log in to the vSphere WebClient for Integrated Data Protection Appliance (IDPA) vCenter and perform the following checks:

  1. Verify that "VSAN disk Claiming" mode is set to "Manual" before attempting to upgrade VSAN on-disk format upgrade.
    VSAN disk Claiming in UI 

  2. Verify that all the disks and disk groups are in a healthy state. Validate the state from vSphere Web Client for VSAN.

    To Validate the disk status from vSphere Web Client, select the VSAN Cluster from hosts and clusters view > Configure > Disk Management under VSAN.

    Click each ESXi host or disk group to check the heath of the Disks under disk group.

  3. Verify that no component rebuilding tasks are currently in progress in the VSAN cluster. Validate the tasks from vSphere Web Client.
    Resyncing Components option in UI 

    If all the checks are passed on VSAN, manually upgrade VSAN On-disk format.

  4. Run the Pre-Check Upgrade task before attempting to upgrade VSAN On-disk format. It performs most of the validation for us. Confirm that Disk Pre-check is Green with the Status Ready to Upgrade -Pre-Check Completed Successfully.
    Pre-check Upgrade button

    If any errors are reported during the Pre-Check, they must be fixed before attempting to upgrade On-disk Format.

  5. If the Pre-check upgrade works successfully, click "Upgrade."

 

Affected Products

Integrated Data Protection Appliance Family

Products

PowerProtect DP5300, PowerProtect DP5800, PowerProtect DP8300, PowerProtect DP8800, PowerProtect Data Protection Software, Integrated Data Protection Appliance Family, PowerProtect Data Protection Hardware , Integrated Data Protection Appliance Software ...
Article Properties
Article Number: 000171627
Article Type: Solution
Last Modified: 11 أغسطس 2026
Version:  5
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