Error: An error occurred during host configuration when downloading vmware-hbr-agent VIB

Products

VMware Live Recovery

Issue/Introduction

When attempting to configure or pair sites within VMware vSphere Replication, the installation or upgrade of the hbr-agent fails on the ESXi host.

Symptom:

The vCenter Server display logs a recurring task: "Host fails to download vmware-hbr-agent.vib".
The ESXi host frequently retries installing the vmware-hbr-agent.vib package.
The vCenter Server task console displays the following error status:

Install
esxi01.####.com
An error occurred during host configuration.
com.vmware.vr-sa-####@vsphere.local
dd/mm/yyyy, hh:mm:ss 
dd/mm/yyyy, hh:mm:ss 

Task Name: Install
Status   : An error occurred during host configuration: /usr/sbin/esxupdate returned with exit status: 7.
Initiator: com.vmware.vr-####@vsphere.local
Target   : Host 192.####
Server   : vCenter vcsa.####.com

Install error with "An error occurred during host configuration" on the vCenter.

Virtual Machine on Live Site Recovery - show in Not Active State with Error

"hbr-agent" service is missing on the vCenter. Select host > Configure > Services.

The /var/log/vpxa.log files on ESXi indicate a vim.fault.PlatformConfigFault combined with exit status 7.

yyyy-mm-ddThh:mm:ssZ info vpxa[2100734] [Originator@6876 sub=Default opID=####-HMSINT-29-72-65] [VpxLRO] -- ERROR task-41013 -- patchManager -- vim.host.PatchManager.InstallV2: vim.fault.PlatformConfigFault:
--> Result:
--> (vim.fault.PlatformConfigFault) {
-->  faultCause = (vmodl.MethodFault) null,
-->  faultMessage = <unset>,
-->  text = "/usr/sbin/esxupdate returned with exit status: 7"
-->  msg = "An error occurred during host configuration."
--> }
--> Args:
-->
--> Arg metaUrls:
--> (string) []
--> Arg bundleUrls:
--> (string) []
--> Arg vibUrls:
--> (string) [
-->  "https://vSphere-replication.####.com:8043/vib/vmware-hbr-agent.vib"
--> ]
--> Arg spec:
--> (vim.host.PatchManager.PatchManagerOperationSpec) {
-->  proxy = "http://vcenter.####.com",
-->  port = 80,
-->  userName = <unset>,
-->  password = <unset>,
-->  cmdOption = <unset>
--> }

The /var/log/vmware/vpxd.log files on vCenter indicate a vim.fault.PlatformConfigFault combined with exit status 7.

yyyy-mm-ddThh:mm:ssZ info vpxd[07995] [Originator@6876 sub=Default opID=####HMSINT-46-18] [VpxLRO] -- ERROR task-23603 -- patchManager-10 -- vim.host.PatchManager.InstallV2: vim.fault.PlatformConfigFault:
--> Result:
--> (vim.fault.PlatformConfigFault) {
-->    faultCause = (vmodl.MethodFault) null,
-->    faultMessage = <unset>,
-->    text = "/usr/sbin/esxupdate returned with exit status: 7"
-->    msg = "An error occurred during host configuration."
--> }
--> Args:
-->
--> Arg metaUrls:
--> (string) []
--> Arg bundleUrls:
--> (string) []
--> Arg vibUrls:
--> (string) [
-->    "https://replication.####.com:8043/vib/vmware-hbr-agent.vib"
--> ]
--> Arg spec:
--> (vim.host.PatchManager.PatchManagerOperationSpec) {
-->    proxy = "http://vCenter.####.com",
-->    port = 80,
-->    userName = <unset>,
-->    password = <unset>,
-->    cmdOption = <unset>
--> }

The /var/log/esxupdate.log file on the affected ESXi host contains entries similar to:

An error occurred during host configuration: /usr/sbin/esxupdate returned with exit status: 7.

yyyy-mm-ddThh:mm:ssZ Er(11) esxupdate[8059525]: esximage.Downloader.DownloaderError: ('https://192.####:8043/vib/vmware-hbr-agent.vib', '', '<urlopen error [Errno -3] Temporary failure in name resolution>')

yyyy-mm-ddThh:mm:ssZ Er(11) esxupdate[8059525]: esximage.Errors.VibDownloadError: ('https://192.####:8043/vib/vmware-hbr-agent.vib', None, "('https://192.####:8043/vib/vmware-hbr-agent.vib', '', '<urlopen error [Errno -3] Temporary failure in name resolution
yyyy-mm-ddThh:mm:ssZ esxupdate: 2405325: esxupdate: INFO: viburls = ['https://replication.####.com:8043/vib/vmware-hbr-agent.vib'] 
yyyy-mm-ddThh:mm:ssZ esxupdate: 2405325: downloader: INFO: Opening https://replication.####.com:8043/vib/vmware-hbr-agent.vib for download 
yyyy-mm-ddThh:mm:ssZ esxupdate: 2405325: downloader: INFO: Proxies configured: {'http': 'http://vCenter.####.com:80', 'https': 'http://vCenter.####.com:80', 'ftp': 'http://vCenter.####.com:80'} 
yyyy-mm-ddThh:mm:ssZ esxupdate: 2405325: Proxy: ERROR: Proxy server cannot connect to the endpoint: HTTP/1.1 404 Not Found Connection: close Content-Type: text/html Content-Length: 48  
yyyy-mm-ddThh:mm:ssZ esxupdate: 2405325: downloader: WARNING: Download failed: Proxy server vCenter.####.com:80 returned status 404, 4 retry left... 
yyyy-mm-ddThh:mm:ssZ esxupdate: 2405325: downloader: INFO: Proxies configured: {'http': 'http://vCenter.####.com:80', 'https': 'http://vCenter.####.com:80', 'ftp': 'http://vCenter.####.com:80'} 
yyyy-mm-ddThh:mm:ssZ esxupdate: 2405325: Proxy: ERROR: Proxy server cannot connect to the endpoint: HTTP/1.1 404 Not Found Date: Connection: close Content-Type: text/html Content-Length: 48 
yyyy-mm-ddThh:mm:ssZ esxupdate: 2405325: downloader: WARNING: Download failed: Proxy server vCenter.####.com:80 returned status 404, 3 retry left...

Environment

VMware vSphere Replication 8.x

VMware vSphere Replication 9.x

VMware ESXi 8.x

Cause

This issue occurs when the ESXi host cannot resolve the Fully Qualified Domain Name (FQDN) of the vSphere Replication appliance due to missing or invalid DNS configurations, mismatched hostnames, or firewall policies blocking outbound communication over port 8043.

Resolution

To resolve this issue, verify network name resolution and execute a manual installation of the replication agent VIB.

Verify Existing VIB Installation: Check if the replication agent VIB is already installed on the ESXi host by running:
```
esxcli software vib list | grep -i hbr
```
Remove the Existing VIB (If Found): If the VIB is present in the list, remove it using the following command:
```
esxcli software vib remove -n vmware-hbr-agent
```
Attempt Online Manual Installation: Disable the firewall, attempt to download and install the VIB via the proxy URL, and then re-enable the firewall immediately:
```
esxcli network firewall set --enabled false
esxcli software vib install --proxy=http://vCenter.####.com:80 -v http://replication.####.com:8043/vib/vmware-hbr-agent.vib
esxcli network firewall set --enabled true
```
Note: If this returns a [VibDownloadError] (such as a 404 status), proceed to the offline installation methods below.
Alternative Method A: Download and Upload via WinSCP:
- Connect to the vSphere Replication (VR) appliance via WinSCP, navigate to /opt/vmware/hbr/vib/, and download the .vib file to your local machine.
- Connect to the target ESXi host via WinSCP and upload the .vib file to a local datastore.

Alternative Method B: Copy Directly via SCP (Command Line) Locate the VIB on the VR appliance and copy it directly to the ESXi host's /tmp directory using SCP::

# Find the VIB path
find / -iname *hbr*vib*

# Secure copy to the ESXi host
scp /opt/vmware/hbr/vib/<vib-version>.vib root@<Target_ESXi_Host_IP_address>:/tmp

Install the Offline VIB File: Execute the manual installation from the local path where you uploaded the VIB:
```
esxcli software vib install -v /tmp/<vib-version>.vib
```
Check for Duplicate Hostnames: Ensure that no nodes share duplicate hostnames in the vCenter inventory (e.g., verifying that the ESXi host hasn't mistakenly been assigned the vCenter's hostname or left as an unconfigured localhost.localdomain).
Perform DNS Configuration Troubleshooting:
- Ensure vCenter, vSphere Replication, SRM, and ESXi hosts are pointing to the correct, active DNS servers.
- Create both forward and reverse lookup records in the DNS server for all appliances and hosts if they do not exist.
- Verify that the hostname configured in the Direct Console User Interface (DCUI) matches the DNS record.
- Verify that the custom DNS suffix is properly configured.
Apply Hosts File Workaround (If DNS Cannot Be Fixed Immediately): If DNS resolution still fails, manually update the /etc/hosts file on the vCenter, vSphere Replication, and/or SRM appliances using the format: [IP] [FQDN] [Hostname]. Example: 192.#### SRM01.####.local SRM01
Contact Support: If the VIB still fails to install or replication errors persist after completing all network and manual installation steps, Contact support.

Additional Information

For instructions on retrieving host diagnostic files, see Collecting diagnostic information for VMware ESXi.