"Cannot execute upgrade script on host" error when upgrading the VUM using iso2dd

Products

• VMware

Issue/Introduction

Symptoms:

• When performing VUM upgrade on progress bar while at 92%.
  You see error similar to:
  
  "Cannot execute upgrade script on host."

• BOOT.CFG is missing in /altbootbank
• In the /var/log/vua.log, file you see entries similar to:
  
  2016-07-06T14:49:46.619Z info vua[216CBB70] [Originator@6876 sub=SysCommandPosix] ForkExec(/tmp/vuaScript-Fm1pWs/prep.py --ip=10.117.8.34 ) 172103
  2016-07-06T14:50:46.924Z info vua[FFFD6B70] [Originator@6876 sub=ThreadPool] Spawning additional worker - allocated: 7, idle: 1
  2016-07-06T14:50:46.924Z info vua[2174DB70] [Originator@6876 sub=ThreadPool] Thread enlisted
  2016-07-06T14:50:46.924Z info vua[2174DB70] [Originator@6876 sub=ThreadPool] Entering worker thread loop
  2016-07-06T14:50:46.929Z info vua[216CBB70] [Originator@6876 sub=VUA] Command '/tmp/vuaScript-Fm1pWs/prep.py --ip=10.117.8.34' finished with exit status 1
  --> stderr: --------
  --> Traceback (most recent call last):
  --> File "/tmp/vuaScript-Fm1pWs/prep.py", line 1081, in <module>
  --> sys.exit(main(sys.argv))
  --> File "/tmp/vuaScript-Fm1pWs/prep.py", line 1077, in main
  --> prepareEsxiBootloader()
  --> File "/tmp/vuaScript-Fm1pWs/prep.py", line 981, in prepareEsxiBootloader
  --> fp = open(origBootCfgPath)
  --> IOError: [Errno 2] No such file or directory: '/altbootbank/boot.cfg'
  -->
  --> --------
  

Cause

This issue occurs when:

• During upgrade, using certain versions of RHEL for creating dd image creates the BOOT.CFG in upper case.
• During upgrade, the prep script is not able to find boot.cfg (lower case) and this leads to an unstable state where boot.cfg is altogether missing from altbootbank

Resolution

To resolve this issue, you can perform either of the following:

• Upgrade using iso image
  
• Upgrade using esxcli
• Upgrade to vSphere6.0U3, for downloading see VMware Download page.
  

Additional Information

Impact/Risks:
Blocking upgrades to 60u2 or 6.5