Error: "No such file or directory: patching_backup_config.json" when updating vCenter via vCenter Server Appliance Management Interface (VAMI)

Products

• VMware vCenter Server

Issue/Introduction

This article addresses upgrade failures in the VCSA that occur during the patching process, specifically when the Appliance Management Interface (VAMI) fails to locate the necessary patch manifest files.

• The issue occurs while patching the VMware vCenter Server Appliance (VCSA) using a manually mounted ISO.

• The patching process fails immediately at 0% progress and displays the following error:

  [Errno 2] No such file or directory: '/storage/seat/software-update*/stage/update/patching_backup_config.json'
  
  Error: mount: /mnt/iso-contents: no medium found on /dev/sr0

  Downstream service failures: java.lang.NullPointerException in the vsphere-ui service.

Environment

• VMware vCenter Server 8.0.x

Cause

This issue occurs when a full vCenter Server installation or upgrade ISO (e.g., VMware-VCSA-all-*.iso) is mounted to the appliance instead of the required Full Patch (FP) ISO image (e.g., VMware-vCenter-Server-Appliance-*-patch-FP.iso).

The standard installer ISO lacks the necessary metadata and directory structures required for the patching workflow. The update microservice cannot read the required patch manifest because the virtual CD-ROM drive lacks a connected medium or the correct patch ISO is not mounted. This causes a disruption in the patch sequence.

Resolution

Note: Verify that a working backup exists before proceeding. Follow the Snapshot Best practices for vCenter Server Virtual Machines for guidance.

1.  Log in to the vCenter Server Appliance as the root user using an SSH client.

2. To unstage the staged patches, run the following command: /bin/appliancesh/software-packages unstage

3. Stop the Appliance Management service: service-control --stop applmgmt

4. Remove existing update and staging files:

   Note: These commands permanently delete downloaded or partially staged patch files. This is destructive and requires a complete re-download or re-mount of the correct ISO.

   1. rm -rf /storage/core/software-update/updates/*

   2. rm -rf /storage/core/software-update/stage/*

   3. rm -rf /storage/db/patching.db

   4. mv /storage/core/software-packages/staged-configuration.json /storage/core

   5. mv /etc/applmgmt/appliance/software_update_state.conf /storage/core

5. Start the Appliance Management service: service-control --start applmgmt

6. Download the vCenter Full Patch (FP) ISO. Follow Download vCenter Server patches and ISOs for latest releases for guidance.

7. Ensure the correct Full Patch (FP) ISO image (e.g., VMware-vCenter-Server-Appliance-*-patch-FP.iso) is uploaded to a datastore accessible by the vCenter VM.

8. Mount ISO:

   1. Right-click the VCSA VM in the vSphere Client > Edit Settings.

   2. Under CD/DVD Drive, select Datastore ISO File, browse to the FP ISO.

   3. Ensure Connected and Connect At Power On are checked.

9. Initiate Update: Log in to the VAMI (https://<vCenter_FQDN>:5480) and initiate the update.