Error: "No such file or directory: patching_backup_config.json" during vCenter patching due to Input/Outout error

Products

• VMware vCenter Server

Issue/Introduction

When attempting to upgrade vCenter Server, the upgrade fails with an error similar to:

[Errno 2] No such file or directory: '/storage/seat/software-update*/stage/update/patching_backup_config.json'

This error typically occurs during the Staging phase of the process and prevents the upgrade from completing successfully.

Similar Input/Output errors are observed in the /var/log/vmware/applmgmt/update_microservice.log file.

2026-07-15 03:50:16,466 - 30411 -    update_b2b_target::                    stage_rpms:3753 -    ERROR - Returning from resume_do
wnload(). Exception: OSError(5, 'Input/output error')
Traceback (most recent call last):
  File "/storage/core/software-update/updates/8.0.3.00900/update/update_b2b_target.py", line 3722, in stage_rpms
    count = coroutine.send(1)
  File "/storage/core/software-update/updates/8.0.3.00900/update/update_b2b_target.py", line 1343, in _stageFromIso
    yield coroutine.send(1)
  File "/storage/core/software-update/updates/8.0.3.00900/update/update_b2b_target.py", line 1257, in _copyPackages
    if _copyPackageToStageDir(
  File "/storage/core/software-update/updates/8.0.3.00900/update/update_b2b_target.py", line 1175, in _copyPackageToStageDir
    copyFileFunc(sourcefile, destDir)
  File "/usr/lib/python3.10/shutil.py", line 417, in copy
    copyfile(src, dst, follow_symlinks=follow_symlinks)
  File "/usr/lib/python3.10/shutil.py", line 277, in copyfile
    copyfileobj(fsrc, fdst)
  File "/usr/lib/python3.10/shutil.py", line 195, in copyfileobj
    buf = fsrc_read(length)
OSError: [Errno 5] Input/output error

Environment

• vCenter Server 7.x
• vCenter Server 8.x

Cause

During the stage_rpms phase of a vCenter Server Appliance (VCSA) update. The file system encountered a error while attempting to read the patch packages or write them to the appliance storage

Resolution

1. Verify the ISO / Patch File Integrity

Before troubleshooting the underlying infrastructure, rule out a bad download:

• Check the SHA-256 / MD5 checksum of the patch file on the datastore and compare it directly to the official VMware/Broadcom download page.

• If the checksums don't match, delete the file, re-download it, and re-upload it to another shared datastore.

2. Check ESXi Host & Storage Health

Since the datastore itself is reporting I/O errors, check the logs of the ESXi host running the vCenter VM:

• Log into the ESXi host or review its vmkernel.log. Look for lines containing SCSI error, Sense Key, or Lost connectivity to storage device.

• Verify if there are active hardware or storage alerts on the underlying array.

3. Remount or Re-attach the Patching Media

If you are staging directly from a datastore-attached ISO via the vCenter CD/DVD drive:

• Disconnect the CD/DVD drive from the vCenter VM edit settings.

• Re-attach the ISO file, ensuring it connects properly, then attempt the staging process again.

Additional Information

vCenter Upgrade Fails with Error: "No such file or directory: patching_backup_config.json"