Upgrading ESXi to Version 7.0: A Personal Experience and Lessons Learned

As part of my ongoing efforts to ensure the reliability and performance of my NUC cluster, I recently upgraded from ESXi version 6.7 to 7.0. While the upgrade process was generally smooth, I encountered an issue related to available space on the system disk(s). In this blog post, I will share my personal experience with the upgrade process and provide some lessons learned that may be helpful to others.

Background and Reasoning

I have chosen to install ESXi on a USB device because I needed to use both internal disks (2) for vSAN when required. This setup allows me to have a separate boot drive for the ESXi installation, which is recommended by VMware to ensure better performance and reliability. However, this configuration also introduced some challenges during the upgrade process.

Issue with Available Space on System Disks

During the upgrade process, I encountered an error message indicating that there was not enough available space on the system disks to complete the installation. This was a bit surprising, as I had plenty of free space on both disks. However, after some investigation, I realized that the issue was related to the fact that the USB device containing ESXi was also used as a data store for vSAN.

Solution and Lessons Learned

To resolve this issue, I performed the following steps:

1. Removed all vSAN data stores from the USB device.

2. Upgraded ESXi to version 7.0.

3. Added the USB device as a new vSAN data store.

Here are some lessons learned from this experience:

1. Always ensure that you have enough available space on your system disks before attempting an upgrade. This includes both the ESXi installation disk and any other data stores used by vSAN.

2. When upgrading from version 6.7 to 7.0, removing “store.old” is not necessary, as the new version will overwrite the existing filesystem and remove the old store.old folder automatically.

3. If you are using a USB device for both ESXi installation and vSAN data storage, make sure to remove all vSAN data stores from the device before upgrading ESXi. This will ensure that there is enough space available on the system disks to complete the upgrade.

4. After the upgrade, re-add the USB device as a new vSAN data store to ensure continued performance and reliability.

5. When encountering issues during an upgrade process, consult the official VMware documentation and community forums for assistance. This can help you identify and resolve any potential issues before they become critical.

Conclusion and Future Plans

In conclusion, upgrading ESXi from version 6.7 to 7.0 can be a bit challenging, especially when using a USB device for both installation and vSAN data storage. However, with careful planning, attention to detail, and the right troubleshooting skills, it is possible to resolve any issues that may arise.

For my future plans, I have decided to install ESXi directly on the disks of my NUC cluster, rather than using a USB device. This will ensure better performance and reliability, as well as eliminate any potential issues related to available space on the system disks. Additionally, I plan to re-evaluate my vSAN configuration to ensure that I am using the most optimal storage layout for my needs.

In summary, upgrading ESXi to version 7.0 can be a bit challenging, but with careful planning and attention to detail, it is possible to overcome any issues that may arise. By sharing my personal experience and lessons learned, I hope to help others who may encounter similar challenges in the future.