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Why are we getting Free flash: file system space errors when trying to upload controller images into our VX9000?

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TitleWhy are we getting Free flash: file system space errors when trying to upload controller images into our VX9000?
Question
Why are we getting Free flash: file system space errors when trying to upload controller images into our VX9000?
Environment
  • VX9000
  • RFS4000
  • WiNG 5.9.3.3
  • ESXI versions 5.0, 6.5, 6.7
  • TFTP, FTP
  • VMWARE
Answer
If the process of uploading controller firmware images into the VX9000 for adopted controller upgrade fails, check the logs for possible cause:
vx9000-A31F8C#show log
Logging module: enabled
    Aggregation time: disabled
    Console logging: level warnings
    Monitor logging: disabled
    Buffered logging: level warnings
    Syslog logging: level warnings
        Facility: local7

Log Buffer (2250539 bytes):

Jul 17 08:50:44 2019: vx9000-B30388 : %DIAG-4-FREE_FLASH_DISK: Free flash: file system space, 1.1% is less than limit 90.0%
Jul 17 08:44:44 2019: vx9000-B30388 : %DIAG-4-FREE_FLASH_DISK: Free flash: file system space, 9.1% is less than limit 90.0%
In this case the issue is linked to file system space. Start by checking the available storage size in Flash:
vx9000-A31F8C#show file systems
File Systems:

Size(Mb) Free(Mb) Use% Type  Prefix
68        59      13   flash nvram:
68        53      21   flash flash:
98451     93259   5 -  vmsdb:
98451     93259   5    flash internal (/vms)
If the storage Size(Mb) in flash flash is not enough to store the controller firmware image/s to start with (shown above only 68 Mb), you will get this error and the upload process will fail.
Increasing the storage space in ESXI will probably not make any difference. If you had allocated enough storage space during the installation process but still encountered this issue then the problem might be with the VMWARE ESXI version being used. If an older version (5.0 for example) is being used, start by upgrading it to the latest available build (we tested with both versions 6.5 and 6.7 without issue), then uninstall your current VX9000 installation and install it anew. Recheck available flash storage size once done:
vx9000-A31F8C#show file systems
File Systems:

Size(Mb) Free(Mb) Use% Type  Prefix
68       59       13   flash nvram:
19233    18083    5    flash flash:
59127    55942    5 -  vmsdb:
59127    55942    5    flash internal (/vms)

Related articles:
How to remove AP firmware images from the controller once not needed anymore
AP free file system space less than limit 90.0 percent
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