Just a quick guess. Did you set DRS to manual prior to starting the upgrade/deployment to ensure that Initial Placement kick in, and migrate the newly created vCSA to another host?
I DID set DRS to manual, but I have not tried another host! I also noticed that when I signed into the vCenter admin console (port 5480) that there was an update so maybe one of these will fix the issue? I'll give it a go, thanks!
Oh, and I tried the upgrade about 4 times so far and the exact same thing happens each time.
I logged into the console of the new appliance and this is what I see:
So I logged into the new vCenter server console and opened the "/var/log/vmware/upgrade/upgrade-requirements.log and found the following:
So, it seems that the new appliance cannot contact the host? I tried to ping the host by IP and it did not resolve so I may be able to fix.....
So, I fixed the issue. Not only does the installer need access to both the host management network but so too does the newly created vCenter server, so I created a new VMKernel port group on the standard switch, and configured the VMKernel port group for management traffic and gave it an IP on the same subnet as the vCenter server. In essence, this creates a new entry point to the host and bridges the vCenter server network to the host's management network!
I completed the upgrade with this change! Thanks all for your help.