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Not sure if this is a permanent solution but I have found that for those VMs that report "Disk consolidation needed" after VDP appliance backup, if you check the VDP appliance hardware configuration you may see that there are extra VM's disk files attached to the appliance.
It looks like the VDP backup appliance takes a snapshot, attaches the target VM disk to itself temporarily and then makes the backup.
After the backup it is supposed to release/dismount the VM disk and consolidate the snapshot (since it was backing up a running VM), but sometimes it fails to do so.
The VM disk remains locked in a snapshot mode.
Attempting to do a manual snapshot consolidation fails because the VDP appliance has an open file handle of the VMDK.
When I look at my own VDP backup appliance in vCenter, I have seen sometimes up to two extra VM Hard disks mounted.
The solution is easy: Just click the Remove button to dismount them.
I can then successfully do a snapshot consolidation procedure to clear the warning message.
The problem seems to be intermittent for me but when it happens the above described procedure to release the disk solves the problem.
in the attached screenshot I have seen Hard disk 8 and Hard disk 9 for some of the backup target VMs.
Hope this helps.
Anthony Maw, Vancouver, Canada