How to expand a protected volume to beyond 2TB. (Prevent VPG from “Needs Configuration”)

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By default, expanding a protected volume to a size beyond 2TB will result in the VPG entering "Needs Configuration" state and the VM will have to be re-added. (Results in delta-sync)
An administrator may want to prevent that behavior and enable expanding disks to over 2TB without resulting in unnecessary syncs.

As ESXi 5.5.x and 6.0.x do not support hot disk expansion above 2TB. (Volume expansion of a powered on VM). Please see the NOTE below for ESXI 6.5 and above.
The VRA on the target site, which can only perform a hot-expansion, will not be able to expand the disk. Therefore, the protected and mirror volumes will not match in size. For more information on this VMware limitation see:

NOTE: VMware limitation has been changed if the user is running ESXi 6.5 and above versions. Important: Hardware Version 13 (vHW 13) is not required for this to work – therefore just the vSphere platform and not the VM has to be upgraded.

  1. Verify the recovery disk is on a VRA-H and not a VRA. If not on VRA-H:
    1. Open the tweaks.txt file located in the ZVR folder on the ZVM. (Default location is: C:\Program Files\Zerto\Zerto Virtual Replication)
    2. Enter the following tweak in a new line: "t_maxDiskboxVolumesAllowedOnVra=0". (Only what's in the quotation marks)
    3. Restart the Zerto service on the ZVM.
    4. Change recovery VRA for the VM and then change back:
      1. On the Zerto GUI, under the "Setup" tab, choose "Change VM Recovery VRA" on the relevant VM.
      2. Select a different VRA and click done.
      3. After a successful change, repeat step 1+2 to revert to the original VRA. (Not a necessity)
  2.  Turn off the VRA-H that has the disk.
  3.  Resize the disk on the protected source VM. 
  4. Wait for the VPG to finish updating. 
  5. Turn on VRA-H. 

Affected Versions:
ZVR 4.0Ux and earlier ZVR 5.0U1 and greater

VMWare (ESXi 5.5.x, ESXi 6.0.x)

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