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but the polar flag was not set in the bdy_control namelist

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What is the issue in real.exe, the following is the error that is coming out of Version 4.2.2

(upto Version 4, everything is fine)

Domain 1: Current date being processed: 2019-08-05_00:00:00.0000, which is loop # 1 out of 145
configflags%julyr, %julday, %gmt: 2019 217 0.0000000E+00
d01 2019-08-05_00:00:00 Yes, this special data is acceptable to use: OUTPUT FROM METGRID V4.2
d01 2019-08-05_00:00:00 Input data is acceptable to use:
metgrid input_wrf.F first_date_input = 2019-08-05_00:00:00
metgrid input_wrf.F first_date_nml = 2019-08-05_00:00:00
d01 2019-08-05_00:00:00 Timing for input 2 s.
d01 2019-08-05_00:00:00 flag_soil_layers read from met_em file is 1
Max map factor in domain 1 = 0.00. Scale the dt in the model accordingly.
-------------- FATAL CALLED ---------------
Maybe this is a global domain, but the polar flag was not set in the bdy_control namelist.
Looks like the issue is either in geogrid or metgrid.

The file sizes from metgrid.exe are not uniform in 4.2.2 (unlike in upto version 4.0)

Am I seeing this correct?
I would like to apologize for the delay. I was out of the office last week and am trying to get caught up now. Thank you for your patience.

As for the polar flag issue, it's stating that it believes you are using a global domain, but you don't have the polar flag set in your namelist. To correct this, you simply need to add (in the &bdy_control section)
polar = .true.

This isn't a new piece of code (since 2017). Is your domain different than in previous simulations with older versions?

As for the file size difference with metgrid and geogrid output, since V4.2, by default, the compile uses the netcdf-4 compression capability, and because of this, the file sizes are no longer uniform in size. This is completely normal and okay.