AP9640 firmware update from EcoStruxureIT failure rate

[DavidYerger]

Two days ago, I initiated a firmware update to version 2.4.0.11 for 50 NMC3's using the Management->Firmware Update section of EcoStruxureIT - 

Of the 50:

5 showed "Unable to verify binary image" in the logs - of which 

    3 became unresponsive (found to be stuck at the BM> prompt, had to reformat and reconfigure on site)

    1 was accessible but had reverted (to 2.2.1.1)

    1 seemed to have upgraded OK

The rest upgraded with no issues.

If doing a format (and reset) at the BM> prompt causes the card to work again, with the intended firmware version (2.4.0.11), what could have happened?  Is there a separate configuration partition that had become corrupted?  Could bad flash cells cause this?  Is there a way to check the installed firmware checksum, or is this done automatically?  

[reej]

Same issues here with EcoStruxureIT and also with the offline upgrade utility from APC.

More problems with v3 nmc then v2 cards.

Other brands have secondary/backup flash rom, when there is a failed firmware issue you can still boot on the old firmware.