"Communication error during data transfer" attempting firmware download to AC800M controllers
Getting "Communication error during data transfer" Pop-up error when downloading firmware for AC800M, while reverting from SV5.1 FP4 firmware to an earlier firmware version, i.e. SV5.1 Rev C or SV5.0 SP2 Rev E
Can no longer downgrade the firmware using the Control Builder Path: Tools -> Maintenance -> Show Remote Systems -> Show Firmware Information: If FP4 fimrware is currnetly installed in the controller, will throw a Pop-up error : "Communication error during data transfer" while attempting to download the firmware to an earlier version of firmware
This is done by design. The downloading format has changed in SV5.1 FP4. The firmware cannot be downgraded to a SV5.0 or SV5.1 Rev C or earlier version. Resolution:
The work around is to use the Serial Firmware Upgrade tool or the use of the CF/SD Memory Card to revert the firmware to a previous version.
The tool can be found by going to Programs -> ABB Industrial IT 800xA -> Engineering -> Utilities -> Serial Firmware Upgrade
For PM891, the only method is to use the SD card.
Upgrading Controller Firmware from a CF/SD card
When a controller is started, or when a long reset is done, the execution starts in the Boot Loader. While starting, the controller checks for any inserted CF card or SD card. If a card is present, then the controller checks for valid firmware in it. If valid firmware is found, it will be used for upgrading the current firmware.
1. Insert the CF card or SD card in the card reader slot of the CPU and Power-On.
2. Perform a Controller Reset, by pressing and holding the INIT button till the green Run LED starts flashing.
3. Release the INIT button to start the loading firmware. The process to load the Firmware starts, and the Run and the Battery LEDs indicate the progress.
At the end of the operation, the hardware reset starts the newly programmed system.