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System Upgrade failure - Causes, Prevention & Recovery (Updated) by IPGuru
Posted: 4 Aug 04 (Edited 7 Jul 08)

Upgrade Failure = Dead IPO

As a number of posters have already discovered a failure in the upgrade process can result in a dead box this is the most common cause of returns to the Avaya repair centre, however recovery on site is possible.

Causes of upgrade Failure

1) Manager PC not having a fixed IP Address & loosing connection after firmware erase. This is the most common cause & should not be a problem after V2.1
2) Rouge network traffic causing data corruption during upload.
3) Trying to upgrade an IP403 from 1.X to 2.X without upgrading the monitor loader 1st (V1.99)
4) Some VPN clients can interfere with TFTP traffic (Symantec VPN client and Checkpoint Secure Remote Client are known to cause problems.)

Prevention of failure (prevention is better than cure)

1) Ensure the manager PC has a fixed IP address – if you do not know a spare IP addr. Get one using DHCP then set this as your fixed IP addr.
2) Disconnect all other network connections from the IPO.
3) Download a current copy of the CFG,
4) Make sure the bin file directory is correct for 1.x this is the same as the working directory for the cfg's for 2.X it can be set differently
5) Temporarily disable your VPN software in network properties


If you already have a bootp entry for the system  (this will be created when you download the CFG- told you it was a good idea): -
1) Make sure your manager PC is on a fixed IP addr. On the same subnet & physical network to the IPO (again this IS the biggest cause of error)
2) Set the IP address of manager to (File/preferences/Edit)
3) Select View/TFTP Log
4) Reboot the IPO, you should see the IPO download the BIN file (or die trying)

If this fails you will need an RS232 cable & HyperTerminal or similar

1) If you do not have a bootp entry watch the TFTP Log above to identify the MAC address of the IPO it will be 00e007XXXXXX
2) Create a bootp entry as follows:
Mac address – as above
IP address
Bin file       ip401.bin/ip401ng.bin/ip403.bin/ip406.bin/ip412.bin system dependent.
If using V2.1 make sure the bootp entry is enabled
3) Set the manager PC's IP address to
4) Connect the RS232 cable to the DTE port & start HyperTerminal at 38400,n, 8,1
5) Reboot the IPO & press escape
6) Type the following commands AT-X2 <RETURN> AT-X3 <RETURN> & if a V2.0+ IP403 AT-X4, this will erase the cfg from the system.
7) Type AT-X <RETURN> this will erase the bin file from the system. If manager has been left running the system should download the bin file & restart.
8)    Restore the Backup CFG

If the download does not start check the bin file directory is correct & reboot the IPO.

I would recommend to all IPO engineers that you try this procedure on a safe system before it happens in the real world.

1st use HyperTerminal to erase the bin file on a default system that you are able to talk to, & then repeat after deleting the bootp entry. Once it has been done a couple of times an upgrade fail is no longer a scary situation, a system with a good backup should easily be recovered in 30 min (including a 15 min tea break).


V2.1 introduced an update to the upgrade wizard- Validated Upgrade.
This transfers all bin files to the IPO & checks for corruption before proceeding with the upgrade & prevents the dead box scenario & will even function over remote links if necessary.

This is the preferred option for all V2.1+ systems

* Various System units now require a 2 stage upgrade *
* Depending on the software level, please check the  *
* Avaya release notes carefully.                     *
* attempting to upgrade direct to the final release  *
* Will Cause th3e upgrade to fail                    *


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