Resolving Siemens IM 152-1 ET 200iSP Firmware Update Error

1. Problem Description

The ET 200iSP IM 152-1 interface module (article number 6ES7152-1AA00-0AB0) with hardware version 3 rejects a firmware update partway through transmission. The error manifests during STEP 7 / SIMATIC Manager online update as:

Reported error: "File not accepted by module"

The update operation reaches the IM 152-1 over PROFIBUS, the module begins to receive the new firmware file, then aborts mid-transfer without completing the flash procedure. The IM 152-1 returns to its prior firmware state (V2.04 in this case) without becoming bricked, but the new firmware (V2.05) is not applied. The same fault is reproducible across multiple IM 152-1 modules of identical article number and hardware revision on the same PROFIBUS segment.

This issue is specific to the PROFIBUS variant IM 152-1 (6ES7152-1AA00-0AB0). Users of the PROFINET variant IM 152-1PN follow a related but distinct procedure documented separately by Siemens.

2. Affected Hardware and Firmware Identification

Verify the exact MLFB and firmware baseline before applying any workaround. Navigate in HW Config to the IM 152-1 slot, right-click → Object Properties → Diagnostics, or read the diagnostic buffer (path: PLC → Module Information → Diagnostic Buffer) to capture the current article number, hardware release, and firmware version string.

3. Root Cause Analysis

The "File not accepted by module" message is a generic firmware-loader rejection returned by the IM 152-1 bootloader. On the ET 200iSP platform this loader performs a strict, sequential check of three preconditions before accepting the firmware container:

1. Article-number match: The firmware file's embedded MLFB must exactly match the MLFB printed on the module's front label.
2. Hardware-version compatibility: The firmware must be marked as compatible with the module's hardware revision. Siemens explicitly states that "when an update of the firmware is performed, it is always necessary to update to the latest version available for the respective article number." This rule implies a one-way compatibility path: certain later firmware versions may drop support for very old hardware revisions.
3. Container integrity: The file must arrive without transport-layer truncation (PROFIBUS telegram loss, CRC errors, or timeout).

For the reported case (HW V3, target firmware V2.05) the most probable root cause is incompatibility between firmware V2.05 and the hardware revision 3 module. Siemens' firmware versioning policy for the IM 152-1 reserves the same firmware train for compatible hardware releases, but when Siemens publishes a new minor revision they occasionally tighten the minimum hardware baseline. The December-2007 success on V2.04 does not guarantee V2.05 acceptance because the HW V3 module's bootloader was produced before the V2.05 acceptance window opened.

4. Update Variant Selection

Siemens documents three firmware-update variants for the IM 152-1. The selection is not arbitrary: the failed variant must be abandoned for a different path; do not retry the same variant repeatedly.

Reference: Operating System Updates for IM152-1 (Siemens Support ID 21344491).

5. Solution 1: MMC Memory Card Update Procedure

The MMC route is the most reliable fallback when an online update is rejected mid-stream. The MMC carries the firmware image directly to the IM 152-1's onboard slot; the bootloader reads from the card rather than over PROFIBUS, eliminating transport-layer truncation as a failure mode.

5.1 Prerequisites

• SIMATIC Micro Memory Card (MMC) with sufficient free capacity (typically 2 MB or larger).
• Field PG or programming device with MMC writer and STEP 7 installed.
• The .UPD firmware file for firmware V2.05 (or whatever target Siemens confirms compatible with HW V3).
• If the target firmware is genuinely incompatible with HW V3, a different target firmware must be selected before proceeding. Confirm the target via the readme or via Siemens Support.

5.2 Step-by-Step Procedure

1. Insert the MMC into the programming device's MMC slot.
2. Open STEP 7 / SIMATIC Manager and select File → Memory Card → Update Firmware on Memory Card (the menu text varies slightly between STEP 7 versions).
3. Browse to the .UPD file matching the IM 152-1 article number 6ES7152-1AA00-0AB0.
4. Confirm the article-number check; STEP 7 will reject a mismatched file.
5. Write the firmware to the MMC. Verify the file is written without error.
6. Power down the ET 200iSP station at the hazardous-area-approved power isolator; observe the Ex-relevant safety time before opening the enclosure.
7. Insert the MMC into the IM 152-1's MMC slot with the correct polarity (label side facing outward per module marking).
8. Restore power to the station. The IM 152-1 detects the MMC, validates the firmware, and flashes the image to internal flash.
9. Observe the SF and BF LEDs; refer to Section 8 for the LED matrix.
10. After the flash completes (BF may blink during the procedure, then go off), remove the MMC.
11. Read back the firmware version via PLC → Module Information → Diagnostics to confirm.

6. Solution 2: PROFIBUS Online Update (Variant 3)

When the STEP 7 menu-driven update (Variant 1) aborts, an alternate online procedure documented as Variant 3 in the Siemens firmware-update documentation can be attempted. Variant 3 uses a different transfer sequence and is more tolerant of timing issues on degraded PROFIBUS segments.

6.1 Procedure

1. Verify PROFIBUS health: open PLC → Diagnostics → PROFIBUS Diagnostics in STEP 7. Bus error rate must be zero; otherwise correct the segment first.
2. Confirm the CP type and slot; the engineering station routes through the CP 443-1 to a PROFIBUS CP in the S7-400 backplane. Both CPs must be in RUN with no diagnostic entries.
3. In HW Config, select the IM 152-1 station and choose Target System → Update Firmware as in Variant 1, but in the subsequent dialog select the PROFIBUS update variant explicitly if STEP 7 offers the choice.
4. Increase the PROFIBUS retry count in the dialog if available; some STEP 7 SP revisions allow a "robust transfer" option that raises the telegram retry budget.
5. Monitor the transfer window; do not interrupt. A typical V2.x firmware image is 1.5 to 2 MB and transfers in 2 to 10 minutes depending on PROFIBUS baud rate (1.5 Mbps typical, 12 Mbps supported).

6.2 PROFIBUS Baud-Rate Reference

7. Solution 3: HW Config Re-targeting

If the firmware truly is incompatible with HW V3, the only path to V2.05 is hardware replacement. The compatible successor article number is documented in the Siemens catalog; for the IM 152-1 family the migration path typically ends at the latest MLFB of the same family with HW revision ≥ the minimum required by V2.05. The replaced module must be returned through RMA; confirm via Siemens Support.

8. Error Code and LED Reference

Diagnostic buffer entries for firmware rejection typically carry event ID 0xE2FE or similar with detail text "Firmware file rejected — incompatible hardware revision" or "Firmware file checksum error." Capture the buffer contents with timestamp before contacting Siemens Support.

9. Hardware-Version Compatibility Logic

Siemens' firmware policy for the IM 152-1, as stated in the official ET 200iSP firmware-update support entry, is: "always upgrade to the latest version that is available for the respective article number." This applies to the PN variant as well, where the rule is identical.

Reference: Firmware Update: ET 200iSP Interface Module IM 152-1PN (Siemens Support ID 109825299) and Firmware-Update: ET 200iSP Interfacemodul IM 152-1PN (German, Siemens Support ID 109982549).

The practical decision tree for an engineer confronted with a "File not accepted" error:

10. Verification Procedure

After every firmware update — successful or aborted — perform these checks before returning the module to production service.

1. Confirm the new firmware version string in PLC → Module Information → Diagnostics. The "Firmware version" field must reflect the target.
2. Confirm HW version, MLFB, and serial number unchanged.
3. Read the diagnostic buffer; it must be empty of error events.
4. Force I/O update on the ET 200iSP station; verify all I/O modules report OK in HW Config.
5. Trigger a brief stop/start of the PROFIBUS slave; verify cyclic data exchange resumes without re-init.
6. Run a 30-minute burn-in with all I/O channels exercised. Monitor SF and BF LEDs.
7. Document the new firmware version, update date, technician name, and STEP 7 project revision in the plant's change log.

11. Service Request Path

If the firmware file is genuinely incompatible with HW V3 and the engineer cannot identify an alternate compatible firmware train, open a Siemens Service Request through the official Siemens Industry Online Support portal. Include:

• Full MLFB (six-digit MLFB including the -0AB0 suffix): 6ES7152-1AA00-0AB0
• Hardware version: 3
• Current firmware: V2.04
• Target firmware attempted: V2.05
• Exact error text from the diagnostic buffer
• STEP 7 version and service pack (e.g., STEP 7 V5.5 SP4)
• CP 443-1 firmware version and PROFIBUS CP firmware version
• Plant serial number and module serial number

Siemens Customer Support can confirm whether an intermediate firmware exists that bridges HW V3 to a different update train, or whether module replacement is mandatory.

12. Preventive Measures and Best Practice

• Read the readme before flashing. Every Siemens firmware package ships with a readme.txt listing the minimum hardware revision. Skipping this step is the single most common cause of "File not accepted" errors.
• Maintain a firmware matrix in the plant documentation. Track MLFB, HW version, current FW version, and last update date for every IM 152-1 in the fleet.
• Standardize on MMC updates for HW V3 modules. The MMC path eliminates PROFIBUS transport variables and gives a deterministic result.
• Never interrupt power during a firmware flash. The IM 152-1 bootloader protects against partial flashes but a hard power loss can still leave the module in bootloader recovery mode, requiring an MMC re-flash.
• Plan updates during scheduled shutdowns. Firmware updates may briefly interrupt cyclic I/O even when successful.
• Keep STEP 7 current. Older STEP 7 SPs may not recognize newer firmware container formats; Siemens recommends the latest SP level for the deployed STEP 7 version.
• For ET 200iSP stations in Ex zones, observe the plant's hot-work and permit-to-work procedures. The IM 152-1 is hot-swappable only within its Ex certification envelope.

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