Unable to upgrade Catalyst 2960 through USB

[JAISONTHOMAS]

Folks, I am trying to upgrade a 2960-x using USB, I have formatted the drive to FAT16 and copied the files c2960x-universalk9-mz.152-7.E12.bin and c2960x-universalk9-tar.152-7.E12.tar.

However when inserting the USB stick into the switch, I am getting the following error,

Sw_test1#
Jul 5 15:41:07.477: %USBFLASH-4-FORMAT: usbflash0 contains unexpected values in partition table or boot sector. Device needs formatting before use!
Sw_test1#
Jul 5 15:41:07.477: %USBFLASH-5-CHANGE: usbflash0 has been inserted!
Sw_test1#

Sw_test1#copy usbflash0:c2960x-universalk9-mz.152-7.E12.bin flash:
Destination filename [c2960x-universalk9-mz.152-7.E12.bin]?
%Error opening usbflash0:c2960x-universalk9-mz.152-7.E12.bin (Invalid DOS media or no media in slot)
Sw_test1#

Any idea whats going on and how to sort this? Thank you.

[marce1000]

  - The USB stick is corrupt ; try another one , or format it first as was pointed out,

  M.

[JAISONTHOMAS]

tried another usb

Formatted it to fat16

same error

[Leo Laohoo]

What firmware is the switch currently on?

[JAISONTHOMAS]

Switch Ports Model SW Version SW Image
------ ----- ----- ---------- ----------
* 1 54 WS-C2960X-48LPS-L 15.2(7)E10 C2960X-UNIVERSALK9-M

[Leo Laohoo]

Use a different brand of USB flash drive.  Preferably, 8Gb or smaller.

[marce1000]

  - @JAISONTHOMAS   Have a try with   fat32

  M.

[Leo Laohoo]

---

@JAISONTHOMAS wrote:
Device needs formatting before use!

---

I strongly recommend using the switch and formatting the USB flash drive.  

---

@JAISONTHOMAS wrote:
copy usbflash0:c2960x-universalk9-mz.152-7.E12.bin flash:

---

And I would never recommend anyone "copy the BIN file" as a method to upgrade the switch firmware.  Download the TAR file and use the following command:  

archive download-sw flash:filename.tar

[JAISONTHOMAS]

@marce1000 @Leo Laohoo  At this point, I am convinced that its not an issue with the USB stick. Because I have formatted the same stick to FAT32 and upgraded a Catalyst 9200 successfully. So I will try 2960 as well with FAT32 and update you folks. Cheers

[marce1000]

 - @JAISONTHOMAS   If the problem persists , try the same USB on your PC and check if you get the same errors or not,

  M.

[pieterh]

can you try formatting  the usb IN the 2960 switch ?