1532i not joining WLC CT81K9

[hosamedin-abdelatty-external]

We have around 20 APs Model AIR-CAP1532I-E-K9 recently purchased and trying to deploy them in our network with WLC CT8510-K9. AP is getting IP but couldn't join WLC then it keeps rebooting. I have accessed AP by console and got the below

boot_method is set to IOS_BOOT, boot IOS bootloader in NOR flash

Loading .text @ 0x84000000 (208000 bytes)
Loading .rodata @ 0x84032c80 (39072 bytes)
Loading .data @ 0x8403c520 (3264 bytes)
Loading .data.rel.local @ 0x8403d1e0 (1084 bytes)
Loading .data.rel @ 0x8403d61c (124 bytes)
Loading .data.rel.ro @ 0x8403d698 (960 bytes)
Clearing .bss @ 0x8403da60 (161116 bytes)
Clearing .scommon @ 0x84064fbc (56 bytes)
## Starting application at 0x84000000 ...

IOS Secondary Bootloader - Starting system.HW Test Status(0)

Ath Nand ID: 95:80:f1:2c:00

Using driver version 1 for media type 2

Valid buffers 430

total430 430

success found all blocks

start end 65 82

found in range

high low end 2652 2089 82

Invalid version Number for sector = 1052719 read = 34989 expect =2221Xmodem file system is available.

mifs[0]: 213 files, 11 directories

mifs[0]: Total bytes : 131334144

mifs[0]: Bytes used : 27451392

mifs[0]: Bytes available : 103882752

mifs[0]: mifs fsck took 1 seconds.

Base Ethernet MAC address: 00:81:c4:88:61:20

Setup MAC....

Waiting for PHY auto negotiation to complete...Port 0 Negogiation success.

Ethernet speed is 1000 Mb - FULL duplex

Scorpion ----> F1 PHY *

: cfg1 0xf cfg2 0x7215

Loading "flash:/ap1g3-k9w8-mx.153-3.JC/ap1g3-k9w8-mx.153-3.JC"...##########################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################

bad mzip file, uncompressed to wrong length , (0x2424da4 != 0x24253e0)

Error loading "flash:/ap1g3-k9w8-mx.153-3.JC/ap1g3-k9w8-mx.153-3.JC"

Interrupt within 5 seconds to abort boot process.

Loading "flash:/ap1g3-k9w8-mx.153-3.JC/ap1g3-k9w8-mx.153-3.JC"...##########################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################################

bad mzip file, uncompressed to wrong length , (0x2424da4 != 0x24253e0)

Error loading "flash:/ap1g3-k9w8-mx.153-3.JC/ap1g3-k9w8-mx.153-3.JC"

Interrupt within 5 seconds to abort boot process.

Boot process failed...

The system is unable to boot automatically. The BOOT

environment variable needs to be set to a bootable

image.

ap1g3 Boot Loader (ap1g3-BOOT-M) Version 15.2(4)JB3b, RELEASE SOFTWARE (fc1)

Technical Support: http://www.cisco.com/techsupport

Compiled Thu 23-Jan-14 21:52 by prod_rel_team

ap:

[marce1000]

 - Note that the CT8510-K9 is long end of life and beyond support , if these APs you bought have an incompatible software version on them , then it simply may not work. And probably it then can't be fixed neither.
   As  you purchased AP's recently you should look for a modern controller based on the 9800 platform series
   The virtual version can be downloaded and deployed for free , but the APs must be licensed.

 M.

[hosamedin-abdelatty-external]

But There are 5 APs Model 1526 connected and working

[marce1000]

               >....But There are 5 APs Model 1526 connected and working
   - Then compare the software version on both working and not working with show version on the APs (e.g.)

 M.

[marce1000]

  - Added , possibly the only chance you may have for the 8510 is going to the last release
                 https://software.cisco.com/download/home/284493532/type/280926587/release/8.5.182.0
   and check if that can help , 

 M.

[hosamedin-abdelatty-external]

What about the error below

The system is unable to boot automatically. The BOOT environment variable needs to be set to a bootable image.

Thanks

[marce1000]

      >What about the error below
          The system is unable to boot automatically. The BOOT environment variable needs to be set to a bootable image.

                    (from your initial post)
                    >....
                    bad mzip file, uncompressed to wrong length

   The installed software looks corrupt or invalid on these APs, you may need to install the needed software
    again in them, 

 M.

[Rich R]

That means the AP flash is corrupted and the AP software is corrupted.  This was a common problem on old software and that software is very old!  You will need to format the flash and re-install the software as per https://community.cisco.com/t5/wireless-mobility-knowledge-base/access-point-rommon-recovery-ap-prompt-recovery-example/ta-p/3119495
The flash issues are documented at:
https://www.cisco.com/c/en/us/support/docs/field-notices/703/fn70330.html
https://www.cisco.com/c/en/us/support/docs/wireless-mobility/wireless-lan-wlan/213317-understanding-various-ap-ios-flash-corru.html

The last downloadable software version for the AP which will work with 8510 is:
https://software.cisco.com/download/home/284620606/type/280775090/release/15.3.3-JF15

The latest software available for 8510 is 8.5.182.12 - link below.  You will normally need a Cisco service contract to download that but because 8510 is already end of support (as Marce pointed out) you will not be able to purchase a new support contract.  Whoever you purchased the 8510 from might be able to help you.

Take note of the field notices below which may impact you.