Mate3s upgraded to 1.5 and lost network interface

[CaribSnake]

My Mate3s had firmware rev 1.004.006 from the time I purchased it. I thought some of the changes in rev 1.005 may improve monitoring of my LFPO4 battery. I downloaded the rev from the OB site and followed the "menu-driven" upgrade procedure. Nothing said about stopping anything or unplugging anything.
After the reboot, I discovered that the OpticsRE site told me my Mate3s was offline. Rebooted a few times before checking the router to find that there was no signal coming from the Mate.

So, questions: Has anyone else had problems with their network interface post rev 1.005 upgrade? Can I safely roll back to my previous rev.? Any suggestions?

[raysun]

Version 1.5 is only meant for use with Mate3s attached to Outback's new battery system. If installed otherwise it disables the ethernet processor.
Hopefully a previous version can be installed to restore functionality.
Try 1.4.7.

[CaribSnake]

Oops ... guess I was sloppy on the research/planning end of that one! That was not at all obvious on the site.
Thanks for the info ...
I have 1.4.6 ,,, rev 1.5 is the only one I could find on the OB site. Where else might I find the 1.4.7?

[raysun]

Oops ... guess I was sloppy on the research/planning end of that one! That was not at all obvious on the site.
Thanks for the info ...
I have 1.4.6 ,,, rev 1.5 is the only one I could find on the OB site. Where else might I find the 1.4.7?

1.5 was published without any warning it was "special purpose".

1.4.7 here:
MATE3s Firmware Updates - OutBack Power Inc https://share.google/DEJX4cdvlhdRRWMBW

[CaribSnake]

OK ... I typed the last mesg before I thought. Located rev. 1.4.7. In my defense, I DID read the rev 1.5 Readme file. I installed because I thought it may supply more options for addressing needs of the LFPO4 battery. The file said nothing about doing anything to the network interface. I guess installing w/o further research was thoughtless of me ... but it was incredibly thoughtless of the engineer(s) who packaged/published the rev. without mention of the implications. And the plot sickens ...

I obtained rev 1.4.7 and, in the process, read discussion about needing to do multiple installs to get both the main and the comm processors updated. Some even suggested that using the "boot loader" method might be better. That did not seem to apply in my case, since update of the interface was attempted (see discussion below).
Extracted the .zip file for the rev. directly to newly formatted SD card.
Two bin files were included in the package:
M3s.bin
M3sEth.bin
So, I attempted (several) reinstalls, both with and without the network interface being connected to my router.
I got
"Reading Files"
"Wait Ehternet Processor Init"
"Ethernet Processor Timeout"
"Updating Main Processor"

The Mate3s menu option I have not tried is "Reset Factory Defaults" ... but I'm reticent to do that w/o a pretty clear indication of how that would help. This hole I've started is getting deeper.

[raysun]

Its unfortunate that Outback's artempt to retrofit their new battery into the legacy architecture has left broken installations in its wake. It is concerning that this may be the tip of the iceberg, but we have no way of knowing.

At this point, I'd suggest contacting Outback tech support via their chat service, and see if they can offer help.

[CaribSnake]

I searched the forum for Mate3s rev 1.5 upgrade but didn't get much ... then this AM, there was a post from Jan 6, front and center! Same problem. Seems that OB has been aware of the problem for at least 4.5 months. In that thread was the same suggestion as yours (found it after I added a rant .
Anyway, I used the chat feature and recited my problem. I was told they were aware of the problem and were addressing it (how hard is it to add a line of text to the Mate3s firmware page? ... and to the Readme file?). Moreover, they have agreed to remedy my specific issue, directly.
When a replacement is in hand, I will sing "Kim R's" praises. Until then, I'm just cautiously optimistic.
Thanks for steering me through this.

[raysun]

At this point I'm ready to recommend Kim R. for sainthood.

[Specialist]

Mate3S Firmware Release v1.5.2
================================

OVERVIEW
--------
Firmware v1.5.2 includes a special two-phase update process for all Mate3S products.

A software defect was identified in the firmware updater used by existing Mate3S devices. Because of this, the standard one-step firmware update process must not be used for this release.

This package includes a corrective update process that works across both Mate3S hardware variations:

- Phase 1 bootstraps the MAIN CPU to repair the firmware updater logic.
- Phase 2 uses the repaired updater to successfully update both the MAIN CPU and Ethernet CPU.

WARNING
-------
This firmware must be installed in two phases.
Failure to follow the required update sequence may brick the device.

COMPATIBILITY
-------------
This update applies to:

- All Mate3S products
- Both known Mate3S hardware variations

IMPORTANT UPDATE REQUIREMENTS
-----------------------------
Before starting, ensure the following:

- Use a FAT32-formatted SD card
- SD card capacity must be 32 GB or less
- Complete Phase 1 first, then Phase 2
- Do not proceed to Phase 2 if Phase 1 reports an error

FIRMWARE UPDATE PROCEDURE
=========================

PHASE 1 — Repair the Firmware Updater on the MAIN CPU
-----------------------------------------------------
1. Copy all files from the Phase 1 directory to the root directory of the SD card.
2. Safely unmount or eject the SD card from the PC.
3. Unplug the Mate3S Hub/Device cable.
4. Insert the Phase 1 SD card into the Mate3S.
5. While holding the PORT or UP button, reconnect the Hub/Device cable.
6. Wait for the LCD to confirm:

MAIN cpu is "Programmed Successful."

7. If an error is displayed:
- Correct the issue before continuing
- Do not proceed to Phase 2

8. After the MAIN CPU update completes successfully, remove the SD card.

PHASE 2 — Update the MAIN CPU and Ethernet CPU
-----------------------------------------------
1. Insert the SD card back into the PC.
2. Copy all contents of the Phase 2 directory to the root directory of the SD card.
3. Safely unmount or eject the SD card from the PC.
4. Insert the SD card into the running Mate3S.
5. Navigate to:

Lock -> 141 -> Firmware Update -> MATE3s

6. If the next screen displays:

SD-Card not found

return to the main screen and wait for the SD card icon to stop blinking.

7. If the screen displays:

New Version 00x.00x.00x

press the Update button.

8. Monitor the update screens and confirm that no errors occur.
- If an error appears during this phase, repeat Phase 2.

POST-UPDATE VERIFICATION
------------------------
After the Mate3S reboots:

1. Navigate to:

Lock -> 141 -> Settings -> System -> Firmware Versions

2. Verify that:
- MAIN firmware version is 1.5.2 or greater
- Ethernet firmware version is 1.5.2 or greater
- Both versions match

RECOVERY / ROLLBACK NOTE
------------------------
Returning to a previous firmware version is not recommended.

QUICK REFERENCE
---------------
1. Prepare FAT32 SD card (32 GB or less)
2. Copy Phase 1 files to SD card root
3. Run Phase 1 using PORT or UP button during cable reconnect
4. Confirm MAIN CPU reports Programmed Successful
5. Copy Phase 2 files to SD card root
6. Run update from Lock -> 141 -> Firmware Update -> MATE3s
7. Verify both MAIN and Ethernet are 1.5.2 or greater





********************************************************************************
1.5.2 changes:
********************************************************************************
Release date:
- Mar 2026

SPECIAL INSTRUCTIONS:

- Update this flash in two steps.
- 1st unplug hub cable from Mate3s, insert SDCARD with this firmware installed,
and hold down PORT or UP button when reinserting hub cable
- Make sure the LCD shows the Mate3S is performing update of the Main CPU.
- After unit reboots, perform normal SDCARD firmware update to program the
Ethernet processor and Main processor.
- After this update returning to an older firmware is not recommended.

Bug Fixes:

- Stability fixes to Ethernet Processor
- Fixes related to infield flashing of Ethernet Processor

Known Issues:

- Satellite Modems. Systems using a satellite modem may lose connectivity to
Optics.

- Calibration. When updating from 1.4.0, please check your calibration settings
(especially for FNDC) to make sure they have not changed and that they are in range.

Enhancements:

- None

[CaribSnake]

Well, OB came through with a replacement for my "communicationally challenged" Mate3s. Thanks to Kim for helping me out with this. My biggest hassle was getting it through customs. Their opinion: You owe duty/taxes/fees on VALUE.

Now on to making the swap:
It's been a long time since I did a backup/restore ... and never across revisions. I'd like to be able to save my current configuration and restore it on the new Mate, but I'm not sure just how much info the backup contains. Is it just the settings data or may some of the effects of the rev 1.5 "upgrade" be saved as well. I.e. Is it safe to do a backup and restore it to the new Mate or should I go through all the screens and write down what I need and set everything manually?

[raysun]

I never trusted backup/restore to work properly without going through and checking all the values anyway.
It only backs up the configuration data. Several folks use it to make seasonal changes so it does work AFIK.
Also, once the new unit is updated with the configuration data, it might be fun to set it aside and try the 1.5 installation technique posted above by @specialist on the dead unit to see if if reserects it. This is the season for that, you know.
Finally, with the new unit installed DO NOT register it in OpticsRE or you will lose access to the existing historical data (though that may be less important with Outback hacking it to the last 6 months only.) If you want to keep the historical data in Optics, contact Kim and ask they manually add the new Mate's MAC address to your account.