[Solved] Unable to update firmware  

Not sure I understand the procedure you describe but the correct way to upgrade Mini firmware is described here: https://help.prusa3d.com/en/guide/how-to-update-firmware-mini-mini_128421/

TL;DR: Copy the downloaded .bbf file to the root of a USB stick, stick it into the mini, then reboot.

That's what I did, and more

Yes that's exactly what I did, I also tried playing with the updating settings in the printer.

The printer simply ignores the update.

You know that file you downloaded needs to be unpacked (un-zipped) first, right?

Firmware 4.3.2 Successfully installed

Fischex - I had the exact same problem.... I got my new mini+ with 4.3.1 installed on it. My mini+ was actually giving me an error #12610 (saying that the firmware/printer versions don match and to go and make sure I had the correct firmware for my printer). Confusing! So I decided to try and flash the system backward to 4.3.0, see if that worked, and then climb back to to 4.3.1, and then 4.3.2.  I did this and it seemed to have solved my problem:

1. One thing I made sure I did, was I reformatted my USB stick again, and made the "Allocated Unit Size" 2048 bytes (instead of 4096 bytes - which is what I think was set with the USB stick that came with the mini+).

2. Next, I downloaded the .BBF .zip file, then I clicked to "open" .zip file. (I did all of this from the bottom bar in my web browser)

3. Next, I dragged and dropped the file to my desktop

4. Next, I opened file explorer up

5. Next, I dragged and dropped the newly downloaded .BBF file onto the USB drive (as it is listed in the left hand portion of the file explorer window).

6. Then, I selected to eject the drive

7. I plugged the USB into the mini+, hit restart button, and when the first PRUSA screen comes up, push the button wheel, and the flash process was successful for each version I did (going downward to 4.3.0, then back upward to 4.3.1, and then upward again to 4.3.2).

Let me know if this works!

RE: Unable to update firmware

I ran into this problem as well.  If anyone is still attempting to upgrade I used a few extra steps in order to get mine to work.  For each step I had to reformat the drive with "Allocated Unit Size" 2048 bytes.

First I downgraded to 4.3.0 with freshly formatted 1GB USB drive.  "prusa3d_fw_4_3_0_MINI.bbf"

Next I upgraded to 4.4.0 with the same now re-formatted drive.  This drive had the bootloader and the new firmware files on it.  "mini_release_boot_4.4.0+4180.bbf" and "mini_release_boot_update_pre_4.4_4.4.0+4180.bbf".

This step took some time to upgrade the bootloader and then on self restart failed to load the new firmware.  I tried several time with no luck.  I realized I should try to reformat the drive again and place the same two files on it.

It worked with the new bootloader and the new 4.4.0 firmware.

RE: Unable to update firmware

I saw this tip elsewhere on the forums.

If you find it will not read the file, preset the reset button and immediately click the selector dial twice.

I was about to say bad words before realizing this option existed!

Up and running now myself.

JPW

RE:

Having two .bbf files in the 4.4.1 download, both with obscure names, confused me. I did finally figure out which file to use and to update successfully, but this process could have been made a LOT clearer. Prusa folks: please don't assume that everyone is up-to-date on version evolution and names and other minutiae. Assume that the user is just got their printer out of the closet after a year and is not a veteran of a thousand firmware updates. 😣 

RE: Unable to update firmware

I am stuck here also. Following what seems like the solution that worked for @chris-barnes.

Reset my Mini+ to factory. which set the firmware to 4.3.1.

Downloaded 4.3.2, loaded on USB. The bootloader detected the new firmware and installed properly.
Downloaded 4.3.3, loaded on USB. The bootloader detected the new firmware and installed properly.
Downloaded 4.3.4, loaded on USB. The bootloader detected the new firmware and installed properly.

The next firmware version is 4.4.0. It contains 2 .bbf files, unlike previous firmwares which are only one file. Download, loaded both files on USB, tried to install.

ERROR #12603. Firmware file has invalid size.

USB drive is Fat32, with "Allocated Unit Size" 2048 bytes. Reformatted drive, same specs, tried again. Bootloader bypasses firmware files. Tried double-click on bootload, same error.

CANNOT go from 4.3.4 to 4.4.0.

RE: Unable to update firmware

The fix that worked for me-

Get 4.3.4 stable. Then to go from 4.3.4 to 4.4.0:

Load USB with only this file: mini_release_boot_update_pre_4.4_4.4.0+4180.bbf

It was detected, and worked for me. Then the process will stall, saying it's "looking for BBF". Pull out the USB, copy the other file to the USB: mini_release_boot_4.4.0+4180.bbf.

It should be detected, and continue installing. Mine did some weird auto-restart, and installation twice. But it emerged with stable 4.4.0.

Then to update to 4.4.1, I put BOTH files on the UDB, inserted, turned on the printer. It worked...

RE:

Hoo-Boy, Has it been a fun ride for me, too, and deciced to chime in in case this helps anyone 🙂

I've been running 4.3.1 for ages without any need to upgrade since I pretty follow "Don't fix it if it works" -principle what comes to 3D-printing and Prusa Mini+ has been an excellent work horse for so long, especially with the Bondtech feeder upgrade that made it more reliable. However, that included some hardware changes that I now need to revert (probably) after going all the way to 5.1.2 since these polarity changes are no longer necessary. Anyway, just an additional hassle, but this worked with me regarding the upgrade path:

• Yes, had to format the USB stick again using the 2048 allocation size. If you're running MacOS, here's how to do it easily:
  • Check your PRUSA USB stick label for instance with "sudo diskutil list" and assume here it's /dev/disk4
  • Format via terminal using: "sudo newfs_msdos -F 32 -v PRUSA_MINI -b 2048 /dev/disk4" (and you can't do this from the Disk Util app for example)
  • If you get "Resource busy" or some else error, you can use "sudo diskutil unmount /dev/disk4" before
  • If you're still having trouble, check "sudo lsof|grep disk4" or similar to debug what process is using the disk and retry the unmount
• For whatever reason Finder refused to copy things into this stick after formatting saying always it's full, so you can just do cp command instead, something like: cp ~/Downloads/Your_Prusa_Files /Volumes/PRUSA_MINI assuming this is the name you used.
• Oh, and copy *all* the bff files, not just the one that looks like the right language for example 🙂 This is a bit confusing. And do these one by one: do not mix firmware versions. Delete the old, add the new like 4.3.4 files, upgrade, delete, add 4.4.0 etc. and repeat.
• I noticed the bootloader was still 1.0.0 so that probably needed to be upgraded along the way, so I downloaded 4.3.2 onwards until there was a bootloader upgrade and support for bff files etc.
• My Mini did not go into firmware upgrade mode in any way, so I had to do reset+multiple times rotary knob pressing immediately, and sometimes it finally went into looking for flashed files. If you get the error of incompatibility, try one step lower firmware until it accepts the new one.

And off I went, step by step into 5.1.2 without any major hiccups. Now, it's time to see if the bondtech upgrade could be reverted without disassembling the extruder...

And have to say this: as much as I love Prusa and have been using their printers for years, Bambu Labs have really taken a HUGE step with their P2x-series. Quality is simply amazing and the price with (working, ahem) multi-color support, Prusa has to make something to catch up. And how was firmware update? "I noticed there's a new FW available, do you want to upgrade?" After some minutes it was done and all good.

3D printing is no longer the lifestyle it has been, nor does it have to be.

RE: Unable to update firmware

This fixed the issue for me. Thanks