E2-40

Wrong Firmware Version

ABB · AC500-S Safety Controller

What does E2-40 mean?

The Safety PLC is operating with an incorrect or incompatible firmware version. This can lead to unexpected behavior, functional limitations, or complete system failure, compromising safety.

Common Causes

  • The firmware version loaded on the SM560-S Safety PLC does not match the version specified in the engineering project or is incompatible with the installed hardware revision.
  • An incorrect firmware file was inadvertently downloaded to the Safety PLC during a maintenance or upgrade procedure.
  • The engineering software version being used is not compatible with the firmware version currently running on the Safety PLC (e.g., older software trying to manage newer firmware features).
  • Firmware corruption on the Safety PLC's internal memory, leading to an incorrect version identifier being reported or causing unstable operation.
  • Mismatch between the firmware version of the Safety PLC CPU and specific safety I/O modules, leading to communication errors.

Repair Steps & Checklist

Click steps to track your progress.

  1. 1

    1. Connect to the SM560-S Safety PLC via engineering software and retrieve the currently installed firmware version from the device information.

  2. 2

    2. Compare the installed firmware version with the version specified in the engineering project settings and consult the manufacturer's compatibility matrix.

  3. 3

    3. Download the correct and compatible firmware version for the SM560-S Safety PLC from the manufacturer's website using the engineering software's firmware update utility.

  4. 4

    4. After successfully updating the firmware, perform a complete download of the safety application project to ensure all parameters and configurations are re-initialized for the new firmware.

  5. 5

    5. Ensure the engineering software version is compatible with the target PLC firmware; upgrade the software if necessary to match required versions.

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Verified technical data. Last updated: March 2026

Related Faults

Source: ABB AC500-S Safety Controller