I had a similar issue recently where I could not download or load firmware to the PLC, and it turned out to be the firmware version in the PLC did not match the Logix 5000 / Designer software. For example, Logix Designer V28 needs firmware version 28.* loaded to the PLC (use ControlFlash to load firmware because Logix Designer cannot identify different firmware and Who Active buttons remain disabled). If the PLC processor has a display window, look for the firmware version to scroll across.