Aruba engineering found the problem was bug in the code 6.1.3.1 code that affect the loading of APs across a wan link, and can also cause problem loading the new code on AP on the local network.
We were getting excessive timeouts while trying to upgrade/update the campus APs at the remote office. This has always worked in the past, and we were beginning to question our Wan and local network (which checked out fine), when we verified it happens on the local network as well.
If you are loading a new AP with no code (purge, clear os) or with a version that is prior to .2 code you can have trouble with the AP failing to load the new code.
If they fail to load you will probably need to pull them down, clear the OS and point then to a "local" TFTP server with the new code to get them to come up. We also need to send a reset to the AP from the controller to get them to come up and be recognized.
This was a tough process pulling down all of the AP in our NY education office and manually reloading them.
This is the quote from Aruba TAC.
"Engineering has identified the reason of APs fail to upgrade over WAN link where it took more than 9 minutes ( approximately ) to upgrade. This issue is addressed in Aruba OS 6.1.3.2 onwards. The reason we hit this issue, as the APs at NY location still had 6.1.3.1 in their flash. Bug ID for your reference is 65344. As we have all the APs up and running 6.1.3.4 in their flash, we would not see this issue in further upgrade."