Michael,
I am having the same problem with upgrading an A620 controller. I get an error that says I need 60MB for the upgrade. When I show storage, I see that I only have 51MB in flash.
(Aruba620) # show stor
Filesystem Size Used Available Use% Mounted on
/dev/mtdblock11 156.0M 105.0M 51.0M 67% /flash
none 300.0M 1.8M 298.2M 1% /tmp
/dev/mtdblock9 50.0M 24.6M 25.4M 49% /mnt/img0
/dev/mtdblock10 50.0M 24.7M 25.3M 49% /mnt/img1
When I look at the flash directory contents, it looks like I only have about 27KB of file storage in flash.
(Aruba620) #dir
-rw-r--r-- 1 root root 17666 Jun 24 15:32 default.cfg
drwxr-xr-x 3 root root 0 Jun 26 2013 fieldCerts
-rw-r--r-- 1 root root 9426 Jun 26 2013 original.cfg
drwx------ 2 root root 0 Jun 26 2013 tpm
I can't figure out what composes the 51MB, or how to free up the neccessary 60MB in order to complete the upgrade. I have tried performing the upgrade through the GUI and the CLI, but get no love either way. Any suggestions, or recommedations would be greatly apprciated.