I've been down this road, and like you, I tried a bunch of old sticks. Age isn't important, how much current the stick tells the OS it needs is what is important. I had some sticks that only drew 83mA but they told the OS they needed 200mA. And they didn't work. I had to check each stick using Windows Device Manager. I had to poke through the USB section looking at the hubs and gateways to see which one was driving my stick (my PC had 2). Go to the Power tab to see how much power is being asked by the devices. I would look at the screen as I plugged in the stick to see if something was added to the list. I finally found one that listed less than 100mA. Voila! That one stick worked. You can tell when the green LED stays lit for over 4 seconds as the firmware is downloaded and installed.

So I sent my Gateway back to MCThings and Tom helped me by loading on the new firmware version 0.6-357

Got it back. However, I don't think it worked as nothing has changed - the project still will not work - Then I look at the GW Version and it's still 0.6-355



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I had the same problem. I found out that when I downloaded the latest version of the BIN file.  The original file mcGw110.bin was already in download folder, so the new file was renamed mcGw110 (1).bin. When I copy the file to my USBstick, it copy the old version.

Solution: before downloading the latest version, make sure that the old one is deleted.
A note in the documentation could help.

How can we upgrade our bootloader to v0.1? I just updated to v0.6-360 and I still only see 3 blinks, and higher power consumption USB sticks still don't work.

Unfortunately you cannot upgrade the bootloader in anyway. This has to be done at the time of manufacturing or through our manufacturing setup using an actual ICP (In Circuit Programmer).

I assume that is what the pic ICP headers are for?