The .BIN file is for when it is still a OEM router (stock firmware), to upgrade to a mesh node. You will need to verify you are getting the proper bin file for what exact model you are using (ex WRT54GSv2 vs a WRT54GLv1.1, found ont he label underneath in small print)
If it already has BBHN firmware (or open/dd-wrt), then use the available TRX file, which works across all hardware models ONCE IT IS ALREADY a BBHN node. So if you were trying to use a BIN file on a mesh node, yes you would get an error. Go download the TRX file and use it on those nodes to update from a previous BBHN version.
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