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OTA Update Fails on ESP8266 with Relay Enabled When Upgrading from WLED 0.15.1 to 0.15.3

Open curfew3749 opened this issue 2 months ago • 3 comments

What happened?

When attempting to update an ESP8266 running WLED 0.15.1 to 0.15.3, the OTA update consistently fails if the relay feature is enabled. The device begins the update process but never completes it, eventually reverting to the previous version.

I was able to successfully update only by disabling the relay, which worked without issues.

To Reproduce Bug

Set relay IO to 16, and attempt to update from 15.1 to 15.3 OTA.

Expected Behavior

I would expect the version to be upgraded to 15.3, not fail.

Install Method

Binary from WLED.me

What version of WLED?

WLED_0.15.3_ESP8266.bin

Which microcontroller/board are you seeing the problem on?

ESP8266

Relevant log/trace output


Anything else?

No response

Code of Conduct

  • [x] I agree to follow this project's Code of Conduct

curfew3749 avatar Dec 06 '25 14:12 curfew3749

Can you please provide your config.json file?

DedeHai avatar Dec 07 '25 07:12 DedeHai

@DedeHai are there any files on the filesystem that indicate when the firmware has rolled back?

netmindz avatar Dec 07 '25 10:12 netmindz

cfg.json attached

redacted_cfg.json

curfew3749 avatar Dec 07 '25 13:12 curfew3749

@DedeHai are there any files on the filesystem that indicate when the firmware has rolled back?

No, we would need to add one. Only thing that would be detectable if the config was rolled back as that creates a copy with a different backup name.

DedeHai avatar Dec 14 '25 09:12 DedeHai

I was not able to reproduce this. One of my ESP8266 failed to update OTA to 15.3 but that one had so many firmware version changes in testing its hard to link it to this issue. With a fresh install, this does not happen and update works regardless of the relay pin.

DedeHai avatar Dec 14 '25 10:12 DedeHai

Same, I could not reproduce this on my hardware. (I don't have an actual relay, though.) Unfortunately older versions aren't very helpful at telling you why they refused an update -- that was a 0.15.2 feature.

willmmiles avatar Dec 14 '25 19:12 willmmiles

Im having the same issue, its been the case with every point release since v15.0 ... It will try to upgrade, then failing, and remain offline until I turn the power off/on - at which point it will come back with v15.0.

edit: I have only tried updates over the browser - with unit connected to WIFI.

Scope12345 avatar Dec 14 '25 19:12 Scope12345

@Scope12345 Try gzipping the binary and then uploading the gz file. It could be that it's too big for your hardware to fit the OTA binary before installing; the ESP8266 bootloader supports gzip compressed OTAs. (Ref: #3257)

willmmiles avatar Dec 15 '25 01:12 willmmiles

@Scope12345 Try gzipping the binary and then uploading the gz file. It could be that it's too big for your hardware to fit the OTA binary before installing; the ESP8266 bootloader supports gzip compressed OTAs. (Ref: #3257)

@willmmiles Thanks for the suggestion.. I have tried uploading as gzip but the outcome is still the same.. It goes offline until I turn power off and back on again - returning with v15.0.

Scope12345 avatar Dec 15 '25 09:12 Scope12345

does it also happen if you have nothing connected on GPIO16? that is the "sleep" pin, I dont thinkg it is somehow involved in OTA updates but with ESPs you never know.

DedeHai avatar Dec 15 '25 10:12 DedeHai