Upgrading to ESPHome 2024.10.0 prevents OTA from working

[leonardospina]

I have a few athom-4gang-switch devices around the house, and after the latest ESPHome update I installed this morning I cannot do OTA anymore, apparently the binary file is too large for OTA.
Updating form the ESPHome integration fails because of issues with name resolution (just ignore it), posting just to show the logs that show the size of the binary:

but if I download the binary and upload it via the device's web UI I get this:

[madberry]

Have you defined what esp is being used. I've seen this error come up a few times and after defining the esp OTA started to work again.

[leonardospina]

the board type is defined in the config in the original Athom's repo:

[madberry]

Have you tried to reboot the switch and then attempt the flash again? Make sure it's a full power cycle just to be sure.

[leonardospina]

No I haven't, I mean that's hardwired to the mains not really a quick thing... one thing I might try is resetting it to factory defaults and then flash it, but the strange thing is that it's not just one, all of them (same device type) have the same issue since I upgraded ESPHome

[madberry]

Oh it's almost certainly linked to the esphome update. I've seen several people complain about similar OTA issues.

I have a few switches like that as well always a pain to have to flip a breaker to get stuff to update again.

[leonardospina]

yeah very annoying... I'll try with one anyway and see if it works...

[Jannis87]

its an issue for me too.

i think the binary is to big:
Flash: [===== ] 53.9% (used 552101 bytes from 1023984 bytes)

Some of my esphome binaries are smaller. in that case everything works fine:
Flash: [===== ] 49.2% (used 503433 bytes from 1023984 bytes)

[leonardospina]

yep same here, I have many devices and only the switches have that problem

[Jannis87]

yep same here, I have many devices and only the switches have that problem

gzip -9 firmware.bin worked for me :). The compressed file can be uploaded via the web interface. Its a workaround, but at least my devices are up to date :)

[madberry]

I posted this issue to the esphome discord hopefully they will be able to pick it up.

[leonardospina]

Thanks for the hint I'll give it a try!

[leonardospina]

wow it worked! thanks @madberry