Binary file size error? when compiling ESPHOME

this is a little odd… was updating a couple sensor boxes (mod’ed IKEA VINDRIKTNING with a display and BME680)
#1 and #3 took my edits without issue. doing the same on #2 returns some odd compile error

Compiling .pioenvs/ikea-2-680/FrameworkArduino/wpa2_eap_patch.cpp.o
Archiving .pioenvs/ikea-2-680/libFrameworkArduino.a
Linking .pioenvs/ikea-2-680/firmware.elf
RAM:   [======    ]  61.0% (used 49992 bytes from 81920 bytes)
Flash: [======    ]  57.3% (used 586893 bytes from 1023984 bytes)
Building .pioenvs/ikea-2-680/firmware.bin
esp8266_copy_factory_bin([".pioenvs/ikea-2-680/firmware.bin"], [".pioenvs/ikea-2-680/firmware.elf"])
esp8266_copy_ota_bin([".pioenvs/ikea-2-680/firmware.bin"], [".pioenvs/ikea-2-680/firmware.elf"])
======================== [SUCCESS] Took 206.46 seconds ========================
INFO Successfully compiled program.
INFO Connecting to 192.168.1.158 port 8266...
INFO Connected to 192.168.1.158
INFO Uploading /data/build/ikea-2-680/.pioenvs/ikea-2-680/firmware.bin (591040 bytes)
INFO Compressed to 406557 bytes
ERROR Error binary size: Unknown error from ESP

The yaml is straight forward…
.

..
substitutions:
## Location & Entity Names (Capitals and Spaces Allowed)
  name: "IKEA-2"
  tempoffset1: "2"
  humoffset1: "0"
  
esphome:
  name: ikea-2-680
  friendly_name: IKEA-2-680

esp8266:
  board: esp01_1m

# Enable logging
logger:

# Enable Home Assistant API
api:
  encryption:
    key: "pAykYeJ09kk3hkLxRPc2y44KSyEzKZ7+gixzjYY3vZU="

ota:
  - platform: esphome
    password: "aff3dc736929bb6126d8c8dcf31aa43d"

wifi:
  ssid: !secret wifi_ssid
  password: !secret wifi_password
  manual_ip:
    static_ip: 192.168.1.158   #8c:AA:B5:02:B8:AD
    gateway: 192.168.1.1
    subnet: 255.255.255.0
  power_save_mode: none   # none light high

  # Enable fallback hotspot (captive portal) in case wifi connection fails
  ap:
    ssid: "Ikea-2-680 Fallback Hotspot"
    password: "3ZbdPuGVc3qE"

captive_portal:
  # Minimal example configuration with common sensors
i2c:
  sda: GPIO4   #D2
  scl: GPIO5   #D1
  frequency: 400khz
 
## Serial Port for partical co etc Sensor
uart:
  - rx_pin: GPIO13  #D7
    tx_pin: GPIO15  #D8
    baud_rate: 9600
    
binary_sensor:
  ## Use the on-board LED to show "Fan Running"
  - platform: gpio
    name: $name Fan
    id: fan
    pin:
      number: GPIO2  #D4
      inverted: true

  ## Brightness Sensor for HA Automations
  - platform: template
    name: $name Bright
    id: bright

bme680_bsec:
  id: bme680_internal
  # i2c address # - 0x76  # - 0x77
  address: 0x77    #0x77 for 2.4" 128x64 tft display
  iaq_mode: static
  temperature_offset: $tempoffset1

sensor:
  ## IKEA PMS 2.5um Sensor
  - platform: pm1006
    pm_2_5:
      id: aq_sensor
      name: $name 2.5µg
    update_interval: 20s

  ## The IKEA Light Level Sensor
  - platform: adc
    id: light_sensor
    pin: A0
    update_interval: 10s
    ## Check the value and turn On/Off our Binary Sensor
    on_value:
      - lambda: !lambda |
          if (x > 0.01) {
            id(bright).publish_state(true);
            } else {
              id(bright).publish_state(false);
              }
      
  - platform: bme680_bsec
    bme680_bsec_id: bme680_internal
    temperature:
      name: "BME680 Temperature"
      id: bmetemp
      filters:
        - lambda: return x * (9.0/5.0) + 32.0;
      unit_of_measurement: °F
    humidity:
      name: "BME680 Humidity"
      id: bmehumi
      filters:
        - offset: $humoffset1
    pressure:
      name: "BME680 Pressure"
      id: bmepress
      unit_of_measurement: inHg
      filters:
        - lambda: return x * 0.0295299;
    iaq:
      name: "BME680 IAQ"
      id: iaq
    co2_equivalent:
      name: "BME680 CO2 Equivalent"
      id: co2equiv
    breath_voc_equivalent:
      name: "BME680 Breath VOC Equivalent"
      id: bmebreathvoc
    
text_sensor:
  - platform: bme680_bsec
    iaq_accuracy:
      name: "BME680 IAQ Accuracy"
      id: bmeiaqacc

  - platform: template
    name: "BME680 IAQ Classification"
    icon: "mdi:checkbox-marked-circle-outline"
    id: bmeiaqclass
    lambda: |-
      if ( int(id(iaq).state) <= 50) {
        return {"Excellent"};
      }
      else if (int(id(iaq).state) >= 51 && int(id(iaq).state) <= 100) {
        return {"Good"};
      }
      else if (int(id(iaq).state) >= 101 && int(id(iaq).state) <= 150) {
        return {"Lightly polluted"};
      }
      else if (int(id(iaq).state) >= 151 && int(id(iaq).state) <= 200) {
        return {"Moderately polluted"};
      }
      else if (int(id(iaq).state) >= 201 && int(id(iaq).state) <= 250) {
        return {"Heavily polluted"};
      }
      else if (int(id(iaq).state) >= 251 && int(id(iaq).state) <= 350) {
        return {"Severely polluted"};
      }
      else if (int(id(iaq).state) >= 351) {
        return {"Extremely polluted"};
      }
      else {
        return {"error"};
      }

font:
  - file: 'fonts/Ubmonor.ttf'
    id: font1
    size: 14
  - file: 'fonts/Ubmonor.ttf'
    id: font2
    size: 10

display:
  - platform: ssd1306_i2c
    setup_priority: -100
    id: oled
    model: "SSD1306 128x64"
    address: 0x3c   #0x3c 
    lambda: |-
      it.printf(0, 0, id(font1), TextAlign::TOP_LEFT, "%s", id(bmeiaqclass).state.c_str());
      it.printf(0, 16, id(font1), TextAlign::TOP_LEFT, "%s", id(bmeiaqacc).state.c_str());
      it.printf(0, 32, id(font1), TextAlign::TOP_LEFT, "PM25 %.0f", id(aq_sensor).state);
      it.printf(0, 48, id(font1), TextAlign::TOP_LEFT, "IAQ %.0f", id(iaq).state);
      it.printf(128, 0, id(font1), TextAlign::TOP_RIGHT, "%.1f °F", id(bmetemp).state);
      it.printf(128, 14, id(font1), TextAlign::TOP_RIGHT, "%.1f %% ", id(bmehumi).state);
      it.printf(128, 28, id(font1), TextAlign::TOP_RIGHT, "%.1f Hg", id(bmepress).state);
      it.printf(128, 48, id(font1), TextAlign::TOP_RIGHT, "%.0f eCO2", id(co2equiv).state);

All I was doing was anddding an offset vcariable to get all the temps to read the same. Any clue why space seems avail on the esp32-wroom, but an eorr comes up unknown binay size???
any clues here? tia

additions here… rebooting a couple more times… grabbed the log off that unit that will not take the upload after compiling shown above…

INFO ESPHome 2025.2.1
INFO Reading configuration /config/esphome/ikea-2-680.yaml...
INFO Starting log output from 192.168.<s>xxx.xxx</s> using esphome API
INFO Successfully connected to ikea-2-680 @ 192.xxx.xxx.xxx in 0.009s
INFO Successful handshake with ikea-2-680 @ 192.xxx.xxx.xxx in 2.415s
[14:15:48][I][app:100]: ESPHome version 2025.2.1 compiled on Feb 27 2025, 13:40:37
[14:15:48][C][wifi:600]: WiFi:
[14:15:48][C][wifi:428]:   Local MAC: 8C:AA:B5:xx:xx:xx
[14:15:48][C][wifi:433]:   SSID: [redacted]
[14:15:48][C][wifi:436]:   IP Address: 192.xxx.xxx.xxx
[14:15:48][C][wifi:439]:   BSSID: [redacted]
[14:15:48][C][wifi:441]:   Hostname: 'ikea-2-680'
[14:15:48][C][wifi:443]:   Signal strength: -37 dB ▂▄▆█
[14:15:48][C][wifi:447]:   Channel: 6
[14:15:48][C][wifi:448]:   Subnet: 255.255.255.0
[14:15:48][C][wifi:449]:   Gateway: 192.xxx.xxx.xxx
[14:15:48][C][wifi:450]:   DNS1: 0.0.0.0
[14:15:48][C][wifi:451]:   DNS2: 0.0.0.0
[14:15:48][C][logger:177]: Logger:
[14:15:48][C][logger:178]:   Max Level: DEBUG
[14:15:48][C][logger:179]:   Initial Level: DEBUG
[14:15:48][C][logger:181]:   Log Baud Rate: 115200
[14:15:48][C][logger:182]:   Hardware UART: UART0
[14:15:48][C][i2c.arduino:071]: I2C Bus:
[14:15:48][C][i2c.arduino:072]:   SDA Pin: GPIO4
[14:15:48][C][i2c.arduino:073]:   SCL Pin: GPIO5
[14:15:48][C][i2c.arduino:074]:   Frequency: 400000 Hz
[14:15:48][C][i2c.arduino:086]:   Recovery: bus successfully recovered
[14:15:48][I][i2c.arduino:096]: Results from i2c bus scan:
[14:15:48][I][i2c.arduino:102]: Found i2c device at address 0x3C
[14:15:48][I][i2c.arduino:102]: Found i2c device at address 0x77
[14:15:48][C][uart.arduino_esp8266:118]: UART Bus:
[14:15:48][C][uart.arduino_esp8266:119]:   TX Pin: GPIO15
[14:15:48][C][uart.arduino_esp8266:120]:   RX Pin: GPIO13
[14:15:48][C][uart.arduino_esp8266:122]:   RX Buffer Size: 256
[14:15:48][C][uart.arduino_esp8266:124]:   Baud Rate: 9600 baud
[14:15:48][C][uart.arduino_esp8266:125]:   Data Bits: 8
[14:15:48][C][uart.arduino_esp8266:126]:   Parity: NONE
[14:15:48][C][uart.arduino_esp8266:127]:   Stop bits: 1
[14:15:48][C][uart.arduino_esp8266:131]:   Using software serial
[14:15:48][C][gpio.binary_sensor:015]: GPIO Binary Sensor 'IKEA-2 Fan'
[14:15:48][C][gpio.binary_sensor:016]:   Pin: GPIO2
[14:15:48][C][template.binary_sensor:028]: Template Binary Sensor 'IKEA-2 Bright'
[14:15:48][C][template.text_sensor:020]: Template Sensor 'BME680 IAQ Classification'
[14:15:48][C][template.text_sensor:020]:   Icon: 'mdi:checkbox-marked-circle-outline'
[14:15:48][C][bme680_bsec.sensor:148]: bme680_internal via BSEC:
[14:15:48][C][bme680_bsec.sensor:152]:   BSEC Version: 1.4.8.0
[14:15:48][C][bme680_bsec.sensor:155]:   Address: 0x77
[14:15:48][C][bme680_bsec.sensor:162]:   Temperature Offset: 1.60
[14:15:48][C][bme680_bsec.sensor:163]:   IAQ Mode: Static
[14:15:48][C][bme680_bsec.sensor:164]:   Supply Voltage: 3.3V
[14:15:48][C][bme680_bsec.sensor:165]:   Sample Rate: LP
[14:15:48][C][bme680_bsec.sensor:166]:   State Save Interval: 21600000ms
[14:15:48][C][bme680_bsec.sensor:168]:   Temperature 'BME680 Temperature'
[14:15:48][C][bme680_bsec.sensor:168]:     Device Class: 'temperature'
[14:15:48][C][bme680_bsec.sensor:168]:     State Class: 'measurement'
[14:15:48][C][bme680_bsec.sensor:168]:     Unit of Measurement: '°F'
[14:15:48][C][bme680_bsec.sensor:168]:     Accuracy Decimals: 1
[14:15:48][C][bme680_bsec.sensor:169]:     Sample Rate: Default
[14:15:48][C][bme680_bsec.sensor:170]:   Pressure 'BME680 Pressure'
[14:15:48][C][bme680_bsec.sensor:170]:     Device Class: 'atmospheric_pressure'
[14:15:48][C][bme680_bsec.sensor:170]:     State Class: 'measurement'
[14:15:48][C][bme680_bsec.sensor:170]:     Unit of Measurement: 'inHg'
[14:15:48][C][bme680_bsec.sensor:170]:     Accuracy Decimals: 1
[14:15:48][C][bme680_bsec.sensor:171]:     Sample Rate: Default
[14:15:48][C][bme680_bsec.sensor:172]:   Humidity 'BME680 Humidity'
[14:15:48][C][bme680_bsec.sensor:172]:     Device Class: 'humidity'
[14:15:48][C][bme680_bsec.sensor:172]:     State Class: 'measurement'
[14:15:48][C][bme680_bsec.sensor:172]:     Unit of Measurement: '%'
[14:15:48][C][bme680_bsec.sensor:172]:     Accuracy Decimals: 1
[14:15:48][C][bme680_bsec.sensor:173]:     Sample Rate: Default
[14:15:48][C][bme680_bsec.sensor:175]:   IAQ 'BME680 IAQ'
[14:15:48][C][bme680_bsec.sensor:175]:     State Class: 'measurement'
[14:15:48][C][bme680_bsec.sensor:175]:     Unit of Measurement: 'IAQ'
[14:15:48][C][bme680_bsec.sensor:175]:     Accuracy Decimals: 0
[14:15:48][C][bme680_bsec.sensor:175]:     Icon: 'mdi:gauge'
[14:15:48][C][bme680_bsec.sensor:177]:   IAQ Accuracy 'BME680 IAQ Accuracy'
[14:15:48][C][bme680_bsec.sensor:177]:     Icon: 'mdi:checkbox-marked-circle-outline'
[14:15:48][C][bme680_bsec.sensor:178]:   CO2 Equivalent 'BME680 CO2 Equivalent'
[14:15:48][C][bme680_bsec.sensor:178]:     Device Class: 'carbon_dioxide'
[14:15:48][C][bme680_bsec.sensor:178]:     State Class: 'measurement'
[14:15:48][C][bme680_bsec.sensor:178]:     Unit of Measurement: 'ppm'
[14:15:48][C][bme680_bsec.sensor:178]:     Accuracy Decimals: 1
[14:15:48][C][bme680_bsec.sensor:179]:   Breath VOC Equivalent 'BME680 Breath VOC Equivalent'
[14:15:48][C][bme680_bsec.sensor:179]:     Device Class: 'volatile_organic_compounds_parts'
[14:15:48][C][bme680_bsec.sensor:179]:     State Class: 'measurement'
[14:15:48][C][bme680_bsec.sensor:179]:     Unit of Measurement: 'ppm'
[14:15:48][C][bme680_bsec.sensor:179]:     Accuracy Decimals: 1
[14:15:48][D][pm1006:091]: Got PM2.5 Concentration: 252 µg/m³
[14:15:48][D][sensor:093]: 'IKEA-2 2.5µg': Sending state 252.00000 µg/m³ with 0 decimals of accuracy
[14:15:48][C][pm1006:017]: PM1006:
[14:15:48][C][pm1006:018]:   PM2.5 'IKEA-2 2.5µg'
[14:15:48][C][pm1006:018]:     Device Class: 'pm25'
[14:15:48][C][pm1006:018]:     State Class: 'measurement'
[14:15:48][C][pm1006:018]:     Unit of Measurement: 'µg/m³'
[14:15:48][C][pm1006:018]:     Accuracy Decimals: 0
[14:15:48][C][pm1006:018]:     Icon: 'mdi:blur'
[14:15:48][C][pm1006:019]:   Update Interval: 20.0s
[14:15:48][C][adc.esp8266:027]: ADC Sensor 'light_sensor'
[14:15:48][C][adc.esp8266:027]:   Device Class: 'voltage'
[14:15:48][C][adc.esp8266:027]:   State Class: 'measurement'
[14:15:48][C][adc.esp8266:027]:   Unit of Measurement: 'V'
[14:15:48][C][adc.esp8266:027]:   Accuracy Decimals: 2
[14:15:48][C][adc.esp8266:031]:   Pin: GPIO17
[14:15:48][C][adc.esp8266:033]:   Samples: 1
[14:15:48][C][adc.esp8266:034]:   Sampling mode: average
[14:15:48][C][adc.esp8266:035]:   Update Interval: 10.0s
[14:15:48][C][captive_portal:089]: Captive Portal:
[14:15:48][C][mdns:116]: mDNS:
[14:15:48][C][mdns:117]:   Hostname: ikea-2-680
[14:15:48][C][esphome.ota:073]: Over-The-Air updates:
[14:15:48][C][esphome.ota:074]:   Address: 192.168.1.158:8266
[14:15:48][C][esphome.ota:075]:   Version: 2
[14:15:48][C][esphome.ota:078]:   Password configured
[14:15:48][C][safe_mode:018]: Safe Mode:
[14:15:48][C][safe_mode:019]:   Boot considered successful after 60 seconds
[14:15:48][C][safe_mode:021]:   Invoke after 10 boot attempts
[14:15:48][C][safe_mode:022]:   Remain in safe mode for 300 seconds
[14:15:48][C][api:140]: API Server:
[14:15:48][C][api:141]:   Address: 192.168.1.158:6053
[14:15:48][C][api:143]:   Using noise encryption: YES
[14:15:48][C][ssd1306_i2c:023]: I2C SSD1306
[14:15:48][C][ssd1306_i2c:023]:   Rotations: 0 °
[14:15:48][C][ssd1306_i2c:023]:   Dimensions: 128px x 64px
[14:15:48][C][ssd1306_i2c:024]:   Address: 0x3C
[14:15:48][C][ssd1306_i2c:025]:   Model: SSD1306 128x64
[14:15:48][C][ssd1306_i2c:027]:   External VCC: NO
[14:15:48][C][ssd1306_i2c:028]:   Flip X: YES
[14:15:48][C][ssd1306_i2c:029]:   Flip Y: YES
[14:15:48][C][ssd1306_i2c:030]:   Offset X: 0
[14:15:48][C][ssd1306_i2c:031]:   Offset Y: 0
[14:15:48][C][ssd1306_i2c:032]:   Inverted Color: NO
[14:15:48][C][ssd1306_i2c:033]:   Update Interval: 1.0s
[14:15:48][D][sensor:093]: 'BME680 IAQ': Sending state 71.73480 IAQ with 0 decimals of accuracy
[14:15:48][D][sensor:093]: 'BME680 CO2 Equivalent': Sending state 717.34802 ppm with 1 decimals of accuracy
[14:15:48][D][sensor:093]: 'BME680 Breath VOC Equivalent': Sending state 1.01341 ppm with 1 decimals of accuracy
[14:15:48][D][sensor:093]: 'BME680 Pressure': Sending state 29.49505 inHg with 1 decimals of accuracy
[14:15:48][D][sensor:093]: 'BME680 Temperature': Sending state 78.88445 °F with 1 decimals of accuracy
[14:15:48][D][sensor:093]: 'BME680 Humidity': Sending state 25.09856 % with 1 decimals of accuracy
[14:15:50][D][pm1006:091]: Got PM2.5 Concentration: 249 µg/m³
[14:15:50][D][sensor:093]: 'IKEA-2 2.5µg': Sending state 249.00000 µg/m³ with 0 decimals of accuracy
[14:15:51][D][binary_sensor:036]: 'IKEA-2 Fan': Sending state OFF
[14:15:51][D][sensor:093]: 'BME680 IAQ': Sending state 71.79680 IAQ with 0 decimals of accuracy
[14:15:51][D][sensor:093]: 'BME680 CO2 Equivalent': Sending state 717.96802 ppm with 1 decimals of accuracy
[14:15:51][D][sensor:093]: 'BME680 Breath VOC Equivalent': Sending state 1.01436 ppm with 1 decimals of accuracy
[14:15:51][D][sensor:093]: 'BME680 Pressure': Sending state 29.49387 inHg with 1 decimals of accuracy
[14:15:51][D][sensor:093]: 'BME680 Temperature': Sending state 78.87510 °F with 1 decimals of accuracy
[14:15:51][D][sensor:093]: 'BME680 Humidity': Sending state 25.09177 % with 1 decimals of accuracy
[14:15:53][D][sensor:093]: 'light_sensor': Sending state 0.13086 V with 2 decimals of accuracy
[14:15:54][D][sensor:093]: 'BME680 IAQ': Sending state 72.83968 IAQ with 0 decimals of accuracy
[14:15:54][D][sensor:093]: 'BME680 CO2 Equivalent': Sending state 728.39673 ppm with 1 decimals of accuracy
[14:15:54][D][sensor:093]: 'BME680 Breath VOC Equivalent': Sending state 1.03047 ppm with 1 d

So the device operates as last loaded… but now just this one device of three duplicate setups is throwing this upload issue. any ideas? more info needed? HELP!!!

It is presently running esphome 2025.2.1, which is the current latest. What are you trying to upload?

So which one you have?