Flashing OTA of ESP32 failing. [Errno 104] Connection reset by peer

ESPHome
1

I have something strange going on here. I have many ESP32 (ESP32-WROOM-32D) working but lately updating them with OTA is getting more difficult. They just seem to fail with a timeout. These boards are all working and wireless logging also works 100% of the time, Just a OTA code updated fails. I need to try many times to get a successful update. Updating via a USB cable works every time without issues. Seems to suggest network issues but I have no issues with any ESPHome Wifi devices once the code is flashed. I am also using static IP addresses. But this did not help.
Here are few logs with the failures.

INFO ESPHome 2024.6.6
INFO Reading configuration /config/esphome/esp32-pumps.yaml...
INFO Generating C++ source...
INFO Compiling app...
Processing esp32-pumps (board: esp32dev; framework: arduino; platform: platformio/[email protected])
--------------------------------------------------------------------------------
HARDWARE: ESP32 240MHz, 320KB RAM, 4MB Flash
 - toolchain-xtensa-esp32 @ 8.4.0+2021r2-patch5
Dependency Graph
|-- AsyncTCP-esphome @ 2.1.3
|-- WiFi @ 2.0.0
|-- FS @ 2.0.0
|-- Update @ 2.0.0
|-- ESPAsyncWebServer-esphome @ 3.2.2
|-- ESPmDNS @ 2.0.0
|-- noise-c @ 0.1.4
|-- Wire @ 2.0.0
|-- ArduinoJson @ 6.18.5
|-- Improv @ 1.2.3
RAM:   [==        ]  16.2% (used 52968 bytes from 327680 bytes)
Flash: [========= ]  90.4% (used 1658257 bytes from 1835008 bytes)
========================= [SUCCESS] Took 19.18 seconds =========================
INFO Successfully compiled program.
INFO Connecting to 192.168.1.106
INFO Uploading /data/build/esp32-pumps/.pioenvs/esp32-pumps/firmware.bin (1664032 bytes)
Uploading: [============                                                ] 20% ERROR Error receiving acknowledge chunk OK: [Errno 104] Connection reset by peer

And another one

RAM:   [==        ]  16.2% (used 52968 bytes from 327680 bytes)
Flash: [========= ]  90.4% (used 1658257 bytes from 1835008 bytes)
========================= [SUCCESS] Took 19.29 seconds =========================
INFO Successfully compiled program.
INFO Connecting to 192.168.1.106
INFO Uploading /data/build/esp32-pumps/.pioenvs/esp32-pumps/firmware.bin (1664032 bytes)
Uploading: [=======                                                     ] 12% ERROR Error receiving acknowledge chunk OK: [Errno 104] Connection reset by peer

and another

RAM:   [==        ]  16.2% (used 52968 bytes from 327680 bytes)
Flash: [========= ]  90.4% (used 1658257 bytes from 1835008 bytes)
========================= [SUCCESS] Took 19.16 seconds =========================
INFO Successfully compiled program.
INFO Connecting to 192.168.1.106
INFO Uploading /data/build/esp32-pumps/.pioenvs/esp32-pumps/firmware.bin (1664032 bytes)
Uploading: [====                                                        ] 6% ERROR Error receiving acknowledge chunk OK: [Errno 104] Connection reset by peer

But Wireless logging works fine. Always.

INFO ESPHome 2024.6.6
INFO Reading configuration /config/esphome/esp32-pumps.yaml...
INFO Starting log output from 192.168.1.106 using esphome API
INFO Successfully connected to esp32-pumps @ 192.168.1.106 in 0.073s
INFO Successful handshake with esp32-pumps @ 192.168.1.106 in 0.432s
[20:44:38][I][app:100]: ESPHome version 2024.6.6 compiled on Aug 16 2024, 13:43:18
[20:44:38][I][i2c.arduino:096]: Results from i2c bus scan:
[20:44:38][I][i2c.arduino:102]: Found i2c device at address 0x40

Here is a sample yaml but it does not seem to matter as it effects many boards with different yaml

esphome:
  name: "esp32-pumps"
  friendly_name: "esp32-pumps"

esp32:
  board: esp32dev
  framework:
    type: arduino

api:
  encryption:
    key: qN1ks2Cze123xWx5upTDD6H15IYKYExYwCIPoqHg=


wifi:
  ssid: !secret wifi_ssid
  password: !secret wifi_password

  manual_ip:
    static_ip: 192.168.1.106
    gateway: 192.168.1.1
    subnet: 255.255.255.0

  ap:
    ssid: "ESP PUMPS HOTSPOT"
    password: "SXYTSAXXSA1234"


logger:
  level: INFO

ota:
  platform: esphome

improv_serial:

web_server:

esp32_improv:
  authorizer: none

i2c:
  sda: GPIO21
  scl: GPIO22

sensor:
  - platform: ina226
    address: 0x40
    shunt_resistance: 0.1 ohm
    id: ina_sensor
    bus_voltage:
      name: "Bilge Pump Voltage"
      id: bilge_pump_voltage
    update_interval: 1s
2

Had similar issue when WiFi was like a “overloaded”.
OTA failed, as well as devices experienced issues with sending data to HA.
Also connection & handshake timings was big in my case - up to several seconds.
WiFi channel change fixed the issue.

2 Likes
3

Just wanted to let you know I have the same issue with two ESP_DevKitC_v4’s (ESP32-wroom-32d based).
My problem isn’t just upload (and improves when moving closer to the wifi AP as @Masterzz suggested), but my modules also keep crashing in normal operation. Even with a very simple config (only an “uptime sensor”). I’m not sure if this is just a bad batch of modules or if something broke in a newer release of ESPhome. The weird thing is that one module works just fine (same batch, same ESPHome version etc.)… To be continued.

4

Might be worth adding the Wi-Fi sensor, I add that and the uptime sensor to all my devices now. Just helps knowing what is going on.

5

I have solved the problem by reducing the size of the ESPHome code to be flashed and also using a logger of ERROR. I disabled options I did not need like bluetooth etc and the file size to flash went down by 50%.