We’ve found an issue in Home Assistant Connect ZBT-1 that has affected a small number of customers, which appears to be the result of a faulty part incorporated in the most recent batch of ZBT-1 devices. We want to make sure everyone can get a replacement ZBT-1 and ensure they are covered far into the future.
Though Home Assistant SkyConnect is identical to the ZBT-1 under the hood, it is not affected. The design is not what’s at fault, but instead, a defective voltage regulator that was used in this specific batch that is causing the issue. When a ZBT-1 is inserted into certain USB-A ports, the voltage regulator can fail, fully bricking the device. We used high-quality manufacturing and quality control in this and previous batches. We are undertaking an investigation to find out how this could happen and most importantly, to avoid a repeat of anything remotely similar in the future.
We’re sorry for any inconvenience this may cause you. Below are details on our investigation, how devices are affected, and the replacement program.
Background
Around a month ago, we were contacted about one of our latest (and recently rebranded) Home Assistant Connect ZBT-1s not being detected and showing a small mark on the housing. A couple more similar issues were reported, and we began a dialogue with the small number of people who were affected, having them send us the devices to test.
Circled in red the deformation on the case and the board showing the failed chip
When we opened them, we found a dead voltage regulator. The mark in the outer casing is a sign that it overheated and failed. All of our devices are certified by CE and ROHS, and the plastic shell has been designed not to combust. This is a real-life demonstration of just how important this certification is and why we take that step.
We replaced the voltage regulator on the devices we tested, and the devices sprang back to life. We found our culprit, but why was it failing? As mentioned, the SkyConnect internal design and the manufacturing were effectively identical to the ZBT-1, and we received no reports of any such failures in the literally tens of thousands of them in the wild. In manufacturing runs there is always a little variance, and in this run, something went wrong with the voltage regulator that was sourced - again, we’re looking into this.
It took us a couple of weeks to replicate the problem with our own units. We went down some wrong paths, but eventually found it was triggered only by certain devices, specifically certain desktop PCs (internally, we have only found one desktop that causes this failure). We have not observed the failure occur when the device has only been connected to a Home Assistant Green, Raspberry Pi, or even a Mac. If you have plugged your ZBT-1 into a different device, specifically a desktop PC, and it is not recognized by that system, inspect it for this deformation pictured above. Obviously, we want you to be able to use the device with any hardware, and even if only a small number of devices from this batch have reported issues, it is still unacceptable to us.
Pausing sales
We have asked our distributors to pause sales and return all stock. For the next month, you will see “Out of Stock” banners, and if you are attempting to get a replacement device for a failed unit, this will not be possible until production is resumed.
We are working to have replacement ZBT-1s shipped by early November.
Replacement Program
If you have purchased Home Assistant Connect ZBT-1, we are working on a replacement program. This program will see Nabu Casa provide a replacement device free of charge for a period of 60 months (5 years) for verified purchases. Regardless of whether the device has failed, we will provide a replacement upon request.
It is a core value of ours to do things as sustainably as possible, and that’s why we’ve provided such a long coverage period. We want to give owners with working ZBT-1s, who do not expect to use the device in a different system for the foreseeable future, the ability to keep it operating with peace of mind.
If it’s working, keep it plugged into the device it’s working with, and don’t worry about a replacement until you need it. If you need or want a replacement, please contact the seller where you purchased your device, and they will arrange the return process and replacement. Replacement devices are expected by early November, and we will be prioritizing people with non-functioning devices.
Conclusion
We’re sorry for the inconvenience and any disruption to your smart home. As someone who uses Zigbee in their home, which many smart devices rely on, I would hate to have it out of commission.
Worse things can happen, but this has been a gut punch. All our work at Nabu Casa is to fund the development of Home Assistant and support the Open Home. Issues like this eat into our time, and rob our users of new and great things. Ultimately, we’re going to take this setback as a chance to prove we stand by our values and do the right thing.
This is a companion discussion topic for the original entry at https://www.home-assistant.io/blog/2024/10/02/connect-zbt1-issue-and-replacement
