Web Installer uploads wrong binary for S3 Zero/Supermini with 4MB flash -> cannot configure Wi-Fi, no WLED-AP

[softhack007]

The web installer does a wrong firmware installation on S3 Zero (WLED 16.0.1)

The correct binary would be ESP32-S3_4m_qspi, however ESP32-S3_8MB_opi gets installed, together with the 8MB partition file.
As a result, the board boots but Wi-Fi cannot be configured. Also the board does not open WLED-AP after a restart.

Serial monitor log from a debug build:

ESP-ROM:esp32s3-20210327
Build:Mar 27 2021
rst:0x15 (USB_UART_CHIP_RESET),boot:0x29 (SPI_FAST_FLASH_BOOT)
Saved PC:0x420ead9e
SPIWP:0xee
mode:DIO, clock div:1
load:0x3fce3808,len:0x44c
load:0x403c9700,len:0xbec
load:0x403cc700,len:0x2920
entry 0x403c98d8
[   254][E][esp32-hal-misc.c:264] initArduino(): Failed to initialize NVS! Error: 24579

---WLED 16.0.1-dev 2606301 INIT---

esp32 4.4.8.240628
arduino-esp32 v2.0.17
CPU:   ESP32-S3 rev.0, 2 core(s), 240 MHz.
FLASH: 4 MB, Mode 0 (QIO), speed 40 MHz.
heap 326832
TX power: 78/78
PIN ALLOC: Pin 43 successfully allocated by 0x89.
PIN ALLOC: 0x0000000000000lX.
heap 293996
[  2766][E][LittleFS.cpp:123] format(): Formatting LittleFS failed! Error: -1
[  2773][E][LittleFS.cpp:98] begin(): Mounting LittleFS failed! Error: -1
checking for bootloop: time 2531, counter 0, action 0
[  2779][E][vfs_api.cpp:24] open(): File system is not mounted
[  2786][E][vfs_api.cpp:24] open(): File system is not mounted
[  2792][E][vfs_api.cpp:24] open(): File system is not mounted
[  2798][E][vfs_api.cpp:24] open(): File system is not mounted
restore /cfg.json 
no backup found
[  2803][E][vfs_api.cpp:24] open(): File system is not mounted
Reading config
Reading settings from /wsec.json...
JSON buffer locked. (3)
[  2810][E][vfs_api.cpp:24] open(): File system is not mounted
JSON buffer released. (3)
JSON buffer locked. (1)
Reading settings from /cfg.json...
[  2816][E][vfs_api.cpp:24] open(): File system is not mounted
Heap before buses: 293620
No busses, init default
PIN ALLOC: Pin 0 successfully allocated by 0x85.
PIN ALLOC: 0x0000000000000lX.
Starting usermod config.
JSON buffer released. (1)
heap 293488
Initializing strip
[  2827][E][vfs_api.cpp:24] open(): File system is not mounted
[  2833][E][vfs_api.cpp:24] open(): File system is not mounted
[  2838][E][vfs_api.cpp:24] open(): File system is not mounted
[  2844][E][vfs_api.cpp:24] open(): File system is not mounted
[  2850][E][vfs_api.cpp:24] open(): File system is not mounted
[  2855][E][vfs_api.cpp:24] open(): File system is not mounted
[  2861][E][vfs_api.cpp:24] open(): File system is not mounted
[  2867][E][vfs_api.cpp:24] open(): File system is not mounted
[  2872][E][vfs_api.cpp:24] open(): File system is not mounted
[  2878][E][vfs_api.cpp:24] open(): File system is not mounted
[  2883][E][vfs_api.cpp:24] open(): File system is not mounted
[  2889][E][vfs_api.cpp:24] open(): File system is not mounted
[  2895][E][vfs_api.cpp:24] open(): File system is not mounted
[  2900][E][vfs_api.cpp:24] open(): File system is not mounted
[  2906][E][vfs_api.cpp:24] open(): File system is not mounted
Digital buses: 1, I2S buses: 0
Heap before buses: 293488
PIN ALLOC: Pin 16 successfully allocated by 0x82.
PIN ALLOC: 0x0000000000000lX.
Estimated buses + pixel-buffers size: 780B
Heap after buses: 293064
Loading custom palettes
[  2913][E][vfs_api.cpp:24] open(): File system is not mounted
[  2919][E][vfs_api.cpp:24] open(): File system is not mounted
[  2924][E][vfs_api.cpp:24] open(): File system is not mounted
[  2930][E][vfs_api.cpp:24] open(): File system is not mounted
[  2936][E][vfs_api.cpp:24] open(): File system is not mounted
[  2941][E][vfs_api.cpp:24] open(): File system is not mounted
[  2947][E][vfs_api.cpp:24] open(): File system is not mounted
[  2952][E][vfs_api.cpp:24] open(): File system is not mounted
[  2958][E][vfs_api.cpp:24] open(): File system is not mounted
[  2964][E][vfs_api.cpp:24] open(): File system is not mounted
[  2969][E][vfs_api.cpp:24] open(): File system is not mounted
[  2975][E][vfs_api.cpp:24] open(): File system is not mounted
[  2980][E][vfs_api.cpp:24] open(): File system is not mounted
[  2986][E][vfs_api.cpp:24] open(): File system is not mounted
[  2992][E][vfs_api.cpp:24] open(): File system is not mounted
[  2997][E][vfs_api.cpp:24] open(): File system is not mounted
[  3003][E][vfs_api.cpp:24] open(): File system is not mounted
[  3009][E][vfs_api.cpp:24] open(): File system is not mounted
[  3014][E][vfs_api.cpp:24] open(): File system is not mounted
[  3020][E][vfs_api.cpp:24] open(): File system is not mounted
[  3025][E][vfs_api.cpp:24] open(): File system is not mounted
Loading custom ledmaps
[  3031][E][vfs_api.cpp:24] open(): File system is not mounted
strip buffer size: 120B
Heap after strip init: 292928B
-- Creating segment: 0x3fcec770 [0,30:0,1]
-- Started transition without old segment: S=0x3fcec770 T(0x3fcec7c8)
-- Updated transition with segment copy: S=0x3fcec770 T(0x3fcec7c8) O[0x3fcec824] OP[0x600fe210]
heap 292388
Usermods setup
PIN ALLOC: Pin 15 successfully allocated by 0x20.
PIN ALLOC: 0x0000000000000lX.
PIN ALLOC: FAIL for owner 0x20: GPIO 32  cannot be used as input on this MCU.
AR: Failed to initialize sound input driver. Please check input PIN settings.
heap 292144
getWLEDHostname: 'wled-6d7c38'
[  3594][E][WiFiGeneric.cpp:681] wifiLowLevelInit(): esp_wifi_init 4353
WiFi: Default SSID (WLAN2) used.
Ada
DMX input disabled due to rxPin, enPin or txPin not set
initServer
heap 272996
initIR
heap 272996
Initial connect or forced reconnect (@ 3s).
WiFi: Default SSID (WLAN2) used.
initConnection() called @ 3s.
WiFi disconnect.
getWLEDHostname: 'wled-6d7c38'
WiFi mode_null: driver teardown / re-init.
[  3616][E][WiFiGeneric.cpp:681] wifiLowLevelInit(): esp_wifi_init 4353
Access point disabled (init).
[  3624][E][WiFiGeneric.cpp:681] wifiLowLevelInit(): esp_wifi_init 4353
Connecting to WLAN2...
[  3631][E][WiFiGeneric.cpp:681] wifiLowLevelInit(): esp_wifi_init 4353
[  3637][E][WiFiSTA.cpp:166] begin(): STA enable failed!
WiFi maxTxPower set to 78; WiFi sleep disabled.
-- Stopping transition: S=0x3fcec770 T(0x3fcec7c8) O[0x3fcec824]
-- Destroying segment: 0x3fcec824 [0,30:0,1] T[0]
Image playback end called
Not connected AP (@ 15s).
Opening access point WLED-AP
[ 15626][E][WiFiGeneric.cpp:681] wifiLowLevelInit(): esp_wifi_init 4353
[ 15633][E][WiFiGeneric.cpp:681] wifiLowLevelInit(): esp_wifi_init 4353
[ 15639][E][WiFiAP.cpp:154] softAP(): enable AP first!
access point maxTxPower set to 78
Init AP interfaces
Connected AP clients: 34
Connected AP clients: 36
Connected AP clients: 37
Connected AP clients: 38
Connected AP clients: 39
Connected AP clients: 40
Connected AP clients: 41
Connected AP clients: 42
Connected AP clients: 43
Connected AP clients: 44
Connected AP clients: 45
Connected AP clients: 46
Connected AP clients: 47
Connected AP clients: 48
Connected AP clients: 49
Connected AP clients: 50
Connected AP clients: 51
Connected AP clients: 52

[....]

Connected AP clients: 231
Connected AP clients: 0
initConnection() called @ 15s.
WiFi disconnect.
getWLEDHostname: 'wled-6d7c38'
WiFi mode_null: driver teardown / re-init.
[ 15859][E][WiFiGeneric.cpp:681] wifiLowLevelInit(): esp_wifi_init 4353
Access point disabled (init).
[ 15867][E][WiFiGeneric.cpp:681] wifiLowLevelInit(): esp_wifi_init 4353
Connecting to WLAN2...
[ 15874][E][WiFiGeneric.cpp:681] wifiLowLevelInit(): esp_wifi_init 4353
[ 15881][E][WiFiSTA.cpp:166] begin(): STA enable failed!
WiFi maxTxPower set to 78; WiFi sleep disabled.
Last reconnect (15s) too old (@ 15s).
initConnection() called @ 15s.
WiFi disconnect.
getWLEDHostname: 'wled-6d7c38'
WiFi mode_null: driver teardown / re-init.
[ 15897][E][WiFiGeneric.cpp:681] wifiLowLevelInit(): esp_wifi_init 4353
Access point disabled (init).
[ 15904][E][WiFiGeneric.cpp:681] wifiLowLevelInit(): esp_wifi_init 4353
Connecting to WLAN2...
[ 15912][E][WiFiGeneric.cpp:681] wifiLowLevelInit(): esp_wifi_init 4353
[ 15918][E][WiFiSTA.cpp:166] begin(): STA enable failed!
WiFi maxTxPower set to 78; WiFi sleep disabled.
Not connected AP (@ 15s).
Opening access point WLED-AP
[ 15924][E][WiFiGeneric.cpp:681] wifiLowLevelInit(): esp_wifi_init 4353
[ 15931][E][WiFiGeneric.cpp:681] wifiLowLevelInit(): esp_wifi_init 4353
[ 15938][E][WiFiAP.cpp:154] softAP(): enable AP first!
access point maxTxPower set to 78
Init AP interfaces
Connected AP clients: 232
Connected AP clients: 76
[.....]

---DEBUG INFO---
Runtime: 30054
Unix time: 30,054
=== Memory Info ===
DRAM 8-bit:   Free:  250808 bytes | Largest block:  241652 bytes
PSRAM:        Free:       0 bytes | Largest block:      0 bytes
RTC RAM:      Free:    7648 bytes | Largest block:    7156 bytes
PSRAM: 0kB/0kB
TX power: 78/78
Wifi state: 255
ESP-NOW state: 0
State time: 30055
NTP last sync: 999000000
Client IP: 0.0.0.0
Loops/sec: 5712
Loop time[ms]: 0/102
UM time[ms]: 0/1
Strip time[ms]:0/2
Segments: 1 -> 192/0B
  Seg: 30,1 [A=1, 2D=0, RGB=1, W=0, CCT=0]
Modes: 4*220=880B
Data: 4*220=880B
Map: 2*0=0B
Web server status:  Idle
Connected AP clients: 104

[.....]

[softhack007]

• PSRAM init has failed, but we are lucky the bootloader continued without it
• NVS init failed -> not sure what this means
• Why does the firmware run with 40Mhz flash? On S3 this should always be 80Mhz (could be a bootloader problem)
• 8MB "partitions.bin" places the LittleFS filesystem after the 4MB flash end -> Mounting LittleFS failed!
• /wsec.json not found (File system is not mounted)
• bootloop detector tries to restore /cfg.json -> no backup found (File system is not mounted)
• freak-out starts after "Init AP interfaces" : Connected AP clients: 34, 35, ... 255 (rollover), 0, 1, ... -> needs further investigation

[netmindz]

Connected AP clients: 232 - what!

[softhack007]

yes, that's a consequence of the WLED::handleConnection()
using an esp-idf function without first checking error codes 😅

https://github.com/wled/WLED/blob/bc2c80d985d09cac2f9f912f6b14ee9f71f4a9bd/wled00/wled.cpp#L918-L919

should be if (ESP_OK == esp_wifi_ap_get_sta_list(&stationList)) stac = stationList.num;

but the real problem is - why does softAP error out? -> might be related to wrong defaults when file system is missing.