OTA Flashing Sonoff 4CH Pros

[Methuselah]

I'm wondering if other folks using Sonoff 4CH Pros perform firmware upgrades through the web interface.

I have five of these units, and two of them work 100% of the time (first flashing the uploader, rebooting, and then uploading the new firmware).

Three of them fail 100% of the time on the last step (uploading the new firmware) -- they will accept the flash of the uploader and reboot, accept and flash the new firmware image, but fail to reboot after flashing the new firmware image.

It's gotten so bad that I soldered 3 test leads running outside the enclosre to the serial headers, and a SPST switch with wires running to the ESP chip and one of the grounds, so I can quickly connect a serial adapter, flip the switch, reboot, and reflash when the OTA flash fails.

Wondering if others have encountered similar issues.

[TD-er]

If I remember correctly, these 4ch pro versions have some jumpers/dipswitches connecting some ports to high or GND, right?
Is it possible these failing ones have a different setting of those switches compared to the one that's always successful?

Oh and some of the newer SONOFF's need DOUT, maybe the intermediate firmware (needed on 1M flash) also needs to be compiled with DOUT enabled?
Did you try to do all steps (initial firmware, intermediate and final) with DOUT set in the compile flags?

[Methuselah]

to be fair, I am not sure how the uploader I have (which works) was built. I do not recall offhand where I downloaded it from.

I attempted to download the source for the uploader (https://github.com/soif/EspBuddy/), and build it myself using these parameters:

[env:uploader_esp8285]
lib_deps = ${common.lib_deps}
build_flags = ${common.build_flags} -Wl,-Tesp8266.flash.1m128.ld
framework = arduino
platform = espressif8266@1.5.0
board = esp8285
board_flash_mode = dout

However, if I flash the resulting firmware.bin as my intermediate firmware, the system will fail to boot and I get the following over the serial link (endless loop):

Code: Select all

ets Jan  8 2013,rst cause:1, boot mode:(3,7)

load 0x4010f000, len 1384, room 16 
tail 8
chksum 0x2d
csum 0x2d
v3ffef8fc
~ld<LF>system param error
11 21 f7 ff 10 31 20 42 a0 0c 45 d4 da 12 61 04 0c 34 52 c1 10 61 f3 ff 72 c1 20 32 21 12 22 21 
13 29 61 39 51 22 21 10 32 21 11 01 ef ff c0 00 00 22 21 14 32 c1 20 1c 04 01 c1 54 c0 00 00 02 
21 15 12 c1 60 0d f0 00 26 22 14 26 82 15 26 d2 12 26 e2 13 42 d2 ff 0c d3 0c 02 40 23 83 0d f0 
2c 02 0d f0 1c 02 0d f0 0c 52 0d f0 26 22 0f 26 82 14 26 d2 15 26 e2 0a 26 f2 07 0c 02 0d f0 0c 
22 0d f0 0c 62 0d f0 0c 32 0d f0 0c 92 0d f0 00 08 ac 0f 00 37 63 14 51 d0 f8 31 8c fe 42 c2 fe 
40 35 83 46 00 00 0c 03 2d 03 0d f0 67 63 05 31 f8 ff 86 fc ff 17 63 08 51 5d fe 31 83 fe c6 f6 
ff 87 63 08 51 5b fe 31 82 fe c6 f3 ff 77 63 08 51 96 f5 31 c0 f8 c6 f0 ff 07 63 c9 51 53 fe 31 
79 fe c6 ed ff 00 00 00 0c f8 0c 89 72 af ac 0c 06 37 63 14 0c 15 62 42 00 82 42 01 0c 44 72 42 
02 42 42 03 4b 22 46 00 00 5d 06 67 63 0f 1b 55 92 42 03 62 42 00 82 42 01 72 42 02 4b 22 0c 29 
17 63 0f 1b 55 92 42 03 62 42 00 82 42 01 72 42 02 4b 22 07 63 0d 82 42 01 72 42 02 62 42 00 62 
42 03 1b 55 2d 05 0d f0 7c 28 5c 07 0c 29 0c 06 37 63 14 0c 15 62 42 00 72 42 01 0c 44 82 42 02 
42 42 03 4b 22 46 00 00 5d 06 17 63 0f 1b 55 92 42 03 62 42 00 72 42 01 82 42 02 4b 22 07 63 0d 
72 42 01 82 42 02 62 42 00 62 42 03 1b 55 2d 05 0d f0 00 00 f0 aa fe 3f e8 aa fe 3f 12 c1 d0 d9 
51 e9 61 59 81 f9 71 c9 41 09 31 cd 02 cc 33 0c 02 06 12 00 3a f2 29 21 0c 00 bc 25 dd 00 49 11 
69 01 c0 2c 20 72 21 00 61 f3 ff 41 f3 ff 52 21 01 c0 ef c0 3d 0e da 55 52 05 00 70 46 83 05 6e 
d9 96 b2 00 e7 a2 08 ca c2 68 81 1b dd d7 96 d1 82 df ff 28 21 0c 07 20 2c c0 72 48 ff c8 41 d8 
51 e8 61 f8 71 08 31 12 c1 30 0d f0 0c 16 12 c1 f0 09 01 85 f8 ff 08 01 12 c1 10 0d f0 00 00 00 
0c 06 12 c1 f0 09 01 45 f7 ff 08 01 12 c1 10 0d f0 00 00 00 0c 02 0d f0 0c 02 0d f0 12 c1 f0 02 
61 00 16 e3 00 02 02 00 52 a0 30 57 90 05 05 92 ff 46 01 00 10 11 20 c5 aa ff 08 01 12 c1 10 0d 
f0 00 00 00 72 02 01 52 02 05 cc 27 0c 12 0d f0 b6 67 37 82 02 02 92 02 03 62 02 04 00 99 11 80 
66 11 80 88 01 60 55 20 61 53 f8 90 88 20 80 55 20 67 95 16 82 02 06 66 18 10 92 02 07 cc a9 29 
04 a2 02 01 2b aa a9 14 c6 1f 00 5b b2 37 bb 2f 1c 33 77 b3 2a 52 02 05 82 02 02 92 02 03 62 02 
04 00 99 11 80 66 11 80 88 01 60 55 20 61 42 f8 90 88 20 80 55 20 67 95 06 6b 72 79 44 86 12 00 
b6 77 47 81 11 f5 62 02 03 52 02 04 32 02 05 80 55 11 50 33 20 52 02 02 00 66 11 80 55 01 60 55 
20 50 33 20 87 93 0e 6b 72 79 54 62 02 01 62 c6 fc 69 64 06 05 00 b6 77 11 81 30 f8 87 93 0b 6b 
a2 a9 74 92 02 01 92 c9 fc 99 84 0c 02 0d f0 00 12 c1 e0 f9 61 09 21 c9 31 d9 41 e9 51 dd 04 ed 
03 cd 02 0c 03 2d 04 d9 11 2c 44 01 67 57 c0 00 00 a6 2e 70 3c 0f 0c 02 ea dc e2 a0 dd 0b 0d 09 
01 02 0c 00 32 0c 01 e7 90 0c 38 01 c7 13 46 32 0c 01 cc 13 86 0f 00 ca 33 2b 33 37 3d 35 f7 90 
1b 58 11 c9 25 42 0c 01 2b 44 49 35 32 0c 01 ca 33 2b 33 cd 03 1b 43 d7 34 c6 06 06 00 e7 90 f2 
2d 0c 3d 0d 48 11 c5 eb ff 96 92 00 a6 12 dc 0c 02 46 00 00 7c f2 c8 31 d8 41 e8 51 f8 61 08 21 
12 c1 20 0d f0 0c 02 c6 fa ff 00 00 1c 77 37 b7 74 0c 49 82 af dd 0c 13 7c 2b 5c 0a a2 42 03 b2 
42 04 32 42 05 82 42 00 32 42 06 0c 08 82 42 02 82 42 07 66 85 0e 92 42 0b 82 42 08 a2 42 09 b2 
42 0a c6 06 00 66 25 07 0c 25 52 42 0b 06 fa ff 66 f5 1e 82 42 08 a2 42 09 b2 42 0a 0c 55 52 42 
0b 32 42 0c 82 42 0d 26 84 24 66 24 1c 0c 29 06 07 00 66 e5 10 82 42 08 a2 42 09 b2 42 0a 5d 03 
86 f6 ff 26 b6 25 7c f2 0d f0 66 14 f8 9d 08 92 42 11 82 42 0e a2 42 0f b2 42 10 32 42 12 82 42 
13 26 16 09 66 26 db 0c 23 46 00 00 3d 08 82 42 14 a2 42 15 b2 42 16 1c 66 32 42 17 62 42 01 1c 
82 0d f0 00 
90 cc a0 00 66 10 a0 66 30 60 55 30 52 4b 0b 50 a8 75 50 60 f5 62 4b 09 a2 4b 08 50 58 41 52 4b 
0a a8 32 d8 0d c8 0c e0 dd 10 40 e0 74 90 ee a0 e8 0e 00 cc 10 e0 e8 74 e0 aa 30 30 e8 75 90 ee 
a0 e8 0e 08 11 80 ee 11 f0 ee 10 e0 dd 30 f8 51 e8 41 d0 cc 30 c0 aa 30 a2 4b 0f a0 d8 75 a0 c0 
f5 c2 4b 0d d2 4b 0c c8 21 d8 31 a0 a8 41 a2 4b 0e 12 c1 20 0d f0 00 00 00 28 28 40 42 a0 73 30 
63 20 20 72 20 12 c1 f0 c2 61 03 22 a0 f4 31 fa ff 09 21 79 11 69 01 01 12 54 c0 00 00 cd 02 9c 
92 48 01 38 11 d0 44 11 c5 14 00 d6 22 01 2d 0c 31 f2 ff 42 a0 78 01 59 4a c0 00 00 0c 0c 86 00 
00 22 6c 3c 2d 0c 08 21 c8 31 12 c1 10 0d f0 00 5d 04 12 c1 f0 4d 03 09 01 32 22 3c 05 b8 ff 08 
01 12 c1 10 0d f0 00 00 0c 03 42 a0 f4 12 c1 f0 c9 11 09 01 cd 02 01 fc 53 c0 00 00 31 df ff 2d 
0c 42 a0 8a c8 11 01 45 4a c0 00 00 08 01 12 c1 10 0d f0 00 12 c1 c0 f2 61 08 02 61 04 c2 61 05 
d9 61 e9 71 39 c1 ed 05 32 a0 a6 dd 02 cd 04 2d 05 0c 84 01 ed 53 c0 00 00 3d 0c 48 c1 8b 2e 29 
a1 d0 44 11 01 7f 50 c0 00 00 2d 0d 1c 03 c5 f2 ff cc 32 7c f2 c6 22 00 8b f1 29 e1 68 c1 0c 05 
0c 07 79 d1 59 b1 1b 66 69 91 82 21 0c c2 21 0a a6 18 55 92 21 0d a8 91 1b d9 aa 99 99 f1 2d 01 
3d 0e 0c 84 01 6f 50 c0 00 00 2d 0f 3d 0c 0c 84 01 6c 50 c0 00 00 28 e1 3d 01 4d 01 05 f3 ff 2d 
0e 3d 01 0c 84 01 66 50 c0 00 00 2d 0c 3d 0f b2 0e 07 0c 84 b0 bd 30 b2 4e 07 01 61 50 c0 00 00 
8b cc 08 f1 1b dd 07 9d b4 42 21 0c 22 21 0b 32 21 0d 1b 22 29 b1 4a 33 39 d1 66 62 8c 28 e1 85 
f0 ff 0c 02 c8 51 d8 61 e8 71 f8 81 08 41 12 c1 40 0d f0 00 f0 d0 ff 3f 12 c1 e0 09 31 a2 03 03 
c9 41 b2 03 02 c2 03 01 80 bb 11 b0 aa 30 b2 03 00 00 cc 11 80 bb 01 c0 bb 30 b0 aa 30 a9 02 a2 
03 05 92 03 06 82 03 07 80 99 11 90 88 30 92 03 04 00 aa 11 80 99 01 a0 99 30 90 88 30 a1 86 fe 
91 66 66 89 12 82 03 09 72 03 0a 62 03 0b 80 77 11 70 66 30 72 03 08 00 88 11 80 77 01 80 77 30 
70 66 30 81 7e fe 71 54 5f 69 22 62 03 0d 52 03 0e 02 03 0f 80 55 11 50 00 30 52 03 0c 00 66 11 
80 55 01 60 55 30 61 db ff 50 00 30 09 32 66 e4 6d ab c6 0d 06 48 32 62 00 00 1b 00 80 66 01 40 
30 74 40 b8 75 40 50 75 a0 55 a0 a0 bb a0 a0 33 a0 38 03 b8 0b 58 05 b0 b8 74 80 55 11 b0 66 30 
40 b8 74 a0 bb a0 b8 0b 80 33 10 70 bb 10 b0 33 30 b8 02 90 55 10 50 bb 30 30 bb 30 58 12 38 22 
b0 66 30 69 42 60 55 30 50 33 30 59 52 39 62 40 33 30 39 72 22 c2 10 c7 90 9a 0c a2 46 79 00 02 
03 11 c2 03 12 b2 03 13 80 cc 11 c0 bb 30 c2 03 10 00 00 11 80 cc 01 00 cc 30 c0 bb 30 b9 42 c2 
a0 c0 c0 c4 c0 b2 03 15 52 03 16 02 03 17 80 55 11 50 00 30 52 03 14 00 bb 11 80 55 01 b0 55 30 
7b b6 50 00 30 09 52 56 ac 08 0d 06 8b 56 59 01 58 52 59 21 50 c8 74 50 60 74 a0 66 a0 a0 cc a0 
c8 0c 68 06 70 7c 10 80 66 10 70 66 30 c8 02 50 70 75 50 58 75 a0 77 a0 78 07 a0 55 a0 58 05 80 
77 11 50 58 74 90 77 10 70 cc 30 60 cc 30 72 00 00 68 12 80 77 01 50 77 30 c0 77 30 58 22 c8 32 
79 62 70 66 30 69 72 60 55 30 71 03 5f 59 82 50 cc 30 c9 92 b0 60 c0 16 86 13 1b 00 68 42 58 21 
c0 66 30 69 a2 50 66 30 69 b2 58 01 22 c2 18 57 10 02 86 de ff 02 03 19 c2 03 1a 62 03 1b 80 cc 
11 c0 66 30 c2 03 18 00 00 11 80 cc 01 00 cc 30 c0 66 30 c2 d4 ff 69 62 62 03 1d 52 03 1e 02 03 
1f 80 55 11 50 00 30 52 03 1c 00 66 11 80 55 01 60 55 30 50 00 30 09 72 56 7c 0c 01 76 ff 6b 30 
39 11 c2 00 00 48 72 80 cc 01 40 50 74 40 38 75 40 60 75 a0 66 a0 a0 33 a0 a0 55 a0 58 05 38 03 
68 06 30 38 74 80 66 11 30 cc 30 40 38 74 a0 33 a0 38 03 80 55 10 70 33 10 30 55 30 38 02 90 66 
10 60 33 30 50 33 30 68 12 58 22 30 cc 30 c9 82 38 32 c0 66 30 69 92 60 5<NUL>’<FF><CAN>Ž<FF><FS><NUL>lŽã<FF><CAN><STX>bÇ<NUL>lŽÀ<FF><CAN>Žì<FS><NUL>ì<FS>€<FF><CAN>’<FF><US><NUL>l`<ESC>$<SO>‚<FF><CAN>Žl<US><NUL>Œ8Œ<FF><CAN>’ìŽ<NUL>l`<ESC>ÄŽ‡<FF><CAN>œŒ8<NUL><FF><FS>€<FF><CAN><FF>Ž<NUL>ŒŽÃ<FF><CAN>žl<US><NUL>Œ<FS><SO><STX>ÄÛ<FF>Ž<NUL>ŒŽã<FF><CAN>œ<FF>œ<NUL>ŒŽ›<FF><CAN>Œ<FF><FS><NUL><FF><FS>€<FF><CAN>Œœ<NUL>ŒŽ<ESC><STX>ÄÀ<FF><FS><NUL><FF>Ž<FS><STX>ÄÜŒŽ<NUL>ŒŽÜ<FF><CAN>€<FF><FS><NUL><FF><FS>€<FF><CAN>Œœ<NUL>ìŽÛ<FF><CAN>ž<FF>Ž<NUL>ìŽÀ<FF><CAN>žlŽ<NUL>ìŽØ<FF><CAN>€<FF><FS><NUL>l`<ESC>üá
Exception (29):
epc1=0x4000e1c3 epc2=0x00000000 epc3=0x00000000 excvaddr=0x00000018 depc=0x00000000

ctx: cont 
sp: 3fff0600 end: 3fff0ab0 offset: 01a0

>>>stack>>>
3fff07a0:  402352d5 00000017 60000200 40106958  
3fff07b0:  4022a0c1 40231c52 00000001 40213f16  
3fff07c0:  42fff2ec 402255e3 3fff283c 3fff22e4  
3fff07d0:  4022a302 3fff283c 3fff22e4 00000000  
3fff07e0:  3ffeef68 3ffee060 3ffedfdc 3fff22e4  
3fff07f0:  00000000 00000000 00000000 00000000  
3fff0800:  00000018 00000064 9f940162 fffeffff  
3fff0810:  3ff20a00 0000ffff 3fff0838 40225c66  
3fff0820:  3ffedfdc 3fff22e4 3fff22e4 00000000  
3fff0830:  9f940162 3fff1346 00000000 00000000  
3fff0840:  00000000 00000000 00000000 00000000  
3fff0850:  00000000 00000000 00000000 00000000  
3fff0860:  00000000 00000000 00000000 40226db4  
3fff0870:  3fff22e4 00000000 3ffeef68 40226dfc  
3fff0880:  00000000 3ffee060 3ffedb58 00000000  
3fff0890:  40218239 00000003 00000003 4020a508  
3fff08a0:  40218389 00000003 00000003 000e1d00  
3fff08b0:  3ffee1d4 40218412 00000003 00000001  
3fff08c0:  402011e3 3ffef8fc 00000001 00000000  
3fff08d0:  40201214 000e1d00 3ffef8fc 40201236  
3fff08e0:  3fff1500 3ffeef68 3ffeef88 40201807  
3fff08f0:  3fff1bdc 00000100 0000000a 4020aa0d  
3fff0900:  3fff1500 3fff198c 000e1d00 3fff1bc8  
3fff0910:  3fff1500 3fff198c 000e1d00 4020cd7d  
3fff0920:  00000005 3fff0950 00000000 00000000  
3fff0930:  0000000e 00000000 0000000e 3fff18d8  
3fff0940:  0000006d 00006d00 3fff1500 4020a70c  
3fff0950:  00000002 000000fc 00001000 63657301  
3fff0960:  00000001 3fff0a30 00000074 3fff0bac  
3fff0970:  00000010 3fff0a14 00000000 4020919d  
3fff0980:  00000100 3fff1500 3fff18d4 4020c968  
3fff0990:  000000af 00000000 3fff09a6 3ffefa88  
3fff09a0:  00000010 3fff0a14 3fff0a14 40206474  
3fff09b0:  3ffe8fb8 00000000 3fff0a14 402064c3  
3fff09c0:  00000000 3ffef8fc 00000001 3fffdad0  
3fff09d0:  4021902f 3ffef9cc 3fff0a14 3ffeef68  
3fff09e0:  00000001 3ffeef4c 3ffef8fc 40201988  
3fff09f0:  3fffdad0 3ffeef4c 3ffef8fc 40210179  
3fff0a00:  3ffeef68 00000001 3fff1f0c 40207cbb  
3fff0a10:  3ffeef68 3fff1f0c 0000000f 00000000  
3fff0a20:  3ffeef68 000000a0 3fff0a50 4020580e  
3fff0a30:  3fff1f0c 3fff1f4c 00000000 00000000  
3fff0a40:  3ffeef68 000000a0 000000a0 4020ff71  
3fff0a50:  3ffe8c58 00000000 000003e8 3ffefa88  
3fff0a60:  00000003 00000000 3fff14fc 402085d3  
3fff0a70:  3fffdad0 3ffef9cc 3ffef9cc 3ffefa88  
3fff0a80:  3fffdad0 3ffef9cc 3ffef8fc 402102cc  
3fff0a90:  feefeffe 00000000 3ffefa80 40206d04  
3fff0aa0:  feefeffe feefeffe 3ffefa90 402093e4  
<<<stack<<<

[TD-er]

Sounds like the ones failing OTA are newer than the ones that work.
The thing is the uploader is also writing to the flash, so it should also run in the same (limited) mode demanded by the flash chip.
And if the working modules use a flash chip that is willing to use >1 data pin, but also can communicate in DOUT mode, then it doesn't really matter which flash mode is selected.
However if there was some budget-cut decision to lower costs and only use 1 data pin, then all writes to the flash should be done in DOUT mode or else data is lost or corrupted.

[Methuselah]

Removing the board_flash_mode parameter from the intermediate firmware build yields a firmware.bin that will not boot whatsoever (no activity on the serial port).

[TD-er]

Well at least it is proven then that there is a need for something slower than QIO, and that the build parameter is doing something Not sure what the default flash speed is though.

The used flash chips are mentioned in the Tools => info page.
Do they differ between the versions that work with OTA and those that won't?

[Methuselah]

Alas, both appear to be identical, with the exception of the Chip ID, which differs for each unit.

ESP Chip ID 10438163 (0x9F4613)
ESP Chip Freq: 80 MHz
Storage
Flash Chip ID Vendor: 0x51 Device: 0x4014
Flash Chip Real Size: 1024 kB
Flash IDE Size: 1024 kB
Flash IDE speed: 40 MHz
Flash IDE mode: DOUT

[TD-er]

N.B. The chipID is the last 24 bits of the MAC address.

[Methuselah]

Yeah.

Not really sure why I have a problem with these units. I can git pull the regular repo and build it out, flash it with flashesp8266, and not have an issue.... but cannot build the intermediate loader and flash it without getting that dump on boot. No idea if the intermediate loader I have (which works) was built w/ dout or not in the compile flags.... *shrug* guess I'm stuck with SPST switches and external connections.

[TD-er]

Or that the intermediate file should be specially built for ESP8285 instead of ESP8266?