Error: The program size is greater than maximum allowed. But worked on version 2022.10

[quizzical86]

The problem

I updated ESPHOME to 2022.12 and wanted to upgrade my devices. However one of them can't compile and generates the error:
Error: The program size (1874625 bytes) is greater than maximum allowed (1835008 bytes)

On ESPHome version 2022.10.2 the YAML compiled just fine.
I wonder whether the issue is due to the changes in the flash partition table in version 2022.12? I understand those are for the bluetooth proxy and I am using that.
Is there a way I could solve this issue?

Which version of ESPHome has the issue?

2022.12.4

What type of installation are you using?

Home Assistant Add-on

Which version of Home Assistant has the issue?

2023.1.4

What platform are you using?

ESP32

Board

MH-ET LIVE D1 mini ESP32

Component causing the issue

No response

Example YAML snippet

No response

Anything in the logs that might be useful for us?

Linking /data/kamerlo/.pioenvs/kamerlo/firmware.elf
Error: The program size (1874625 bytes) is greater than maximum allowed (1835008 bytes)
RAM:   [==        ]  18.6% (used 61000 bytes from 327680 bytes)
Flash: [==========]  102.2% (used 1874625 bytes from 1835008 bytes)
*** [checkprogsize] Explicit exit, status 1
========================= [FAILED] Took 399.23 seconds

Additional information

No response

[quizzical86]

Could this change be the cause of my problem?
esphome/esphome#4171

[jgracio]

Here same error without any code change

[quizzical86]

The only solution I found was to cut parts of my code, e.g. the logger functionality so no more checking the logs for issues :-(

[marek-vrana]

same here, using nspanel with ble proxy configuration. Program is too big to fit even with the minimal features and no logging. Before it worked without any issues.

[lukin79]

Same issue w/o code change. Quite annoying.

[elik745i]

same thing: Error: The program size (1939513 bytes) is greater than maximum allowed (1835008 bytes)

[toomone]

Also same with Home Assistant 2023.7.3 and ESPHome v2023.2.2 :

Linking .pioenvs/irrigation-controller/firmware.elf
RAM:   [====      ]  43.2% (used 35388 bytes from 81920 bytes)
Flash: [==========]  106.6% (used 532625 bytes from 499696 bytes)
Error: The program size (532625 bytes) is greater than maximum allowed (499696 bytes)
*** [checkprogsize] Explicit exit, status 1
========================= [FAILED] Took 149.29 seconds =========================

Update: Same behavior with esphome 2023.7.0
Update2: after removing captive_portal, webserver and logger. This is better but still not ok.

Linking .pioenvs/irrigation-controller/firmware.elf
RAM:   [====      ]  39.4% (used 32276 bytes from 81920 bytes)
Flash: [========= ]  90.6% (used 452479 bytes from 499696 bytes)
Building .pioenvs/irrigation-controller/firmware.bin
esp8266_copy_factory_bin([".pioenvs/irrigation-controller/firmware.bin"], [".pioenvs/irrigation-controller/firmware.elf"])
======================== [SUCCESS] Took 128.56 seconds ========================
INFO Successfully compiled program.
INFO Connecting to 192.168.68.42
INFO Uploading /config/.esphome/build/irrigation-controller/.pioenvs/irrigation-controller/firmware.bin (456624 bytes)
INFO Compressed to 321025 bytes
ERROR Error binary size: Error: ESP does not have enough space to store OTA file. Please try flashing a minimal firmware (remove everything except ota)

[marek-vrana]

If you're using BLE proxies with arduino and having this issue, try to switch to esp-idf framework.
For nspanel, we'll just need to wait until esp-idf is supported (see this issue).

[toomone]

I got it working by doing the firmware update not over the air. Plug on the computer and with web Esphome works nicely. Then the OTA update works again.

[dabepp]

Plug on the computer and with web Esphome works nicely.

Same issue with my esp32 :-(

Linking .pioenvs/esphome-web-ee267c/firmware.elf RAM: [== ] 18.3% (used 60076 bytes from 327680 bytes) Flash: [==========] 112.8% (used 2070677 bytes from 1835008 bytes) Error: The program size (2070677 bytes) is greater than maximum allowed (1835008 bytes) *** [checkprogsize] Explicit exit, status 1 ========================= [FAILED] Took 117.91 seconds =========================

Gonna post my YAML later if anybody is intrested in.

[Tscherno]

Same issue here with three different devices. None of them can be updated OTA. I also can't easily reach them anymore for wired updating. That's really bad!

[lsdlsd88]

still an issue... any ideas?