System hanging/crashing when I unmute

[rosscullen]

Flavor

OpenWakeWord or no wake word

Checklist

• This issue only contains 1 issue (if you have multiple issues, open one issue for each issue).
• This issue is not a duplicate issue of currently previous issues..
• I am able to consult debug logging for my ESPHome instance.

Describe the issue

Hi, hope you can help me out on this one.
Have 2 x Onju Voice using ESPHome 2024.06.3.
Device appears to hang/crash when I unmute. Won't appear in logs if I boot the device unmuted.

Below are the logs (at [23:50:26] I flick the physical switch from "mute" to "unmute" - note personal detailed redacted in logs with *).
I note the 4 physical LEDS on device blink between Orange->Green->Orange->fadeout. Then after 9 cycles of this, the green LED's stay on and I am still unable to connect.

Config wise, i'm using exactly whats on the YAML file (and additionally my WiFi credentials and encryption key.

Any guidance greatly appreciated!

Reproduction steps

1. Unable to connect if unmuted. So I...
2. Boot up with mute on
3. Observe logs
4. Connection disconnected shortly afterwards
5. Have checked all connections
6. Have swapped boards in nests (in case of hardware faults with Onju Board or Nest Mini)
   ...

Debug logs

INFO ESPHome 2024.6.3
INFO Reading configuration /config/esphome/onju-voice-2a****.yaml...
INFO Starting log output from 192.168.*.* using esphome API
INFO Successfully connected to onju-voice-2a**** @ 192.168.9.26 in 0.026s
INFO Successful handshake with onju-voice-2a**** @ 192.168.9.26 in 0.131s
[23:50:13][I][app:100]: ESPHome version 2024.6.4 compiled on Jun 27 2024, 21:53:00
[23:50:13][I][app:102]: Project tetele.onju_voice_satellite version 1.0.0
[23:50:13][C][wifi:599]: WiFi:
[23:50:13][C][wifi:427]:   Local MAC: DC:DA:0C:********
[23:50:13][C][wifi:432]:   SSID: [redacted]
[23:50:13][C][wifi:435]:   IP Address: 192.168.9.**
[23:50:13][C][wifi:439]:   BSSID: [redacted]
[23:50:13][C][wifi:440]:   Hostname: 'onju-voice-2a****'
[23:50:13][C][wifi:442]:   Signal strength: -59 dB ▂▄▆█
[23:50:13][C][wifi:446]:   Channel: 6
[23:50:13][C][wifi:447]:   Subnet: 255.255.255.0
[23:50:13][C][wifi:448]:   Gateway: 192.168.*.*
[23:50:13][C][wifi:449]:   DNS1: 192.168.*.*
[23:50:13][C][wifi:450]:   DNS2: 0.0.0.0
[23:50:13][C][logger:185]: Logger:
[23:50:13][C][logger:186]:   Level: DEBUG
[23:50:13][C][logger:188]:   Log Baud Rate: 115200
[23:50:13][C][template.number:050]: Template Number 'Touch threshold percentage'
[23:50:13][C][template.number:051]:   Optimistic: YES
[23:50:13][C][template.number:052]:   Update Interval: never
[23:50:13][C][esp32_rmt_led_strip:175]: ESP32 RMT LED Strip:
[23:50:13][C][esp32_rmt_led_strip:176]:   Pin: 11
[23:50:13][C][esp32_rmt_led_strip:177]:   Channel: 0
[23:50:13][C][esp32_rmt_led_strip:202]:   RGB Order: GRB
[23:50:13][C][esp32_rmt_led_strip:203]:   Max refresh rate: 0
[23:50:13][C][esp32_rmt_led_strip:204]:   Number of LEDs: 6
[23:50:13][C][switch.gpio:068]: GPIO Switch 'dac_mute'
[23:50:13][C][switch.gpio:091]:   Restore Mode: always OFF
[23:50:13][C][switch.gpio:031]:   Pin: GPIO21
[23:50:13][C][gpio.binary_sensor:015]: GPIO Binary Sensor 'Disable wake word'
[23:50:13][C][gpio.binary_sensor:016]:   Pin: GPIO38
[23:50:13][C][light:103]: Light 'leds'
[23:50:13][C][light:105]:   Default Transition Length: 0.0s
[23:50:13][C][light:106]:   Gamma Correct: 2.80
[23:50:13][C][light:103]: Light 'left_led'
[23:50:13][C][light:105]:   Default Transition Length: 0.1s
[23:50:13][C][light:106]:   Gamma Correct: 2.80
[23:50:13][C][light:103]: Light 'top_led'
[23:50:13][C][light:105]:   Default Transition Length: 0.1s
[23:50:13][C][light:106]:   Gamma Correct: 2.80
[23:50:13][C][light:103]: Light 'right_led'
[23:50:13][C][light:105]:   Default Transition Length: 0.1s
[23:50:13][C][light:106]:   Gamma Correct: 2.80
[23:50:13][C][template.switch:068]: Template Switch 'Use Wake Word'
[23:50:13][C][template.switch:091]:   Restore Mode: restore defaults to ON
[23:50:13][C][template.switch:057]:   Optimistic: YES
[23:50:13][C][psram:020]: PSRAM:
[23:50:13][C][psram:021]:   Available: NO
[23:50:13][C][i2s_audio:028]: I2SController:
[23:50:14][C][i2s_audio:029]:   AccessMode: duplex
[23:50:14][C][i2s_audio:030]:   Port: 0
[23:50:14][C][i2s_audio:032]:   Reader registered.
[23:50:14][C][i2s_audio:035]:   Writer registered.
[23:50:14][C][i2s_audio:139]: I2S-Writer (Fixed-CFG):
[23:50:14][C][i2s_audio:141]:   sample-rate: 16000 bits_per_sample: 32
[23:50:14][C][i2s_audio:142]:   channel_fmt: 4 channels: 1
[23:50:14][C][i2s_audio:143]:   use_apll: no, use_pdm: no
[23:50:14][C][i2s_audio:136]: I2S-Reader (Fixed-CFG):
[23:50:14][C][i2s_audio:141]:   sample-rate: 16000 bits_per_sample: 32
[23:50:14][C][i2s_audio:142]:   channel_fmt: 4 channels: 1
[23:50:14][C][i2s_audio:143]:   use_apll: no, use_pdm: no
[23:50:14][C][esp32_touch:073]: Config for ESP32 Touch Hub:
[23:50:14][C][esp32_touch:074]:   Meas cycle: 0.80ms
[23:50:14][C][esp32_touch:075]:   Sleep cycle: 2.00ms
[23:50:14][C][esp32_touch:095]:   Low Voltage Reference: 0.8V
[23:50:14][C][esp32_touch:115]:   High Voltage Reference: 2.4V
[23:50:14][C][esp32_touch:135]:   Voltage Attenuation: 0V
[23:50:14][C][esp32_touch:169]:   Filter mode: IIR_16
[23:50:14][C][captive_portal:088]: Captive Portal:
[23:50:14][C][mdns:115]: mDNS:
[23:50:14][C][mdns:116]:   Hostname: onju-voice-2a****
[23:50:14][C][esphome.ota:073]: Over-The-Air updates:
[23:50:14][C][esphome.ota:074]:   Address: onju-voice-2a****.local:3232
[23:50:14][C][esphome.ota:075]:   Version: 2
[23:50:14][C][safe_mode:018]: Safe Mode:
[23:50:14][C][safe_mode:020]:   Boot considered successful after 60 seconds
[23:50:14][C][safe_mode:021]:   Invoke after 10 boot attempts
[23:50:14][C][safe_mode:023]:   Remain in safe mode for 300 seconds
[23:50:14][C][api:139]: API Server:
[23:50:14][C][api:140]:   Address: onju-voice-2a****.local:6053
[23:50:14][C][api:142]:   Using noise encryption: YES
[23:50:14][C][improv_serial:032]: Improv Serial:
[23:50:14][C][micro_wake_word:058]: microWakeWord:
[23:50:14][C][micro_wake_word:059]:   Wake Word: okay nabu
[23:50:14][C][micro_wake_word:060]:   Probability cutoff: 0.500
[23:50:14][C][micro_wake_word:061]:   Sliding window size: 10
[23:50:14][C][esp_adf_pipeline.microphone:020]: ADF-Microphone
[23:50:14][C][adf_media_player:016]: ESP-ADF-MediaPlayer:
[23:50:14][C][adf_media_player:018]:   MP_ANNOUNCE enabled
[23:50:14][C][adf_media_player:024]:   Number of ADFComponents: 3
[23:50:22][D][binary_sensor:036]: 'action': Sending state ON
[23:50:26][D][binary_sensor:036]: 'Disable wake word': Sending state OFF
[23:50:26][D][micro_wake_word:178]: State changed from IDLE to START_MICROPHONE
[23:50:26][D][light:036]: 'top_led' Setting:
[23:50:26][D][light:047]:   State: ON
[23:50:26][D][light:051]:   Brightness: 60%
[23:50:26][D][light:059]:   Red: 100%, Green: 0%, Blue: 100%
[23:50:26][D][light:109]:   Effect: 'listening_ww'
[23:50:26][W][component:237]: Component gpio.binary_sensor took a long time for an operation (57 ms).
[23:50:26][W][component:238]: Components should block for at most 30 ms.
[23:50:26][D][micro_wake_word:116]: Starting Microphone
[23:50:26][D][esp_adf_pipeline.microphone:025]: start request while ine state 0