Leviton Decora Smart Plug DW15 Solving Power Surge Reset Failures

Introduction

The Leviton Decora Smart Plug DW15 is a popular choice for homeowners who want to add remote control and scheduling to everyday appliances. Its built‑in surge protection is one of the key selling points, promising to safeguard sensitive electronics from voltage spikes. However, many users report a specific problem: after a power surge, the plug fails to reset and remains non‑functional until a manual reset is performed. In some cases the reset button does not respond at all, leaving the device effectively dead.

Understanding why these reset failures occur, and learning a systematic approach to solve them, can save you time, money, and frustration. This article walks through the underlying technology, common failure modes, and a step‑by‑step troubleshooting guide that will help you get your DW15 back online or decide when it is time to replace it.

How the DW15 Surge Reset Feature Works

The DW15 incorporates a small metal‑oxide varistor (MOV) circuit that shunts excess voltage away from the downstream outlet. When a surge exceeds the MOV’s threshold, the component conducts and the internal logic flags a fault condition. The smart plug then disables power to the outlet and requires a manual reset to clear the fault.

The reset mechanism is a physical button located on the side of the plug. Pressing it sends a brief low‑level pulse to the microcontroller, which interprets the signal as a command to re‑enable the power MOSFET that controls the outlet. The microcontroller also checks the status of the surge protection circuit; if the MOV has been permanently damaged, the reset will be blocked to prevent unsafe operation.

In a fully functional unit, the reset process takes less than two seconds: press the button, hear a click, and the LED indicator changes from red (fault) to green (ready). When this sequence fails, the root cause can be either a software glitch, a hardware fault, or an issue with the surrounding electrical environment.

Common Causes of Reset Failures

Over‑stressed MOV

If a surge is larger than the MOV’s rating, the component can become permanently shorted. The internal firmware detects this condition and disables the reset button to avoid passing dangerous voltage to connected devices.

Firmware Bugs

Leviton periodically releases OTA (over‑the‑air) updates to improve stability. Certain early firmware versions had known bugs where the reset flag was not cleared after a surge, causing the plug to stay in fault mode even after a manual reset.

Power Supply Instability

The DW15 draws power from the line voltage to run its Wi‑Fi radio and control circuitry. If the incoming voltage fluctuates repeatedly (for example, due to a failing breaker or loose neutral), the microcontroller may not receive a clean reset signal, leading to a “stuck” state.

Mechanical Button Wear

Repeated pressing of the reset button can wear down the contacts. A compromised button may not deliver the required voltage pulse, resulting in an apparent software issue when the problem is purely mechanical.

Network Interference

Because the DW15 communicates via Wi‑Fi, a loss of network connectivity can prevent the device from reporting its status correctly. The companion app may show the plug as “offline” while the hardware is actually awaiting a reset.

Diagnosing Your DW15

Before diving into disassembly or replacement, follow a systematic diagnostic process. This reduces the chance of overlooking a simple fix and gives you clear data to share with Leviton support if needed.

Visual Inspection

1. Unplug the DW15 from the wall outlet.
2. Examine the plug’s exterior for scorch marks, melted plastic, or a burnt smell. These are strong indicators of a failed MOV.
3. Check the reset button for any visible debris or damage.

LED Indicator Check

• Solid red: Fault state, usually due to a surge.
• Flashing red: Attempting to reconnect to Wi‑Fi.
• Solid green: Normal operation.
• No light: Power supply issue or internal failure.

App Status

Open the Leviton Decora Smart app and locate the DW15 device. Note the status message:

• “Surge fault – reset required” – the plug has detected a surge and is waiting for a manual reset.
• “Offline” – the plug is not communicating; could be a network or power issue.
• “Error – reset button not responding” – the app has logged a failed reset attempt.

Power Meter Test

If you have a plug‑in power meter, connect it between the DW15 and the wall outlet. Verify that the meter reads a small standby current (typically under 0.5 W) when the plug is in fault mode. A zero‑reading suggests the internal circuitry is completely shut down.

Step‑by‑Step Troubleshooting Guide

Step 1 – Perform a Hard Reset

1. Unplug the DW15 from the wall.
2. Wait at least 30 seconds. This allows any residual charge in the MOV and capacitors to dissipate.
3. Press and hold the reset button for five seconds while the plug is still unplugged.
4. Plug the device back into the outlet while still holding the button for another two seconds, then release.

If the LED turns green, the reset was successful. If the LED remains red or dark, proceed to the next step.

Step 2 – Verify Firmware Version

1. Open the Leviton app and navigate to the device settings.
2. Locate the firmware information; it is displayed as a version number (e.g., 2.3.1).
3. Compare this version with the latest release listed on Leviton’s support page.

If your plug is running an older firmware known to have reset bugs, initiate an OTA update:

• Ensure the plug is powered and connected to Wi‑Fi.
• Select “Check for updates” in the app and follow the prompts.
• Allow the update to complete without interruption; the plug will reboot automatically.

After the update, repeat the hard reset procedure.

Step 3 – Test the Reset Button Mechanically

If the button feels loose or does not produce a click, try the following:

1. Using a small, non‑conductive tool (such as a wooden toothpick), press the button firmly to ensure full travel.
2. Observe whether the LED changes state.
3. If there is still no response, the internal contacts may be worn out, and the plug will likely need replacement.

Step 4 – Isolate the Electrical Environment

Surge protection devices can be sensitive to the quality of the upstream power. Perform these checks:

• Plug the DW15 into a different wall outlet on a separate circuit.
• Use a surge protector or a UPS (uninterruptible power supply) between the wall and the plug to provide a clean voltage source.
• Observe whether the reset now works. If it does, the original circuit may have a persistent voltage irregularity that continues to trigger the fault.

Step 5 – Reset via the App (Software Reset)

Some newer firmware versions allow a remote reset command:

1. In the Leviton app, select the DW15 device.
2. Tap “More options” and choose “Reset device.”
3. Confirm the action.

If the app reports success but the plug remains in fault mode, the issue is likely hardware‑related.

Step 6 – Examine the MOV (Advanced)

Warning: This step involves opening the plug and should only be performed by qualified persons. Doing so may void the warranty.

1. Remove the outer shell by unscrewing the mounting screws.
2. Locate the MOV; it is a small cylindrical component attached near the power input.
3. Use a multimeter set to resistance (Ω) to measure the MOV across its leads. A healthy MOV reads high resistance in both directions (typically >10 MΩ).
4. If the reading is near zero (shorted) or very low, the MOV has failed and must be replaced.

Replacement requires a MOV with the same voltage rating (usually 275 V RMS) and energy rating (e.g., 150 J). Re‑solder the new component, reassemble the plug, and retry the reset.

Step 7 – Contact Leviton Support

If all the above steps fail, gather the following information before reaching out:

• Serial number and model (DW15).
• Firmware version and date of last update.
• Description of the surge event (e.g., lightning strike, breaker trip).
• Results of the visual inspection, LED behavior, and any measurements taken.

Leviton’s support team can confirm whether the unit is covered under warranty and provide a replacement if a hardware defect is confirmed.

Firmware Update – Why It Matters

Leviton’s OTA updates address several hidden issues that can manifest as reset failures:

• Improved fault detection logic – earlier firmware sometimes misinterpreted transient voltage dips as permanent surges, unnecessarily disabling the reset button.
• Enhanced Wi‑Fi handling – better reconnection algorithms reduce the chance that a loss of network connectivity leaves the device stuck in fault mode.
• Security patches – keeping the firmware current protects the plug from remote exploits that could manipulate the reset state.

Always ensure your plug is running the latest stable version. The update process typically takes 2‑3 minutes, during which the plug will blink blue. Avoid unplugging or turning off Wi‑Fi until the update completes.

Preventing Future Surge Reset Issues

Even a perfectly functioning DW15 can be knocked offline by a severe power event. Here are proactive steps to minimize the risk of future reset failures.

Use Whole‑House Surge Protectors

A dedicated whole‑house surge protector installed at the service panel can absorb the bulk of a lightning‑induced surge before it reaches branch circuits. This reduces the stress on individual device MOVs.

Avoid Overloading Circuits

Connecting high‑draw appliances (e.g., space heaters, air conditioners) to the same circuit as your smart plugs can create voltage sag and spikes when those appliances cycle on and off. Distribute load across multiple circuits.

Regular Firmware Maintenance

Set a reminder to check for firmware updates monthly. The Leviton app can send push notifications when a new version is available.

Check Wiring Integrity

Loose connections at outlets or in the breaker panel can cause intermittent surges. Periodically tighten outlet screws and have an electrician inspect the panel for corrosion or loose lugs.

Keep the Reset Button Clean

Dust and debris can interfere with the mechanical action of the reset button. Occasionally use compressed air to blow out any particles that may have settled around the button aperture.

When Replacement Is the Best Option

Not every reset failure can be repaired cost‑effectively. Consider replacing the DW15 under the following circumstances:

• MOV Shorted – a failed MOV typically requires soldering a new component, which is impractical for most homeowners.
• Physical Damage – cracked housing, melted plastic, or burnt odor indicate severe internal damage.
• Repeated Failures – if the plug has experienced multiple surge events and each time the reset fails, the cumulative stress may have weakened internal components beyond repair.
• Outdated Model – newer Leviton smart plugs offer higher energy ratings, faster Wi‑Fi, and additional features such as energy monitoring. Upgrading may provide better overall reliability.

When ordering a replacement, ensure you choose a model with the same voltage and current ratings (typically 15 A, 125 V) and the Decora form factor for seamless wall‑plate integration.

Summary

The Leviton Decora Smart Plug DW15 is a reliable device when its surge protection and reset mechanisms function as intended. Reset failures usually stem from one of three sources: a permanently damaged MOV, outdated firmware, or a mechanical issue with the reset button. By following a structured diagnostic approach—visual inspection, LED status check, firmware verification, hard reset, and, if necessary, MOV testing—you can resolve most problems without resorting to a wholesale replacement.

Keeping the plug’s firmware up to date, protecting your home’s electrical system with a whole‑house surge protector, and maintaining clean, well‑wired outlets are proactive measures that reduce the likelihood of future reset failures. When hardware damage is evident, replacing the unit is safer and more economical than attempting a repair.

With these strategies in hand, you can enjoy the convenience of remote control and energy monitoring that the DW15 offers, while ensuring that your connected devices remain protected from the inevitable power surges that accompany modern living.