Hey @pixelboy. It can be hard to say exactly why SmartConfig is failing, but I'm glad that setup over USB is working for you. In our experience, SmartConfig can fail in the following cases:
- The router is set to 5GHz mode
- The network is configured as an enterprise network
- The network is configured as an 802.11n or ac network without legacy support
You can find some more information about failure conditions for SmartConfig in this thread:
Ultimately lots of the issues with SmartConfig are rooted in hard limitations of the CC3000, and aren't "fixable" until we have a chance to redesign the Core.
Hope that helps!