When I’m testing locally, it’s only occurring when the original image is smaller than the size I’m specifying, which makes sense because that’s the default behavior for wp_get_attachment_image_src() which is what is ultimately returning the images. But when I have this running on my server, it’s failing to return smaller files even when the original is huge (15MP images). It is seemingly random on the live site.
You’re not alone with this issue. Did you figure out the problem? I’m looking at plugin’s code to see if I can figure out what’s causing it, but no luck so far.