My setupper gives the ERROR access denied dialog when overwriting one DLL fails,
its locked&in use sometimes.
what is recommended procedure for doing this..
Can I somehow make INNO to compare if its even necessary to overwrite this DLL (size match?)
InnoSetup automatically compares the files to see if it needs to be replaced by looking at the version resource in the file.
You should add the RestartReplace flag to the [Files] entry for your DLL (and any other file that might be in memory / locked). From the InnoSetup documentation: