Packaged as a Home Assistant add-on, with a field guide
Turns the reference RS485 controller into something a technician can install at a client site: a typed config form instead of YAML, an ingress UI that names misconfiguration in words, and persistent state that cannot be broken by a timezone. Why an add-on rather than YAML packages or blueprints: - Blueprints cannot create helpers, and the maintenance cycle is a state machine whose phase and completion date must survive restarts. - YAML packages need filesystem access, a configuration.yaml edit and a restart - none of which belong in a client install. - Add-ons authenticate with SUPERVISOR_TOKEN, so there is no long-lived token to generate, store or leak on someone else's machine. - Requires HA OS/Supervised. Container and Core installs cannot run add-ons at all, which is a market decision, not an oversight. The control law and the maintenance machine are pure functions with no Home Assistant imports, and both ship with runnable checks (22 and 22 assertions). Every assertion corresponds to a rule whose absence caused an observed failure on hardware - the saturation duration term, the clamp-before-slew ordering, the deadband, the sign convention. One behaviour deliberately differs from the implementation it replaces: when its inputs go missing this commands 0 W rather than replaying the last setpoint. The reference version kept replaying, which the hardware watchdog cannot catch - from the ESP32's side, Home Assistant is still talking to it. Includes the ESPHome firmware (now parameterised: node name, inverter rating, watchdog timeout) and the optional RS485 e-stop. FIELD-GUIDE.md carries the commissioning gates, all judged on the wire rather than on how Home Assistant looks, plus the written statement a site without an e-stop needs signed. Co-Authored-By: Claude Opus 5 <noreply@anthropic.com> Claude-Session: https://claude.ai/code/session_016NckgXecasQb2eSsPYNSW6
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Claude Opus 5
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"""The monthly battery maintenance cycle.
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⚠️ THIS IS THE PART THE VENDOR CONTROLLER DID THAT NOTHING ELSE REPLACES.
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A full low -> full cycle each month is a BMS-health behaviour on a 16S LiFePO4
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pack: the full charge is when the BMS gets to BALANCE CELLS, the deep discharge
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is what RECALIBRATES THE COULOMB COUNTER. Dropping it breaks nothing visibly -
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it degrades the pack over months, and the first symptom is a state-of-charge
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reading nobody can trust any more. Highest consequence, lowest visibility.
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OWNERSHIP, not priority. Exactly one thing writes the setpoint at any moment:
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phase setpoint owned by behaviour
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idle the control loop normal grid-to-zero
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drain THIS module forced discharge, exports the surplus
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charge the control loop charge-only clamp + cheap-window floor
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hold THIS module 0 W, parked full so the BMS can balance
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The loop is never "disabled" - it yields. The heartbeat to the inverter keeps
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running in every phase, so the hardware watchdog stays fed and a crash here
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still ends with the inverter at 0 W rather than latched.
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"""
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import logging
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from dataclasses import dataclass, field
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from datetime import datetime, timedelta, timezone
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_LOG = logging.getLogger("goodwe.maint")
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IDLE, DRAIN, CHARGE, HOLD = "idle", "drain", "charge", "hold"
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# A drain of a 13.5 kWh usable pack at 2500 W is ~5 h even with no house load
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# helping. 12 h means the battery is not following commands - a fault, not a
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# slow day. The charge phase deliberately waits for sun and for cheap hours, so
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# it is expected to span a night; 36 h still bounds it.
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DRAIN_TIMEOUT_MIN = 720
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CHARGE_TIMEOUT_MIN = 2160
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# After an abort, do not immediately re-trigger in the same start hour.
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RESTART_COOLDOWN_MIN = 90
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@dataclass(frozen=True)
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class MaintConfig:
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enabled: bool = False
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interval_days: int = 28
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start_hour: int = 10
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discharge_w: float = 2500.0
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charge_w: float = 2500.0
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soc_floor: float = 11.0
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soc_target: float = 99.0
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hold_min: int = 120
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@dataclass
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class MaintResult:
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phase: str
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owns_setpoint: bool
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setpoint_w: float | None = None
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charge_only: bool = False
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events: list = field(default_factory=list)
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class Maintenance:
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def __init__(self, cfg: MaintConfig, store):
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self.cfg = cfg
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self.store = store
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# -- state ---------------------------------------------------------------
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@property
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def phase(self) -> str:
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return self.store.data.get("phase", IDLE)
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def _enter(self, phase: str, now: datetime, events: list, msg: str) -> None:
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self.store.set("phase", phase)
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self.store.set_time("phase_started", now)
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_LOG.info("%s", msg)
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events.append(msg)
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def _elapsed_min(self, now: datetime) -> float:
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started = self.store.get_time("phase_started")
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return 0.0 if started is None else (now - started).total_seconds() / 60.0
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def due(self, now: datetime) -> bool:
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last = self.store.get_time("last_completed")
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if last is None:
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return True
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return (now - last) >= timedelta(days=self.cfg.interval_days)
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def next_due(self, now: datetime):
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last = self.store.get_time("last_completed")
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return None if last is None else last + timedelta(days=self.cfg.interval_days)
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# -- operations ----------------------------------------------------------
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def force_start(self, now: datetime) -> list:
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"""Start a cycle regardless of the calendar.
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Commissioning uses this: a cycle must be proven end to end before a site
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is signed off, and nobody waits a month to find out the schedule never
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fires.
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"""
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events = []
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self.store.set_time("last_start_attempt", now)
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self._enter(DRAIN, now, events, "maintenance: forced start -> drain")
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return events
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def abort(self, now: datetime, why: str) -> list:
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events = []
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self._enter(IDLE, now, events, f"maintenance: ABORT ({why})")
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return events
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# -- the machine ---------------------------------------------------------
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def tick(self, now: datetime, soc: float | None) -> MaintResult:
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events: list = []
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phase = self.phase
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if phase == IDLE:
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if self.cfg.enabled and now.hour == self.cfg.start_hour and self.due(now):
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last_try = self.store.get_time("last_start_attempt")
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cooled = (
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last_try is None
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or (now - last_try) >= timedelta(minutes=RESTART_COOLDOWN_MIN)
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)
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if cooled:
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self.store.set_time("last_start_attempt", now)
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self._enter(DRAIN, now, events,
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"maintenance: due -> drain (exports the surplus)")
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return MaintResult(DRAIN, True, self.cfg.discharge_w, False, events)
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return MaintResult(IDLE, False, None, False, events)
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# ⚠️ Fail toward inaction. Without a state-of-charge reading none of the
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# transitions below mean anything, and a stale "100 %" would end the
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# charge phase having charged nothing. Hold the current phase's command
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# and wait; the phase timeout is the backstop.
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if soc is None:
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_LOG.warning("maintenance: no SoC reading, holding phase %s", phase)
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if phase == DRAIN:
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return MaintResult(DRAIN, True, self.cfg.discharge_w, False, events)
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if phase == HOLD:
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return MaintResult(HOLD, True, 0.0, False, events)
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return MaintResult(CHARGE, False, None, True, events)
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elapsed = self._elapsed_min(now)
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if phase == DRAIN:
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if soc <= self.cfg.soc_floor:
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self._enter(CHARGE, now, events,
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f"maintenance: drain complete at {soc:.0f} % "
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f"after {elapsed:.0f} min -> charge")
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return MaintResult(CHARGE, False, None, True, events)
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if elapsed > DRAIN_TIMEOUT_MIN:
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events += self.abort(now, f"drain stuck at {soc:.0f} % after {elapsed:.0f} min")
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return MaintResult(IDLE, True, 0.0, False, events)
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return MaintResult(DRAIN, True, self.cfg.discharge_w, False, events)
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if phase == CHARGE:
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if soc >= self.cfg.soc_target:
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self._enter(HOLD, now, events,
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f"maintenance: charge complete at {soc:.0f} % after "
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f"{elapsed:.0f} min -> holding {self.cfg.hold_min} min to balance")
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return MaintResult(HOLD, True, 0.0, False, events)
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if elapsed > CHARGE_TIMEOUT_MIN:
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events += self.abort(now, f"charge stuck at {soc:.0f} % after {elapsed:.0f} min")
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return MaintResult(IDLE, True, 0.0, False, events)
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return MaintResult(CHARGE, False, None, True, events)
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if phase == HOLD:
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if elapsed >= self.cfg.hold_min:
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self.store.set_time("last_completed", now)
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self._enter(IDLE, now, events,
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f"maintenance: cycle COMPLETE ({elapsed:.0f} min hold) "
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"- handing back to the loop")
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return MaintResult(IDLE, False, None, False, events)
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# 0 W, not "do nothing": commanding zero is what stops the loop
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# pulling the pack straight back down the moment it is full, which
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# is exactly when the BMS needs it parked at the top.
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return MaintResult(HOLD, True, 0.0, False, events)
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_LOG.error("maintenance: unknown phase %r, forcing idle", phase)
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events += self.abort(now, f"unknown phase {phase!r}")
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return MaintResult(IDLE, True, 0.0, False, events)
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