SAFETY-85: no false 'not keeping up' while maintenance or the peak guard sets the battery
checks / unit (pull_request) Successful in 25m35s
infra-pin / fresh (pull_request) Successful in 2s

The loop's integrator bound counts only on a cycle the loop decided. A battery
another owner set (maintenance, the peak guard, a safety limit) alarms only
when it gives more than saturation_w less than told for saturation_cycles
cycles. At N>=2 the loop is bounded while maintenance holds a battery, so it
does not wind and control comes back one slew step a cycle. The status row
counts episodes, not cycles. Digests re-pinned where behaviour changed on
purpose; DECISIONS/SAFETY-85-no-false-not-keeping-up.md has the list.

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_019DBUfvndgHwaV339Fvd2gr
This commit is contained in:
glenn schrooyen
2026-10-01 19:05:27 +02:00
co-authored by Claude Opus 5.5
parent 935878193b
commit 4b81387908
12 changed files with 554 additions and 35 deletions
@@ -0,0 +1,80 @@
# SAFETY-85 - no false "not keeping up" while another owner sets the battery
**Status: implemented 2026-10-01, for review.** Tests: `test_safety85.py`.
**The defect.** "Battery is not keeping up" (SAFETY-40, `goodwe_integrator_bound`)
fired about every 2.5 min during maintenance (drain, charge, HOLD) and under the
peak guard, while the battery gave exactly what it was told. Each warning
re-created the HA notification. Rig counts: 24 in an hour (SAFETY-83 F1), 43 in
7 episodes (SAFETY-86), 35 in 16 (SAFETY-87), 12 in 6 (SAFETY-84). The page
counter counted cycles (861), not episodes.
**Cause, measured on the real Controller.**
- N=1: when a higher claim decides, `cycle()` re-seeds the integrator from the
target each cycle, then `compute()` adds `gain * error` for a grid error the
loop does not own. Target + kick crosses the rail and sets `i_clamped`. The
carried integrator is not wound (SAFETY-48 caps the lead at one slew step),
so control comes back one slew step at a time.
- N>=2: a maintenance pin is a unit claim. The loop stays the site winner and
winds to its rail for watts the pinned battery may not give. When the pin
lifts, the site jumps: 2500 W in one cycle when a HOLD ends under a 4500 W
house, 1390 W when a charge pin lifts (`s84 n2_charge_dear`, t=1800 s).
**Decision.** Three rules; the alarm, its text and its id are unchanged.
1. **The loop's clamp counts only on a cycle the loop decided.** The winner is
the loop. Its number is on the wire, or only a rating (`device`,
`supervised`) cut it. No bound held it, and nothing was unmet.
(`Controller._loop_alarm_input`.)
2. **A battery another owner set alarms when it gives less than it was told.**
This covers every battery on a cycle the loop did not decide, and a battery
with its own pin otherwise. The test is more than `saturation_w` short in
the told direction, for `saturation_cycles` cycles in a row, against what
stands on the wire (`clamp.delivery_short`). It covers a real shortfall
during maintenance. Before, that shortfall was silent unless the kick
happened to reach the rail (house 1000 W, drain 2000 W, battery gives
nothing: 0 warnings before, 4 in 10 min now).
3. **At N>=2, while maintenance holds a battery, the loop is bounded** by
OPT-11's `loop_bound()` (what the batteries may place). It does not wind,
and control comes back one slew step a cycle. Why maintenance only: that is
where the jump was measured and where the owner order puts maintenance
above the loop. Other N>=2 limits (pack cut-out, SAFETY-73 refusal) keep
the old law. Rule 1 still silences them (the target is unmet), so they no
longer warn either.
Fixing the windup was chosen over only ignoring the wound part, because at
N>=2 the wound integrator moves real watts at hand-back. At N=1 there was
nothing to fix: re-seeding already prevents windup.
**What SAFETY-03/40 protect is kept.** With the loop in charge, the integrator
bound still warns (a runaway, a house above the rating), and a saturated
inverter under the loop's own command still does not alarm (SAFETY-03 AC 2):
rule 2 grades only batteries another owner set.
**The counter.** `ClampWatchdog.bound_episodes` counts episodes that had a
bound engagement. The status row shows it ("N times since start").
`bound` (cycles) stays for the log and the tests.
**Re-pinned digests.** Every change is intended; nothing at N=1 moves a watt.
| digest | what changed |
|---|---|
| s78 `n1_drain_owner` | the false clamp rows are gone from the log; commands identical |
| s78 `n2_drain`, s84 `n2_charge`, `n2_charge_banked`, s79 `n2_maint` (test_peak_margin) | loop reason (`mode-bound`), integrator and loop claim while bounded; commands identical |
| opt11 `n2_maint` (test_modes) | A drops out at t=1655 s: B follows the house at once, 8 cycles differ (max 920 W) |
| s84 `n2_charge_dear` | A's pin lifts at t=1800 s: 400 W a cycle, not a 1390 W jump; the surplus step after it; 98 cycles |
test_safety86's "without the ceiling the log floods" now needs the ceiling
and the bound both removed: either one alone keeps the loop inside what the
batteries can give. The `alarmed()` helpers in test_safety84/86 also read
SAFETY-81's quarter stamp, because ALLOCATOR rows can push its row out of
the 40-row log.
**Not changed, open for the owner.**
- With the loop in charge and the house above the batteries' total rating,
it still warns (SAFETY-40). On the rig's 2 x 2000 W N=2, most of SAFETY-84's
count came from houses of 4500 and 6500 W.
- A battery that tapers near full during a charge, more than `saturation_w`
under its command for 15 s, now warns (rule 2). The text already says
"check it is not empty or full".
- TEL-10's `loop_reason` reads `mode-bound` while the maintenance bound holds
the loop, with modes off.