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MAINT-04: refuse a maintenance charge the ceiling cannot deliver

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config.yaml shipped max_w 2000 against maintenance_charge_w 2500. The
cheap-window shaping files Claim.limit(hi = -maintenance_charge_w) against
the supervised SAFETY limit's lo = -max_w, so lo > hi - the arbiter's
clause 3, correctly resolved to 0 W and logged as a CONTRADICTION.
Maintenance silently never charged in a cheap window on a default install,
and the only evidence read like a bug in the arbiter rather than like the
two numbers the operator set.

validate_startup_config() now refuses maintenance_charge_w > max_w, the
same shape as CFG-01's sign_disagree_w >= max_w. Equality is reachable
(-max_w is a single valid point) and is not refused. Demonstrated by
starting the add-on on the pre-fix pair: exit 78 and the refusal banner.

maintenance_discharge_w was checked rather than assumed and is NOT the same
case: the drain phase OWNS the actuator (Claim.set at P_MAINTENANCE), so
the ceiling clamps it to +2000 W and the arbiter's explain() names the
clamp every cycle. Loud, and it still moves energy - warned, not refused.

The shipped maintenance rates drop to 2000 so the defaults pass the rule;
max_w was deliberately not raised, because it is the supervised safety
ceiling. test_validate.py now reads config.yaml itself, so a default the
validator refuses cannot ship again.

Co-Authored-By: Claude Opus 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_015VXjA3LWccN1rJsk3okyPC
This commit is contained in:
glenn schrooyen
2026-08-30 02:28:09 +02:00
co-authored by Claude Opus 5
parent bb64f8fdd7
commit 878a6ce452
6 changed files with 276 additions and 8 deletions
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goodwe_controller/DOCS.md
+2 -2
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@@ -414,8 +414,8 @@ help - see "Why the tuning is what it is".
| `maintenance_enabled` | false | Enable the monthly cycle |
| `maintenance_interval_days` | 28 | Minimum gap between cycles |
| `maintenance_start_hour` | 10 | Hour of day a due cycle begins |
| `maintenance_discharge_w` | 2500 | Drain rate (exports the surplus) |
| `maintenance_charge_w` | 2500 | Charge ceiling, capped again by peak headroom |
| `maintenance_discharge_w` | 2000 | Drain rate (exports the surplus). Above `max_w` it is **clamped** to `max_w` — the drain phase SETs the setpoint and the arbiter bounds it, saying so on the status page (`limited by supervised(max_w)`). Warned about, not refused: the cycle still completes, just slower |
| `maintenance_charge_w` | 2000 | Charge ceiling, capped again by peak headroom. Must stay **at or below `max_w`** or the cheap-window shaping (`hi = -maintenance_charge_w`) contradicts the supervised limit (`lo = -max_w`), the arbiter resolves it to **0 W**, and maintenance silently never charges in a cheap window — **the add-on refuses to start** |
| `maintenance_soc_floor` | 11 | Drain target — stay just above the inverter's own floor |
| `maintenance_soc_target` | 99 | Charge target |
| `maintenance_hold_min` | 120 | Hold at full so the BMS can balance |