SAFETY-03: alarm when a computed setpoint exceeds the rating, do not just clip it
The clamp was never the missing half. specs.md 10.3 records an unclamped integrator climbing ~130 W per 4 s past 10 kW and reporting 14 768 W pinned at the 5 kW rail; clipped silently that is a flat, legal-looking 5000 W hold and nothing says the loop asked for three times it. write_setpoint() - the one path every write takes - now clamps to the VALIDATED max_w and reports whether the raw value differed; check_output_clamp() raises OUTPUT_CLAMP as a notification, an ERROR, an event row and a red status banner. Not a trip: the clamped value is written and the loop keeps running. The rating is max_w and nothing is min()ed at runtime - CFG-01 already refuses a max_w outside the device range at startup. The device range is applied second as defence in depth; it cannot bite after a successful validation, so if it ever does it alarms too and names the bound. No new config key. Decision grew i_clamped / clamped booleans, and that is the load-bearing part: `reason` is one string that slew-limiting and the saturation freeze overwrite, so an alarm keyed on it is silent on exactly the cycles a winding loop produces. Mutating main.py back onto the string drops the 10.3 replay from 2 engagements to 0. Distinct from saturation by construction - no shared reason code, notification id, status row or counter - and checked in the negative, after first asserting the saturation freeze really did engage. Two things found by running it rather than by reading it: a row per engagement flushed the 40-row event log and evicted SAFETY-18's own METER FROZEN? row (now coalesced per episode with an exact count), and a naive clamp turns a nan into a command at the full rating because every comparison against nan is False. test_clamp.py is new: assert-based, no framework. Six author mutations reproduced red, including "clamp kept, alarm deleted". Two of the check's own hypotheses about the freeze/clamp interaction were refused by its sweep and rewritten to what it measured. Co-Authored-By: Claude Opus 5 <noreply@anthropic.com> Claude-Session: https://claude.ai/code/session_015VXjA3LWccN1rJsk3okyPC
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## Unreleased
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**A computed setpoint over the rating now alarms instead of being clipped in
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silence (SAFETY-03).** The clamp was never the missing half - specs.md 10.3
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records an unclamped integrator climbing ~130 W per 4 s past 10 kW and reporting
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**14 768 W** while pinned at the 5 kW rail, and a silent clamp turns exactly that
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into a flat, legal-looking 5000 W hold. `write_setpoint()` - the one path every
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write takes, cycle, heartbeat, operator button and shutdown alike - now clamps to
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the **validated** `max_w` and reports whether the raw value differed, and
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`Controller.check_output_clamp()` raises `OUTPUT_CLAMP`: a persistent
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notification (`goodwe_output_clamp`), an `ERROR`, an event row and a red status
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banner. **Not a trip**: the clamped value is written and the loop keeps running,
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per 11.2's "clamp *and alarm*".
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**The bound is `max_w` and nothing is `min()`ed at runtime.** Section 14 requires
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the loop clamp and the driver's `setpoint_limit_w` to agree, validated at startup
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with a refusal on mismatch - which CFG-01 already ships. The device range is
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still applied second, as defence in depth; after a successful validation it
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cannot engage, so if it ever does, that is louder than the first stage and it
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alarms too, naming the bound. No new config key: the guard's limit is the one
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the operator already set, and its cadence is a module constant.
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**`Decision` grew `i_clamped` / `clamped` booleans, and that is the load-bearing
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part.** `reason` is one string that later stages overwrite - a cycle that clamps
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the integrator and is then slew limited reports `slew-limited`, and one that
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clamps while saturated reports `saturated-freeze`. Both *are* the winding case,
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so an alarm keyed on the string is silent on exactly the cycles it exists for:
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mutating main.py back onto `"clamp" in decision.reason` drops the 10.3 replay
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from 2 engagements to **0**. The flags are set where the clamp happens and are
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never overwritten. On a default install (`integrator_max_w` following `max_w`)
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the integrator bound is the one that bites and the output clamp is unreachable,
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so the integrator flag is the whole signal.
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**Distinct from the saturation freeze, and checked in the negative.** A clamp is
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a *software* bug signal; saturation is the *hardware* failing to follow a legal
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command, and its action is to freeze the integrator, not to alarm. They share no
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reason code, notification id, status row or counter. `test_clamp.py` drives a
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loop that saturates for 10 consecutive cycles at 1.4 % of the rating and asserts
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zero clamp notifications, zero engagements, no log row and no status row - after
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first asserting that the saturation freeze *really did* engage, so the silence is
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an observation rather than a scenario that did nothing.
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**The action log is coalesced per episode, and that was a real bug.**
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`log_event()` keeps 40 rows; one row per engagement flushed the entire ring
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within 40 cycles of a winding loop, and the first thing it evicted was
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SAFETY-18's own `METER FROZEN?` row - this guard silencing another guard's log.
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Caught by `test_freeze.py` going red, not by inspection. One row per episode now,
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carrying the exact engagement count read off the counter.
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**A non-finite setpoint is refused, and it was worse than passing one through.**
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`nan` is loss of input (11.1 rule 1: command zero, keep commanding), not an
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out-of-range value. Measured: because every comparison against `nan` is False, a
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naive `max(-limit, min(limit, nan))` keeps its *first* argument and turns a `nan`
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into a command **at the full rating**, then reports it as a clamp engagement.
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**`test_clamp.py`** (new, assert-based, no framework) covers the clamp
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arithmetic and its boundaries - exactly +-`max_w` is *not* an engagement - the
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alarm's edge/re-assert/hysteresis cadence, the 10.3 runaway replayed through the
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real `Controller.cycle()` against an unclamped transcription, the saturation
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negative, and the direct-write path. Six author mutations reproduced red,
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including "clamp kept, alarm deleted" (the historical build) and "alarm keyed on
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`reason`". Two of the check's own hypotheses about how the freeze and the clamp
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interact were **refused by the sweep** and rewritten to what it measured: a
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frozen cycle *can* clamp, and does so exactly when the integrator reverses.
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`test_freeze.py`'s notification assertions now filter by `notification_id`
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rather than by service - the add-on raises more than one kind of notification,
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and its railing scenarios legitimately raise this one too.
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**Cheap-window maintenance charging was unreachable at the shipped defaults, and
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now the config that makes it unreachable is refused (MAINT-04).** `config.yaml`
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shipped `max_w: 2000` against `maintenance_charge_w: 2500`. The cheap-window
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