SAFETY-02 review: a latch that a restart clears is not a latch

BLOCKER. `auto` was persisted and `sign_wd.tripped` was not, so reconstructing
the Controller against the same store - which is what a container restart does -
brought it back ARMED, into the same fault, unattended: tripped=False, banner
back to NOT READY, and it resumed commanding -1000 then -2000 W before
re-tripping 180 s later. "Restart the add-on" is the first thing an operator
looking at a FAILSAFE banner and a 0 W inverter will try, and under a supervisor
that restarts a crashed add-on it is a loop of three-minute wrong-direction
bursts. DOCS.md's "it does not clear itself" was false across a restart.

`sign_tripped` and `sign_reason` are Store keys now, beside the maintenance
state and for the reason store.py's own docstring gives. Written the moment the
trip happens - reason first, flag second, so a crash between the two can never
persist a latch with no explanation - restored in Controller.__init__, cleared
only by the operator's start. The regression is covered: reverting the restore
fails seven checks in test_watchdog.py.

Review follow-ups, no behaviour change:

- The arming gate is tested against the REAL arbiter. It is the decision the
  ticket turns on and it was asserted in three comment blocks and verified by
  nothing - every case passed `following` in as a literal. Twelve claim
  configurations now derive it from resolve(), including the redirect case
  `winner == "loop"` alone would have got wrong and the `lo` limit that raises
  magnitude without flipping sign.
- The MQTT `status: "failsafe"` value is tested. The check that claimed to cover
  it restated the line above it and never touched the payload.
- The worked example described a config that does not ship: at the defaults
  maintenance_charge_w 2500 against max_w 2000 is an arbiter contradiction and
  0 W, not a -2500 W charge. Rewritten at 1500 W. The contradiction is a real
  pre-existing bug - a default cheap-window maintenance charge silently never
  happens - filed separately and deliberately not fixed here.
- Forward hazard recorded at the gate: `winner == "loop"` disarms the watchdog
  under any higher-priority SET, and a peak-shaving strategy at P_PEAK IS
  grid-following in sign, so it would blind this for every peak event.
- disagrees() is public so the replay harness stops carrying its own copy of the
  predicate it grades.
- held_s takes the clock instead of reading one.
- The two limits are now each stated in both places rather than one each.
- The no-false-positive argument is tied to control.py's freeze permitting the
  command to cross zero; under the shrink-only encoding control.py records as
  rejected, this would false-trip on a load step.
- Measured figures corrected: 93.4 % / 4212 of 17280, per-cluster
  0.3/0.9/10.5/0.0, and the near-circularity of those figures is now stated
  rather than leaned on.

Co-Authored-By: Claude Opus 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01Du77usMj8XNKNFZGmUiWDa
This commit is contained in:
glenn schrooyen
2026-08-28 22:33:15 +02:00
co-authored by Claude Opus 5
parent 2513ba1f12
commit cc4e88490b
8 changed files with 458 additions and 61 deletions
+15 -6
View File
@@ -294,11 +294,20 @@ there. The banner reads `FAILSAFE`, the commissioning list says which two
numbers disagreed and for how long, and the `Controller status` entity reports
`failsafe`.
**It does not clear itself.** Pressing *Start / stop control* twice clears it.
That is deliberate: commanding 0 W removes the command side of the comparison,
so the disagreement always vanishes the instant the trip works, and a watchdog
that took that as proof the fault was over would hand the inverter straight back
to the loop that was driving the wrong way.
**It does not clear itself, and restarting the add-on does not clear it either.**
Pressing *Start / stop control* twice — stop, then start — is the only thing that
does. That is deliberate on both counts:
- Commanding 0 W removes the command side of the comparison, so the disagreement
always vanishes the instant the trip works. A watchdog that took that as proof
the fault was over would hand the inverter straight back to the loop that was
driving the wrong way, three minutes later, forever.
- The trip is written to `/data/state.json` and restored on startup. Restarting
the add-on is the first thing most people try when they see a red banner, and
a latch that a restart clears would bring the controller back **armed, into the
same fault, unattended** — and under a Supervisor that restarts a crashed add-on
automatically, would do so in a loop. After a restart the banner, the 0 W and
the recorded reason are all still there.
**What it is for.** This is a loop-integrity check: it asks whether the loop's
output direction still matches the input state it was regulating. It catches a
@@ -326,7 +335,7 @@ must not be mistaken for a fault.
Both numbers are measured rather than chosen, and are exposed only because the
ticket requires defaults rather than constants. On the captured healthy day sign
agreement is 92.9 %; on the four captured fault episodes it is 0.3 %, 0.9 %,
agreement is 93.4 %; on the four captured fault clusters it is 0.3 %, 0.9 %,
10.5 % and 0.0 %. There is no reason to move either value without a capture that
says so.