Merge release/1.0 into SAFETY-18 - CHANGELOG only

MAINT-04 (#10) landed on release/1.0 mid-review, so both branches had
prepended a stanza. config.yaml and DOCS.md auto-merged clean; only the
CHANGELOG needed a hand. Both stanzas are kept verbatim, MAINT-04's
Unreleased above the new 0.5.2 - no text from either author edited.
MAINT-04 is unreleased and 0.5.2 is being cut here, so a release manager
may want to fold the two; that is an editorial call, not a reviewer's.

Full suite green on the merged tree: arbiter, control, loop, maintenance,
p1, validate, watchdog, freeze.

Co-Authored-By: Claude Opus 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_015VXjA3LWccN1rJsk3okyPC

goodwe_controller/CHANGELOG.md

@@ -1,5 +1,139 @@
 # Changelog
 
+## Unreleased
+
+**Cheap-window maintenance charging was unreachable at the shipped defaults, and
+now the config that makes it unreachable is refused (MAINT-04).** `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 an operator set.
+Measured against the real arbiter, loop asking +500 W:
+
+```
+max_w=2000  hi=-2500  ->     +0 W  contradiction=True
+max_w=2500  hi=-2500  ->  -2500 W  limited by supervised(max_w)
+max_w=3000  hi=-2500  ->  -2500 W  limited by maintenance(cheap-window charge)
+```
+
+`validate_startup_config()` now refuses `maintenance_charge_w > max_w` (rule 6),
+the same shape as CFG-01's `sign_disagree_w >= max_w`: a number the operator set,
+overridden by a layer they cannot see. Equality is reachable (`-max_w` is a
+single valid point) and deliberately not refused. Verified by starting the
+add-on on the pre-fix pair: exit 78, the refusal banner, no traceback.
+
+**`maintenance_discharge_w` was checked, not assumed, and it is NOT the same
+case.** The shaping is not symmetric. The drain phase does not shape the loop,
+it OWNS the actuator — `Claim.set(P_MAINTENANCE, +discharge_w)` — and a SET is
+*clamped* by the limits above it rather than contradicted by them. 2500 against
+a 2000 W ceiling emits **+2000 W**, and the arbiter's own `explain()` prints
+`maintenance -> 2000 W, limited by supervised(max_w)` every cycle. Nothing is
+silent and energy still moves; the cycle completes slower (13.8 kWh usable at
+2000 W is ~6.9 h against the 720 min drain timeout). **Warned about, not
+refused.**
+
+**The shipped defaults changed so the validator does not reject them.**
+`maintenance_charge_w` and `maintenance_discharge_w` are now **2000**, at the
+shipped `max_w`. `max_w` was deliberately NOT raised instead: it is the
+supervised safety ceiling and raising a default upward ships more power to every
+new install. Raising `max_w` (the reference install runs 5000) is what unlocks a
+faster maintenance cycle — raise it first, then these. `test_validate.py` now
+reads `config.yaml` itself and asserts the shipped numbers pass the rule, so a
+default that the validator refuses cannot ship again.
+
+### ⚠️ Upgrading an existing default install: the add-on may refuse to start
+
+An install still carrying `maintenance_charge_w: 2500` against `max_w: 2000`
+now meets rule 6 and **exits 78 with the refusal banner** instead of starting.
+That is the intended behaviour — the configuration was already broken, it was
+just silent about it — but an add-on that will not come back after an update
+needs the fix stated here rather than only in the log.
+
+**The fix, either way: set `maintenance_charge_w` to `2000` or lower, OR raise
+`max_w` to `2500` or higher** (Settings → Add-ons → GoodWe RS485 Controller →
+Configuration), then start it. The banner in the log says the same thing and
+names both numbers.
+
+Whether you hit this at all depends on whether the Supervisor kept the old
+value, and **both cases are covered above because we did not verify which one
+applies here.** The Supervisor merges an add-on's *stored* options over the
+defaults in `config.yaml`, so:
+
+- **A key the operator never edited** re-derives from the new `config.yaml` and
+  becomes 2000 on upgrade. Non-event, nothing to do.
+- **A key the operator did set** persists at 2500 and the add-on refuses to
+  start until it is changed. Note this includes anyone who used the
+  Configuration page's YAML editor, which writes the whole options block back —
+  so "I never touched that field" is not a guarantee the old value is gone.
+
+⚠️ **This is reasoned from the Supervisor's documented merge behaviour, not
+measured on the live install.** The reference install's stored options could not
+be read (`/api/hassio/` refuses a long-lived token) and probing it was out of
+scope — it regulates a real battery. It runs `max_w: 5000` and is unaffected
+either way.
+
+⚠️ **Known, deliberately left, and worth a follow-up:** `main.py` and
+`maintenance.py` still fall back to **2500** when the key is absent from the
+options dict, while `config.yaml` and `validate.py` now say 2000. Unreachable on
+a Supervisor install (every key is always supplied) and reachable only from
+tests/`sim`. The real fix is one source of truth for option defaults, which is
+bigger than this ticket and touches files another ticket is in.
+
+## 0.5.2
+
+**A meter frozen at a wrong-but-fresh value now raises an alarm. It still is not
+stopped.** (SAFETY-18)
+
+A meter that answers `200 OK` with a stale document forever is *arriving* on
+every poll, so every freshness mechanism in the stack reads it as healthy:
+`meter_max_age_s` is reset by each response, the firmware watchdog is fed by the
+heartbeat and by a sample age that never climbs, and the arbiter contributes only
+±`max_w`. The loop integrates a constant error and rails — replaying the real
+`compute()` at 15 s cycles, in 150/60/30 s at `max_w: 2000` for a meter frozen at
+350/1000/≥3000 W, and 360/135/75 s at `max_w: 5000`. **The live install runs
+`max_w: 5000`**, which is both the schema maximum and the device rating.
+
+The new detector (`app/freeze.py`) is a **conjunction**, not the bare
+`unchanged_s` threshold TEL-05 measured and rejected:
+
+    unchanged_s ≥ meter_freeze_s   AND   |command| within 5 % of max_w
+
+Both terms already existed and were already on the status page. They fail for
+independent reasons: at the converged point the command is nowhere near the rail,
+and at the rail against a real load the kWh registers move within seconds. At the
+shipped 300 s there is also a structural relation, not just a margin — the
+slowest a healthy 1 Wh register can tick and still look unchanged is 12 W, which
+is inside the 15 W deadband, so the command there is parked at 0 W and the two
+halves cannot both be true.
+
+**Notification only, deliberately.** An HA persistent notification (fixed
+`notification_id`, so a repeat replaces rather than stacks), an `ERROR` log line,
+a UI event and a red status banner. No claim, no latch, no 0 W: a false trip
+parks the battery and the operator's next move is to switch the guard off; a
+false notification costs an alert. The trip is a separate decision that needs
+data from a real install.
+
+- New option `meter_freeze_s` (default 300, range 60–3600, no "off").
+- **Only `meter_source: homewizard_local` is covered** — it is the only transport
+  that sees the meter's own document. Everywhere else the status page says
+  **NOT COVERED** rather than "armed".
+- `DOCS.md` now states the **capacity-tariff exposure** this does *not* close:
+  `peak_cap_w` caps maintenance charging and nothing caps the loop, so a lying
+  meter can drive a 5 kW unattended import, and ≥15 minutes of that sets the
+  month's billed peak (measured: one 4998 W quarter moved a monthly peak from
+  4832 → 5013 W). That cap is SAFETY-07.
+- `test_freeze.py` grades it in both directions: silent over 40 minutes of the
+  live house's real converged capture (committed as
+  `scenarios/p1-age-2026-08-26.jsonl.gz`), silent over an hour of TEL-05's
+  low-power case where a bare threshold is shown to fire, and alarming on a
+  genuinely frozen meter driven over real HTTP through the real
+  `HomeWizardLocalSource` — against the rig's own `hwsim` `freeze` fault when the
+  infra repo is reachable, an equivalent stub otherwise. Its negative twin is the
+  load-bearing one: the same railed command against a meter that is still moving
+  must stay silent at the same threshold.
+
 ## 0.5.1
 
 **SAFETY-02's latch now survives an add-on restart, which is the difference

goodwe_controller/DOCS.md

@@ -30,6 +30,10 @@ The inverter **holds its last command forever** — it has no meter-timeout. So:
 - The **optional RS485 e-stop** is the only thing that covers this machine
   dying. Without it, a failed host leaves the battery latched at its last
   command until someone intervenes.
+- This add-on **raises an alarm — and nothing more —** when the meter keeps
+  answering with a reading that never changes while the command sits at the
+  rail. See "The frozen-meter alarm" and, before you rely on it, "Capacity-tariff
+  exposure of the grid-following loop".
 
 **If anything looks wrong: stop the add-on.** That commands 0 W and the
 hardware holds it there.
@@ -414,8 +418,8 @@ 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 |
@@ -433,6 +437,95 @@ under `peak_cap_w`, and if the forecast goes over the cap the charge-only clamp
 is dropped so the battery can shave the peak instead. Money outranks the
 maintenance schedule.
 
+#### Capacity-tariff exposure of the grid-following loop
+
+⚠️ **`peak_cap_w` caps MAINTENANCE charging. It does not cap the loop.** The
+grid-following loop is bounded by `max_w` and by the device rating, and by
+nothing else. That is deliberate — the loop exists to *reduce* what crosses the
+meter, so under every healthy condition it lowers the peak rather than raising
+it — but it means one thing is true and worth writing down:
+
+**If the meter lies, the loop will happily buy `max_w` from the grid for as long
+as the lie lasts, and no cap in this add-on stops it.** A meter frozen at a large
+export reads as "the house is exporting hard", the loop charges the battery to
+correct it, and the correction is a grid import. At the schema maximum
+`max_w: 5000` — which is what this house runs, and is also the device rating —
+that is a 5 kW unattended import.
+
+The bill is not the energy. In the Belgian capaciteitstarief the month is billed
+on its highest quarter-hour average, so **fifteen minutes of this sets the whole
+month's peak.** A measured case: one 4998 W quarter moved a monthly peak from
+4832 W to 5013 W, and every day of that month was billed at the higher figure.
+
+What exists today, and what does not:
+
+| | |
+|---|---|
+| `max_w` bounds the magnitude | ✅ — but the exposure IS the magnitude |
+| Maintenance charging capped under `peak_cap_w` | ✅ |
+| **Loop capped under `peak_cap_w`** | ❌ — not built. This is SAFETY-07 |
+| Frozen meter detected | ✅ on `homewizard_local` only, **alarm only** |
+| Frozen meter *stopped* | ❌ — the alarm does not command anything |
+| SoC guard on the loop | ❌ — the BMS is the only energy backstop |
+
+So the frozen-meter alarm below **narrows the window; it does not close it.** On
+a capacity-tariff site where an unattended runaway is unacceptable, the mitigation
+today is operational: set `max_w` no higher than the loop actually needs (the
+tuning was measured at 2000 W and a 1.78 kW load step is tracked fine there), fit
+the e-stop, and watch for the alarm.
+
+### The frozen-meter alarm
+
+A meter that has died is easy — it stops answering, the sample age climbs past
+`meter_max_age_s`, the reading becomes missing, and the add-on and the ESP32 both
+command 0 W. A meter that keeps answering `200 OK` with a document that never
+changes is the hard one: **every freshness mechanism in the stack reads it as
+healthy**, because it really is arriving on every poll. The loop then integrates
+a constant error and winds to the rail, in 75–360 s at `max_w: 5000`.
+
+The add-on alarms when **both** of these are true at once:
+
+- the meter's own document (power figure *and* both kWh registers) has not
+  changed for `meter_freeze_s` — 300 s by default; **and**
+- the command standing on the wire is at the rail, within 5 % of `max_w`.
+
+Neither half is usable alone. A bare "unchanged for N seconds" rule false-trips
+at the exact operating point this controller aims for — at a converged −10 W a
+1 Wh register legitimately takes about six minutes to move — and a bare "at the
+rail" rule fires on any genuinely large load. Together they are safe in both
+directions, because a real railed condition means kilowatts still crossing the
+meter, and a kilowatt advances a 1 Wh register every 3.6 s.
+
+**It is an alarm and nothing else.** It does not command 0 W, does not latch, and
+does not claim the actuator. A false trip here parks the battery; a false
+notification costs an alert. Turning it into a trip is a separate decision that
+needs data from a real install — and an answer to "what should the loop do
+instead", given that 0 W is itself an import of whatever the house is drawing.
+
+When it fires you get a Home Assistant persistent notification
+(`goodwe_meter_frozen`, replaced rather than stacked on a repeat), an `ERROR` in
+the add-on log, an entry in the UI's event list, and a red banner on the status
+page. **The loop keeps running.** If the meter really is stuck, stop control from
+the add-on UI.
+
+⚠️ **Only `meter_source: homewizard_local` is covered.** It is the only transport
+that reads the meter's own document; on `ha_dsmr`, `mqtt_p1`, `ha_signed` and
+`off` there is no signal to threshold and the status page says **NOT COVERED**
+rather than pretending the guard is armed.
+
+| option | default | meaning |
+|---|---|---|
+| `meter_freeze_s` | 300 | Seconds of an unchanged measurement, *while the command is at the rail*, before the alarm |
+
+Why 300 s: over 2399 s of this house at the converged operating point (mean grid
+−14.2 W, 1194 polls, 735 of them repeating the previous reading) the largest
+`unchanged_s` any sample sees is **8.0 s**, and the longest interval serving no
+distinct reading at all is **15.4 s**. There is also a structural reason not to
+lower it much: at 300 s the slowest a *healthy* register can tick and still look
+unchanged is 12 W, which is inside the 15 W deadband — so the command there is
+parked at 0 W and the two halves of the rule cannot both be true. At the schema
+floor of 60 s that figure is 60 W and only the margin is left.
+
 ### Site
 
 | option | meaning |

goodwe_controller/app/freeze.py

@@ -0,0 +1,275 @@
+"""SAFETY-18 - the frozen-but-fresh meter detector.
+
+WHAT IT CATCHES, in one sentence: a meter that keeps answering 200 OK with a
+document that never changes, which every freshness mechanism in this stack reads
+as perfectly healthy while the loop winds to the rail and stays there.
+
+THE FAILURE NEEDS NO FAULT ANYWHERE ELSE. A frozen-but-talking meter is
+*arriving* on every poll, so:
+
+  - `meter_max_age_s` is structurally blind. Every response resets the arrival
+    stamp (p1.py, `HomeWizardLocalSource`), so the age never climbs. Age catches
+    a meter that stops TALKING; this one stops CHANGING.
+  - firmware layer 1 is fed. Its watchdog keys on setpoint staleness, which the
+    heartbeat satisfies, and on `sensor.goodwe_p1_sample_age`, which a talking
+    meter satisfies.
+  - the arbiter contributes only the device rating and +-`max_w` - it bounds the
+    magnitude, which is the number this fault drives us to, not away from.
+  - there is no SoC guard on the grid-following loop at all. `soc_floor` belongs
+    to the maintenance cycle; the BMS is the sole energy backstop.
+
+The loop reads a constant error and integrates it. Time from freeze to the rail,
+replaying the real `control.compute()` at 15 s cycles:
+
+    meter frozen at   to rail, max_w 2000   to rail, max_w 5000
+    350 W                    150 s                  360 s
+    1000 W                    60 s                  135 s
+    >= 3000 W                 30 s                   75 s
+
+⚠️ THE LIVE INSTALL RUNS `max_w: 5000`, which is both the schema maximum and the
+device rating, so the right-hand column is the one that describes this house.
+
+------------------------------------------------------------------------------
+THIS HAS A EURO FIGURE, AND IT IS THE REASON THE TICKET IS P1
+
+`maintenance_charge_floor()` caps MAINTENANCE charging against `peak_cap_w`. The
+grid-following loop is not capped by anything but `max_w`. A meter frozen
+reading a large export drives a 5 kW unattended grid IMPORT, and >= 15 minutes
+of that sets the month's billed capaciteitstarief peak: specs.md:583 records a
+measured case where a single 4998 W quarter moved a monthly peak from 4832 W to
+5013 W and billed the whole month at it.
+
+⚠️ THIS CUT DOES NOT CAP THAT. It notifies. See DOCS.md, "Capacity-tariff
+exposure of the grid-following loop", and SAFETY-07.
+
+------------------------------------------------------------------------------
+WHY IT IS A CONJUNCTION AND NOT AN `unchanged_s` THRESHOLD
+
+`unchanged_s` (p1.py) already measures exactly the right thing: seconds since
+the meter served a DIFFERENT measurement, fingerprinted over the power figure
+and both energy registers. It is computed, it is on the status page, and TEL-05
+deliberately refused to threshold it - correctly:
+
+    this controller regulates grid power toward ~0 W, and at a converged -10 W
+    the export register takes about six minutes to advance by its 1 Wh
+    resolution while the power figure legitimately repeats.
+
+So a bare `unchanged_s > N` false-trips at the exact operating point we aim for,
+and `p1.py` says as much in a note that ends "whoever wires a freeze detector
+must handle the low-power case first". This is that handling, and it is not a
+smaller number:
+
+    unchanged_s >= hold_s   AND   |commanded_w| is at the rail
+
+The second term is what TEL-05's case cannot satisfy. At the converged point the
+command is nowhere near +-`max_w`; on the 40 minutes of live converged behaviour
+in `sim/scenarios/p1-age-2026-08-26.jsonl.gz` the meter never once leaves
++-500 W, so the loop never even approaches a 5000 W rail. And the reverse case -
+a command genuinely pinned at the rail by a real 8 kW load - cannot satisfy the
+FIRST term, because a real railed condition means kilowatts still crossing the
+meter, and a kilowatt advances a 1 Wh register every 3.6 s.
+
+The two terms fail for independent reasons. That is the whole design.
+
+⚠️ AND THE SECOND HALF OF THAT WAS MEASURED ON THE RIG, WITH A RESULT WORTH
+READING CAREFULLY. Driving the real transport against the rig's own hwsim under
++8000 W of house load - a genuinely railed command, meter perfectly healthy - the
+POWER FIGURE DID NOT MOVE AT ALL: `active_power_w` sat at exactly 10130.0 W for
+26 consecutive polls. What kept `unchanged_s` pinned at 0.0 s was the kWh
+registers advancing, and nothing else.
+
+So the register terms in `measurement_fingerprint()` are not belt-and-braces
+here, they are the entire negative case. A freeze detector fingerprinted on the
+power figure alone would have raised a false alarm on that rig run - a healthy
+meter, a real load, a correctly railed command - which is the exact failure mode
+that gets a safety guard switched off. Anyone tempted to simplify the fingerprint
+should read that run first.
+
+------------------------------------------------------------------------------
+WHERE `hold_s` COMES FROM
+
+Measured on `sim/scenarios/p1-age-2026-08-26.jsonl.gz` - 2399 s (40 min) of the
+live house at the converged operating point, mean grid -14.2 W, 1194 polls:
+
+    polls that repeated the previous reading      735 of 1193  (61.6 %)
+    distinct-reading transitions                  458
+    median gap between distinct readings          6.0 s
+    p95 gap                                       6.0 s
+    LARGEST `unchanged_s` any sample observes     8.0 s
+    longest interval serving no distinct reading 15.4 s
+    samples outside +-500 W                       0
+
+The default 300 s is 37x the largest `unchanged_s` this house has been recorded
+producing while converged, and 19.5x the longest interval in which it served no
+distinct reading at all. The two figures differ because the capture has an 11.4 s
+hole in its OWN polling; the second is quoted because it is the pessimistic one.
+300 s is not fitted to either margin - it is picked as "clearly past any
+plausible register-tick interval, and clearly inside the 900 s quarter that bills
+the capacity tariff". test_freeze.py re-measures both every run, so this
+paragraph cannot quietly stop being true.
+
+⚠️ BE PRECISE ABOUT WHAT THAT CAPTURE PROVES. It is POWER-ONLY - the shipped
+fingerprint also covers both kWh registers, so a real `unchanged_s` on that data
+can only be shorter, never longer, which makes it a conservative measurement of
+the converged case. But it does NOT on its own refute a bare `unchanged_s`
+threshold, and saying it did would be exactly the overstatement this project
+keeps having to walk back: at 8 s worst, a bare 300 s threshold is silent on it
+too. The case that refutes the bare threshold is the one below, which no capture
+of THIS meter contains because this meter's power figure jitters.
+
+The floor on the other side: at the rail, the smallest residual grid flow that
+still ticks a 1 Wh register inside 300 s is 12 W. Any condition that genuinely
+pins this loop at +-5000 W has three orders of magnitude more than that crossing
+the meter.
+
+⚠️ AND THOSE TWO NUMBERS DO NOT MERELY HAVE MARGIN - THEY CANNOT BOTH BE TRUE.
+The worry the conjunction has to answer is "a HEALTHY meter whose register is
+slower than `hold_s`". At 300 s that is |grid| < 12 W. The shipped `deadband_w`
+is 15 W, so anywhere the register is that slow the control law is already inside
+its deadband and the command is parked - the rail term is not merely unlikely to
+be true there, it is 0 W. The two terms are mutually exclusive by construction
+at the defaults, not just far apart, and the check re-derives that every run.
+
+That relationship is the one to protect. `hold_s` may be lowered only while
+3600/hold_s stays under `deadband_w`; at the schema floor of 60 s that is 60 W
+against a 15 W deadband, and the mutual exclusion is gone. A 60 s `meter_freeze_s`
+is a supported configuration that gives up this argument and keeps only the
+margin - do not set one without a capture that says the margin is enough.
+
+⚠️ WHAT `hold_s` DOES NOT BUY IS DETECTION SPEED. The alert lands at
+max(hold_s, time-to-rail) after the freeze, so at the shipped default and
+`max_w: 5000` that is 300-360 s. The rail is REACHED first, from 75 s. A
+notification is not a brake; see the DOCS.md note.
+
+------------------------------------------------------------------------------
+THE RAIL TERM, PRECISELY
+
+    abs(commanded_w) >= RAIL_FRAC * max_w
+
+`commanded_w` is the EMITTED setpoint - what the arbiter resolved and
+`write_setpoint()` put on the wire - not the loop's raw wish, for the same
+reason SAFETY-02 uses the emitted value: the wire carries the emitted number.
+
+RAIL_FRAC is 0.95 and is a constant rather than an option. The command is
+quantised to `step_w` (max 100) and clamped to `max_w` (min 100), so at the rail
+the emitted value IS `max_w` on every schema-legal combination; the 5 % is slack
+for a device rating that clips `max_w` slightly in `write_setpoint()`, not a
+tuning knob. Making it configurable would offer a way to widen the one term that
+carries the whole no-false-positive argument.
+
+⚠️ NOT GATED ON `following`, and that is deliberate. A maintenance charge
+commands against the meter on purpose and can sit at the rail for hours - but it
+does so while pushing kilowatts through the meter, so the FIRST term is what
+excludes it, and it excludes it on physics rather than on bookkeeping. Gating on
+`following` as well would additionally blind the detector to a maintenance phase
+running against a meter that really has frozen, which is the same fault with a
+worse actuator behind it.
+
+------------------------------------------------------------------------------
+NOTIFY, DO NOT TRIP
+
+First cut is an alarm and nothing else: an HA persistent notification, an ERROR
+in the log, an event on the status page, and a failed check row. It does NOT
+claim the actuator, does NOT file a P_SAFETY claim and does NOT latch.
+
+That is a deliberate ordering of costs, not timidity. A false trip here parks
+the battery - on a house that is running this loop precisely to avoid buying
+power at the wrong moment - and the operator's response to a parked battery is
+to switch the guard off. A false notification costs one alert. The trip is a
+separate decision that has to be earned with observed data from a real install,
+and it needs an answer to a question this cut does not have one for: what should
+the loop do instead, given that 0 W is itself a grid import of whatever the
+house is drawing.
+
+⚠️ TRANSPORT-CONDITIONAL. `unchanged_s` exists ONLY on `homewizard_local`,
+because it is the only transport that sees the meter's own document. Under
+`ha_dsmr`, `mqtt_p1`, `ha_signed` and `meter_source: off` this detector is
+silent and the exposure above is uncovered. The caller passes None and gets
+False; there is no half-measure available on those paths, and pretending
+otherwise would be worse than the gap.
+"""
+
+from dataclasses import dataclass
+from datetime import datetime
+
+# See "THE RAIL TERM, PRECISELY" above. A constant, on purpose.
+RAIL_FRAC = 0.95
+
+
+@dataclass(frozen=True)
+class FreezeWatchdogConfig:
+    """Default, not a constant - config.yaml carries `meter_freeze_s`."""
+
+    hold_s: float = 300.0
+
+
+def rail_w(max_w) -> float:
+    """The magnitude at or above which a command counts as railed."""
+    return abs(float(max_w)) * RAIL_FRAC
+
+
+def looks_frozen(unchanged_s, commanded_w, max_w,
+                 cfg: FreezeWatchdogConfig) -> bool:
+    """The predicate, and the ONLY place the conjunction is written down.
+
+    Public for the same reason `watchdog.disagrees()` is: the checks that grade
+    it must assert on THE SHIPPED EXPRESSION. A safety predicate transcribed
+    into its own test is one copy plus a future disagreement about what the
+    check means, and the copy that drifts is always the one doing the grading.
+
+    `unchanged_s`  seconds since the meter served a different measurement, or
+                   None on a transport that cannot know (see the module note).
+    `commanded_w`  the EMITTED setpoint standing on the wire.
+    `max_w`        the configured output bound the rail is measured against.
+    """
+    if unchanged_s is None or commanded_w is None or not max_w:
+        return False
+    return (float(unchanged_s) >= cfg.hold_s
+            and abs(float(commanded_w)) >= rail_w(max_w))
+
+
+class FreezeWatchdog:
+    """One instance per controller, evaluated once per control cycle.
+
+    Level-triggered state with an EDGE for the alarm: `evaluate()` returns True
+    on the cycle the conjunction first becomes true and False on every cycle
+    after, so the caller raises one notification per episode rather than one
+    every second. `active` is the level, for the status page.
+
+    No latch, deliberately - see "NOTIFY, DO NOT TRIP". A latch exists so a trip
+    cannot erase its own evidence by working; nothing here acts, so there is
+    nothing to erase. When the meter starts moving again the alert clears
+    itself, which is the honest report of the state.
+    """
+
+    def __init__(self, cfg: FreezeWatchdogConfig | None = None):
+        self.cfg = cfg or FreezeWatchdogConfig()
+        self.active = False
+        self.since: datetime | None = None
+        self.reason = ""
+        self.episodes = 0
+
+    def evaluate(self, unchanged_s, commanded_w, max_w, now: datetime) -> bool:
+        """Advance one cycle. Returns True ONLY on the rising edge.
+
+        `now` is the caller's clock so this stays testable and replayable - the
+        same discipline as `SignWatchdog.evaluate()`.
+        """
+        if not looks_frozen(unchanged_s, commanded_w, max_w, self.cfg):
+            self.active = False
+            self.since = None
+            self.reason = ""
+            return False
+
+        self.reason = (
+            f"METER_FROZEN: the meter has answered {float(unchanged_s):.0f} s "
+            f"without its measurement changing while the command stands at "
+            f"{float(commanded_w):+.0f} W, at the {float(max_w):.0f} W rail "
+            f"(limits: unchanged over {self.cfg.hold_s:.0f} s, command over "
+            f"{rail_w(max_w):.0f} W)")
+        if self.active:
+            return False
+        self.active = True
+        self.since = now
+        self.episodes += 1
+        return True

goodwe_controller/app/main.py

@@ -36,6 +36,7 @@ from .arbiter import (
     P_LOOP, P_MAINT_SHAPE, P_MAINTENANCE, P_SAFETY, Claim, resolve,
 )
 from .control import Tuning, compute, maintenance_charge_floor, peak_at_risk
+from .freeze import FreezeWatchdog, FreezeWatchdogConfig, rail_w
 from .hass import HomeAssistant
 from .maintenance import IDLE, MaintConfig, Maintenance
 from .mqtt import MqttPublisher
@@ -127,6 +128,18 @@ class Controller:
                        "once you know why the command opposed the meter.",
                        self.sign_wd.reason or "(reason not recorded)")
 
+        # SAFETY-18. The frozen-but-fresh meter detector - see freeze.py for why
+        # it is a conjunction and not an `unchanged_s` threshold, and for the
+        # measurements behind the default.
+        #
+        # ⚠️ NOT restored from the store, unlike SAFETY-02's latch, and the
+        # asymmetry is the point: this one does not latch because it does not
+        # act. A restart re-derives its state from the meter within one
+        # `meter_freeze_s` window, and until then the honest report is "not
+        # alarming yet" rather than an alarm nobody can clear.
+        self.freeze_wd = FreezeWatchdog(
+            FreezeWatchdogConfig(hold_s=float(opts.get("meter_freeze_s", 300))))
+
         # P1 ingestion (TEL-01). `meter_source: off` keeps the original
         # single-entity meter_entity path, so an existing install is unchanged
         # until it opts in.
@@ -393,6 +406,53 @@ class Controller:
         self.reason = resolution.explain()
         await self.write_setpoint(self.target)
 
+        # --- SAFETY-18, and it runs LAST on purpose --------------------------
+        # Both terms of the conjunction describe the state that now exists: the
+        # command that has just gone on the wire, and how long the meter that
+        # chose it has been standing still. Evaluated before write_setpoint()
+        # it would be reasoning about the PREVIOUS command against THIS cycle's
+        # meter - the one combination that is true of neither moment.
+        await self.check_meter_frozen()
+
+    async def check_meter_frozen(self) -> None:
+        """SAFETY-18. Alarm on a meter that answers forever without changing.
+
+        Notification only - no claim, no latch, no 0 W. freeze.py carries the
+        reasoning and the euro figure; DOCS.md carries the exposure this does
+        NOT close.
+
+        ⚠️ getattr, not an attribute access: `unchanged_s` exists only on
+        `homewizard_local`, and `p1_source` is None until amain() builds the
+        transport. Every other meter_source hands the predicate None and gets
+        False, which is the honest answer - see the transport note in freeze.py.
+        """
+        unchanged = getattr(self.p1_source, "unchanged_s", None)
+        fired = self.freeze_wd.evaluate(unchanged, self.target,
+                                        float(self.o.get("max_w", 2000)),
+                                        datetime.now(timezone.utc))
+        if not fired:
+            return
+        self.log_event("METER FROZEN? " + self.freeze_wd.reason)
+        _LOG.error(
+            "SAFETY-18 - %s. The grid-following loop is regulating against a "
+            "number that has stopped moving, and nothing in this stack stops "
+            "it: the meter is still answering, so the age is fresh, the "
+            "firmware watchdog is fed and the arbiter only bounds the "
+            "magnitude. CHECK THE METER. Sustained for a quarter of an hour "
+            "this sets the month's billed capacity-tariff peak. This is an "
+            "ALARM ONLY - the loop is still running.", self.freeze_wd.reason)
+        # ⚠️ A fixed notification_id, so a second episode REPLACES the first
+        # rather than stacking. An operator who has to dismiss eleven identical
+        # notifications learns to dismiss the twelfth without reading it.
+        await self.hass.call("persistent_notification", "create", {
+            "notification_id": "goodwe_meter_frozen",
+            "title": "GoodWe: the P1 meter may be frozen",
+            "message": (
+                f"{self.freeze_wd.reason}.\n\nThe controller is STILL RUNNING "
+                f"and still following this reading. Check the meter; if it is "
+                f"stuck, stop control from the add-on UI."),
+        })
+
     # -- tasks ---------------------------------------------------------------
     async def run_control(self) -> None:
         entity = self.o.get("setpoint_entity", "")
@@ -581,6 +641,33 @@ class Controller:
                                     f"{self.p1.parse_errors} rejected"
                                     + (f", measurement unchanged for {unchanged:.0f} s"
                                        if unchanged is not None else "")})
+            # SAFETY-18. Reported in both states, for the reason SAFETY-02 is:
+            # a detector nobody can see is armed is a detector nobody trusts
+            # when it fires. ok=False/warn=False so the banner goes red - this
+            # is an alarm, and the banner is the loudest surface we own. It
+            # changes NOTHING about control; see check_meter_frozen().
+            if self.freeze_wd.active:
+                out.append({"ok": False, "warn": False,
+                            "text": "METER MAY BE FROZEN - " + self.freeze_wd.reason
+                                    + ". The loop is STILL FOLLOWING it and is "
+                                      "still running. Check the meter. Held here "
+                                      "for a quarter of an hour this sets the "
+                                      "month's billed capacity peak."})
+            elif getattr(self.p1_source, "unchanged_s", None) is None:
+                # Not "armed". Every transport but homewizard_local is invisible
+                # to this check, and saying "armed" there would be a lie the
+                # status page tells on behalf of a guard that cannot run.
+                out.append({"ok": False, "warn": True,
+                            "text": f"freeze detector: NOT COVERED on "
+                                    f"meter_source {o.get('meter_source')} - only "
+                                    f"homewizard_local sees whether the meter's own "
+                                    f"document changes"})
+            else:
+                out.append({"ok": True, "warn": False,
+                            "text": f"freeze detector: armed (alerts after "
+                                    f"{self.freeze_wd.cfg.hold_s:.0f} s unchanged "
+                                    f"while the command is over "
+                                    f"{rail_w(self.o.get('max_w', 2000)):.0f} W)"})
         rows = [("battery SoC", self.soc, o.get("soc_entity")),
                 ("battery power", self.batt, o.get("batt_entity"))]
         if not self.p1_enabled:

goodwe_controller/app/maintenance.py

@@ -28,9 +28,10 @@ _LOG = logging.getLogger("goodwe.maint")
 
 IDLE, DRAIN, CHARGE, HOLD = "idle", "drain", "charge", "hold"
 
-# A drain of a 13.5 kWh usable pack at 2500 W is ~5 h even with no house load
-# helping. 12 h means the battery is not following commands - a fault, not a
-# slow day. The charge phase deliberately waits for sun and for cheap hours, so
+# A drain of a 13.8 kWh usable pack (300 Ah x 51.2 V, DoD 90) at the shipped
+# 2000 W is ~6.9 h even with no house load helping - and less in practice, since
+# house load drains alongside the export and soc_floor stops short of empty.
+# 12 h means the battery is not following commands - a fault, not a slow day. The charge phase deliberately waits for sun and for cheap hours, so
 # it is expected to span a night; 36 h still bounds it.
 DRAIN_TIMEOUT_MIN = 720
 CHARGE_TIMEOUT_MIN = 2160

goodwe_controller/app/validate.py

@@ -85,6 +85,37 @@ NOT READY banner already names the problem, (b) does not apply.
      watchdog: armed". A disarmed guard that advertises itself as armed is the
      one thing this project has decided repeatedly it will not ship.
 
+  6. `maintenance_charge_w` above `max_w`.  [(a)]
+     The same shape as 5, and found the same way - by checking a worked example
+     against what actually ships. maintenance's cheap-window shaping files
+     `Claim.limit(hi=-maintenance_charge_w)` at P_MAINT_SHAPE, against the
+     `supervised` SAFETY limit's `lo=-max_w`. Both bind (P_SAFETY and
+     P_MAINT_SHAPE both outrank the loop that wins the SET), so a charge rate
+     above the ceiling gives `lo > hi` - the arbiter's clause 3, which it
+     correctly resolves to 0 W and logs as a CONTRADICTION. Measured against
+     the arbiter, loop asking +500 W:
+
+         max_w=2000  hi=-2500  ->     +0 W  contradiction=True
+         max_w=2500  hi=-2500  ->  -2500 W  limited by supervised(max_w)
+         max_w=3000  hi=-2500  ->  -2500 W  limited by maintenance(...)
+
+     So MAINTENANCE SILENTLY NEVER CHARGES IN A CHEAP WINDOW until max_w is at
+     or above the charge rate, and the only evidence is a contradiction line
+     that reads like a bug in the arbiter rather than like the two numbers the
+     operator set. Equality is fine and deliberately not refused - at
+     max_w == charge_w the window is a single reachable point, -max_w.
+
+     ⚠️ `maintenance_discharge_w` IS NOT THE SAME CASE, and this was checked
+     rather than assumed. THE SHAPING IS NOT SYMMETRIC: the drain phase does
+     not shape the loop, it OWNS the actuator - `Claim.set(P_MAINTENANCE,
+     +discharge_w)`. A SET is clamped by the limits above it, not contradicted
+     by them, so 2500 against a 2000 W ceiling emits +2000 W and the arbiter's
+     own explain() says `maintenance -> 2000 W, limited by supervised(max_w)`
+     on the status page every cycle. That is neither (a) - nothing is silent -
+     nor (b) - it moves energy and the cycle still completes, just slower
+     (13.8 kWh usable at 2000 W is ~6.9 h against the 720 min DRAIN_TIMEOUT).
+     It is warned about below, not refused.
+
 WHAT IS DELIBERATELY *NOT* REFUSED, because it is untidy rather than unsafe:
 
   - `integrator_max_w` above `max_w`. DOCS.md is right that the only thing the
@@ -102,6 +133,9 @@ WHAT IS DELIBERATELY *NOT* REFUSED, because it is untidy rather than unsafe:
     NOT READY banner.
   - `meter_poll_s` above half `meter_max_age_s`. One missed poll costs a stale
     reading and a 0 W cycle. Warned about in p1.py, not refused.
+  - `maintenance_discharge_w` above `max_w`. Clamped, not contradicted, and the
+    clamp names itself in the arbiter's explain() - see rule 6. Warned about,
+    not refused.
 """
 
 import logging
@@ -269,6 +303,52 @@ def validate_startup_config(opts: dict, dev_min=None, dev_max=None) -> list[str]
             f"sign_disagree_w below {max_w:.0f} W (300 W is the measured "
             "default), or raise max_w.")
 
+    # --- 6. a maintenance charge the ceiling can actually accommodate --------
+    # ⚠️ Strictly `>`, matching the arbiter exactly. The shaping is
+    # `Claim.limit(hi=-charge_w)` against `supervised`'s `lo=-max_w`, so
+    # charge_w == max_w leaves the single reachable point -max_w and works;
+    # only ABOVE is `lo > hi`, arbiter clause 3, 0 W and a contradiction.
+    #
+    # Not scoped to maintenance_enabled, deliberately. The pair is
+    # contradictory whether or not the schedule is on, and scoping it would
+    # leave the trap armed for the one operator action - ticking
+    # maintenance_enabled - that cannot possibly be expected to change what a
+    # charge rate means.
+    # ⚠️ THE FALLBACK IS config.yaml's SHIPPED VALUE, and it has to be kept
+    # equal to it - that is the whole point of AC3. It is reachable only when a
+    # caller hands over a dict with the key missing (sim/inject.py, a test); the
+    # Supervisor always supplies every key from config.yaml, so on a real
+    # install the argument is always present.
+    #
+    # ⚠️ KNOWN MISMATCH, LEFT DELIBERATELY AND FLAGGED RATHER THAN FIXED HERE:
+    # `main.py` still falls back to 2500 in two places
+    # (`opts.get("maintenance_charge_w", 2500)`), as does maintenance.py's
+    # MaintConfig dataclass. So a dict with the key ABSENT is accepted by this
+    # rule at 2000 and then built by main.py at 2500 - the contradiction this
+    # rule exists to catch, in the one case it cannot see. It is unreachable on
+    # a Supervisor install and those files are another ticket's right now.
+    # THE REAL FIX is one source of truth for option defaults; until then the
+    # divergence is PINNED BY A CHECK rather than by this comment - see
+    # test_validate.py, "the KNOWN cross-file default divergence". It asserts
+    # the mismatch as it stands and goes red if EITHER side moves, including
+    # when somebody closes it in main.py, at which point this block and that
+    # check both get deleted.
+    charge_w = _number(opts, "maintenance_charge_w", 2000.0)
+    if charge_w is None:
+        problems.append(
+            f"maintenance_charge_w {opts.get('maintenance_charge_w')!r} is not a number")
+    elif max_w is not None and max_w > 0 and charge_w > max_w:
+        problems.append(
+            f"maintenance_charge_w is {charge_w:.0f} W but max_w is "
+            f"{max_w:.0f} W, so a maintenance charge in a cheap window can "
+            "never happen: the shaping asks the arbiter for at most "
+            f"{-charge_w:.0f} W while the supervised limit allows no less than "
+            f"{-max_w:.0f} W, which is a contradiction it resolves to 0 W - "
+            "THE CEILING WINS, and what you would see is an ARBITER "
+            "CONTRADICTION line that reads like a bug rather than like these "
+            f"two numbers. Lower maintenance_charge_w to {max_w:.0f} W or less, "
+            f"or raise max_w to at least {charge_w:.0f} W.")
+
     # --- warnings: real, but not worth refusing over -------------------------
     integ = opts.get("integrator_max_w")
     integ_w = None if not integ else _number(opts, "integrator_max_w", None)
@@ -280,6 +360,25 @@ def validate_startup_config(opts: dict, dev_min=None, dev_max=None) -> list[str]
             "saturation. 0 (follow max_w) is the recommended value.",
             integ_w, max_w)
 
+    # ⚠️ THE SIBLING OF RULE 6, AND NOT THE SAME CASE - see the docstring. The
+    # drain phase OWNS the actuator (`Claim.set` at P_MAINTENANCE), and a SET is
+    # clamped by the limits above it rather than contradicted by them. So this
+    # drains at max_w instead of the configured rate, the arbiter says so in
+    # words on the status page every cycle, and the cycle still completes -
+    # slower, and eating into maintenance.DRAIN_TIMEOUT_MIN. Loud and it moves
+    # energy, so it is neither (a) nor (b): warned, not refused.
+    disch_w = _number(opts, "maintenance_discharge_w", 2000.0)
+    if disch_w is not None and max_w is not None and max_w > 0 and disch_w > max_w:
+        _LOG.warning(
+            "maintenance_discharge_w %.0f W is above max_w %.0f W. Not refused - "
+            "the drain phase SETS the setpoint and the arbiter clamps it to "
+            "%.0f W and names the clamp ('limited by supervised(max_w)'), so "
+            "nothing is silent and the cycle still completes. But it drains at "
+            "%.0f W, not the %.0f W you configured, and the drain phase has a "
+            "720 min timeout. Lower it to %.0f W or raise max_w to remove the "
+            "surprise.",
+            disch_w, max_w, max_w, max_w, disch_w, max_w)
+
     return problems
 
 

goodwe_controller/config.yaml

@@ -1,5 +1,5 @@
 name: GoodWe RS485 Controller
-version: "0.5.1"
+version: "0.5.2"
 slug: goodwe_controller
 description: >-
   Drives a GoodWe ES/BP battery inverter over RS485 by emulating its smart
@@ -114,12 +114,47 @@ options:
   sign_disagree_w: 300
   sign_disagree_s: 180
 
+  # --- SAFETY-18 frozen-but-fresh meter detector -----------------------------
+  # Seconds the meter may keep answering with an UNCHANGED measurement while the
+  # command stands at the rail before the add-on raises an alarm. Both halves
+  # are required: neither one alone is safe, and app/freeze.py carries why.
+  #
+  # ALARM ONLY. It does not command 0 W and does not latch. A false trip parks
+  # the battery; a false notification costs an alert.
+  #
+  # ⚠️ Only `meter_source: homewizard_local` can see this at all - it is the
+  # only transport that reads the meter's own document. On every other source
+  # the status page says NOT COVERED rather than "armed".
+  #
+  # 300 s is measured, not chosen. Over 2399 s of the live house at the
+  # converged operating point (sim/scenarios/p1-age-2026-08-26.jsonl.gz, mean
+  # grid -14.2 W, 1194 polls, 735 of them repeating the previous reading) the
+  # LONGEST run without a distinct reading is 15.4 s (the largest unchanged_s any
+  # sample observes is 8.0 s). 300 s is 19.5x the pessimistic figure, and
+  # still inside the 900 s quarter that bills the capacity tariff.
+  meter_freeze_s: 300
+
   # --- maintenance -----------------------------------------------------------
   maintenance_enabled: false
   maintenance_interval_days: 28
   maintenance_start_hour: 10
-  maintenance_discharge_w: 2500
-  maintenance_charge_w: 2500
+  # ⚠️ BOTH MUST STAY AT OR BELOW max_w, and that is why they are 2000 rather
+  # than the 2500 they shipped as. The cheap-window charge shaping asks the
+  # arbiter for `hi = -maintenance_charge_w` against the supervised `lo =
+  # -max_w`: above the ceiling that is `lo > hi`, a contradiction resolved to
+  # 0 W, so maintenance would SILENTLY NEVER CHARGE in a cheap window on a
+  # default install. validate.py refuses that config (rule 6), so these
+  # defaults had to become self-consistent with the max_w above rather than
+  # ship a configuration the validator rejects.
+  #
+  # The discharge side is clamped rather than contradicted - it drains at max_w
+  # and the arbiter says so - so it is only warned about; it is 2000 here for
+  # symmetry and to keep the shipped config warning-free.
+  #
+  # Raising max_w (the live reference install runs 5000) is what unlocks a
+  # faster maintenance cycle. Raise max_w FIRST, then these.
+  maintenance_discharge_w: 2000
+  maintenance_charge_w: 2000
   maintenance_soc_floor: 11
   maintenance_soc_target: 99
   maintenance_hold_min: 120
@@ -181,6 +216,15 @@ schema:
   sign_disagree_w: int(50,5000)
   sign_disagree_s: int(30,1800)
 
+  # No "off" value, for SAFETY-02's reason: disarming a safety alarm is not a
+  # supported configuration. ⚠️ THE FLOOR OF 60 IS NOT A RECOMMENDATION. At 300 s
+  # the slowest a HEALTHY meter's 1 Wh register can tick and still look unchanged
+  # is 12 W, which is inside the 15 W deadband, so the two terms of the
+  # conjunction are mutually exclusive rather than merely far apart. At 60 s that
+  # figure is 60 W and the argument is gone - only the margin is left. See
+  # app/freeze.py.
+  meter_freeze_s: int(60,3600)
+
   maintenance_enabled: bool
   maintenance_interval_days: int(1,90)
   maintenance_start_hour: int(0,23)

goodwe_controller/test_freeze.py

@@ -0,0 +1,539 @@
+"""Runnable check for SAFETY-18, the frozen-but-fresh meter detector.
+
+    python3 test_freeze.py
+
+Three parts, and the last two are the ones that matter:
+
+  1. the predicate's boundaries and the edge-trigger, table-driven;
+  2. SILENT ON REAL CONVERGED DATA. `scenarios/p1-age-2026-08-26.jsonl.gz` is
+     40 minutes of this house's live meter at the operating point, committed
+     here from the infra repo's `sim/scenarios/`. It is replayed through the
+     REAL `control.compute()` at the real cycle rule, and the detector must not
+     make a sound. This is the acceptance criterion TEL-05's objection is
+     about, and it is verified rather than argued;
+  3. FIRES ON A GENUINELY FROZEN METER, over real HTTP, through the REAL
+     `HomeWizardLocalSource` - the transport is what computes `unchanged_s`, so
+     a check that calls the predicate directly would not be testing the thing
+     that ships. Uses the rig's own `sim/hwsim.py --fault freeze` when the infra
+     repo is next to this one (or `$GOODWE_SIM`), and an equivalent local stub
+     otherwise. Both are exercised; the run says which one it used.
+
+⚠️ Part 3 runs in WALL CLOCK - `unchanged_s` is `time.monotonic()` and the
+transport really polls - so it drives the detector at `hold_s=10`, not the
+shipped 300. The THRESHOLD is config; the MECHANISM is what is under test, and
+the mechanism cannot be hurried. Part 2 uses the shipped 300 because that data
+is replayed rather than lived.
+
+⚠️ Part 3 also runs its NEGATIVE twin, and that is the load-bearing half: the
+same railed command against a meter that is still MOVING, at the same 10 s
+threshold. If that one alarms, the detector is a `unchanged_s` threshold with
+extra steps and the whole reason for the conjunction is gone.
+
+------------------------------------------------------------------------------
+THE RIG RUN THIS STANDS IN FOR
+
+Part 3 is the portable version of a run done on the real rig - the `goodwe-sim`
+compose project on 192.168.2.147, under `sim/riglock.py`, with the driver staged
+into `goodwe-sim-plant` so it polls that container's own hwsim while plantsim
+drives it. Both phases passed there. To repeat it:
+
+    DOCKER_HOST=ssh://homelab@192.168.2.147 python sim/riglock.py status
+
+⚠️ WITHOUT `DOCKER_HOST` SET, ON A WINDOWS HOST, `riglock status` REPORTS
+`rig: UNKNOWN` - it shells out to the local `docker` CLI, which resolves to a
+Docker Desktop npipe that is not running. That is INDISTINGUISHABLE from a
+genuinely absent rig, and it is not one: the rig lives on the homelab box and was
+up the whole time. `UNKNOWN` is the tool declining to observe, not an
+observation. Do not read it as "no rig" (this cost this ticket a wrong caveat).
+
+The rig run also produced a result part 3's stub cannot: under +8000 W of house
+load the meter's POWER FIGURE never moved - 10130.0 W for 26 consecutive polls -
+and only the kWh registers kept `unchanged_s` at zero. See the note in
+freeze.py; it is why the fingerprint's register terms are the negative case
+rather than a nicety.
+"""
+
+import asyncio
+import gzip
+import json
+import os
+import subprocess
+import sys
+import time
+from datetime import datetime, timedelta, timezone
+from pathlib import Path
+
+import aiohttp
+
+from app.control import Tuning, compute
+from app.freeze import (
+    RAIL_FRAC, FreezeWatchdog, FreezeWatchdogConfig, looks_frozen, rail_w,
+)
+from app.main import Controller
+from app.p1 import HomeWizardLocalSource, P1Ingest
+
+fails = []
+T0 = datetime(2026, 8, 26, 7, 0, 0, tzinfo=timezone.utc)
+HERE = Path(__file__).resolve().parent
+
+# The live install's numbers, which are the ones the exposure is written at.
+LIVE_MAX_W = 5000.0
+
+
+def check(name, cond):
+    print(f"  {'ok  ' if cond else 'FAIL'} {name}")
+    if not cond:
+        fails.append(name)
+
+
+def tuning(max_w=LIVE_MAX_W):
+    """The shipped defaults from config.yaml, at the live install's max_w."""
+    return Tuning(gain=0.6, max_w=max_w, slew_w=1000, deadband_w=15,
+                  target_grid_w=-10, step_w=10, saturation_w=500,
+                  saturation_cycles=3)
+
+
+# --------------------------------------------------------------------------- #
+# 1. the predicate and the edge
+# --------------------------------------------------------------------------- #
+print("predicate")
+cfg = FreezeWatchdogConfig(hold_s=300)
+
+check("both terms true -> frozen", looks_frozen(300, 5000, 5000, cfg))
+check("unchanged long, command NOT railed -> silent  (TEL-05's case)",
+      not looks_frozen(3600, -40, 5000, cfg))
+check("command railed, meter still moving -> silent  (a real 8 kW load)",
+      not looks_frozen(4, -5000, 5000, cfg))
+check("neither -> silent", not looks_frozen(4, -40, 5000, cfg))
+check("one second under the hold is still silent",
+      not looks_frozen(299.9, 5000, 5000, cfg))
+check("just under the rail fraction is still silent",
+      not looks_frozen(3600, 5000 * RAIL_FRAC - 1, 5000, cfg))
+check("at the rail fraction exactly, it fires",
+      looks_frozen(3600, 5000 * RAIL_FRAC, 5000, cfg))
+check("the rail scales with max_w, not with a fixed watt figure",
+      looks_frozen(3600, 2000, 2000, cfg) and not looks_frozen(3600, 2000, 5000, cfg))
+check("a charge rail counts too - the runaway can be either sign",
+      looks_frozen(3600, -5000, 5000, cfg))
+check("no transport signal (unchanged_s None) -> silent, never assumed frozen",
+      not looks_frozen(None, 5000, 5000, cfg))
+check("no command yet -> silent", not looks_frozen(3600, None, 5000, cfg))
+check("rail_w tracks RAIL_FRAC", rail_w(5000) == 5000 * RAIL_FRAC)
+
+print("the edge")
+wd = FreezeWatchdog(cfg)
+edges = [wd.evaluate(u, c, 5000, T0 + timedelta(seconds=i))
+         for i, (u, c) in enumerate(
+             [(10, 5000), (300, 5000), (305, 5000), (310, 5000),
+              (2, 5000), (300, 5000)])]
+check("rises exactly once per episode", edges == [False, True, False, False,
+                                                  False, True])
+check("two episodes counted", wd.episodes == 2)
+check("clearing the condition clears the alarm state",
+      not FreezeWatchdog(cfg).evaluate(2, 5000, 5000, T0))
+check("the reason names both terms",
+      "unchanged over 300" in wd.reason and "command over 4750" in wd.reason)
+
+
+# --------------------------------------------------------------------------- #
+# 2. silent on 40 minutes of real converged behaviour
+# --------------------------------------------------------------------------- #
+print("converged replay - scenarios/p1-age-2026-08-26.jsonl.gz")
+rows = [json.loads(line) for line in
+        gzip.open(HERE / "scenarios" / "p1-age-2026-08-26.jsonl.gz", "rt")]
+check("the capture loaded", len(rows) > 1000)
+
+# ⚠️ The capture records the POWER figure only. The shipped fingerprint also
+# covers both kWh registers, so a real `unchanged_s` on this data can only be
+# SHORTER than what is reconstructed here - this replay is the pessimistic
+# version of the converged case, not a flattering one.
+def replay(hold_s, max_w, cycle_floor_s=15.0):
+    """Drive the real control law and the real detector over the capture."""
+    wd = FreezeWatchdog(FreezeWatchdogConfig(hold_s=hold_s))
+    t = tuning(max_w)
+    target, i_w, sat = 0.0, 0.0, 0
+    prev_pwr, changed_at = None, rows[0]["t"]
+    last_cycle = None
+    peak_cmd, peak_unchanged, fired_at = 0.0, 0.0, None
+    for r in rows:
+        now, pwr = r["t"], float(r["pwr"])
+        if prev_pwr is None or pwr != prev_pwr:
+            changed_at = now
+        arrival = (prev_pwr is None or pwr != prev_pwr)
+        prev_pwr = pwr
+        # main.run_control()'s rule: a cycle per changed reading, or the floor.
+        if arrival or last_cycle is None or now - last_cycle >= cycle_floor_s:
+            last_cycle = now
+            d = compute(prev_w=target, grid_w=pwr, actual_w=target, tuning=t,
+                        sat_count=sat, i_w=i_w)
+            target, i_w, sat = d.target_w, d.i_w, d.sat_count
+        # ⚠️ The detector is evaluated on EVERY poll, not only on cycles, and
+        # that is deliberately harsher than the shipped wiring (which evaluates
+        # it inside cycle()). On an arrival-triggered cycle `unchanged_s` is 0
+        # by construction, so grading only there would be grading the detector
+        # on the one sample it cannot possibly fire on.
+        unchanged = now - changed_at
+        peak_cmd = max(peak_cmd, abs(target))
+        peak_unchanged = max(peak_unchanged, unchanged)
+        if wd.evaluate(unchanged, target, max_w,
+                       T0 + timedelta(seconds=now - rows[0]["t"])) \
+                and fired_at is None:
+            fired_at = now - rows[0]["t"]
+    return wd, peak_cmd, peak_unchanged, fired_at
+
+
+for mw in (2000.0, LIVE_MAX_W):
+    wd_r, peak_cmd, peak_unchanged, fired = replay(300.0, mw)
+    print(f"    max_w {mw:.0f}: worst |command| {peak_cmd:.0f} W (rail "
+          f"{rail_w(mw):.0f} W), worst unchanged {peak_unchanged:.1f} s "
+          f"(hold 300 s), episodes {wd_r.episodes}")
+    check(f"max_w {mw:.0f}: never alarms on the converged capture", fired is None)
+    check(f"max_w {mw:.0f}: and the rail term had margin to spare",
+          peak_cmd < rail_w(mw))
+
+# The margin on the OTHER term, as numbers rather than as trust. Both figures
+# are quoted in config.yaml and freeze.py, so they are re-measured every run and
+# a capture swapped underneath them cannot leave the prose saying the old thing.
+_, _, worst_unchanged, _ = replay(300.0, LIVE_MAX_W)
+gaps, last, prev = [], rows[0]["t"], None
+for r in rows:
+    if prev is None or r["pwr"] != prev:
+        gaps.append(r["t"] - last)
+        last = r["t"]
+    prev = r["pwr"]
+print(f"    longest unchanged_s any sample would observe: {worst_unchanged:.1f} s")
+print(f"    longest interval serving no distinct reading:  {max(gaps):.1f} s "
+      f"(spans an 11.4 s hole in the capture's own polling)")
+check("worst observed unchanged_s is the 8 s the docs quote",
+      7.5 < worst_unchanged < 8.5)
+check("longest distinct-reading interval is the 15.4 s the docs quote",
+      15.0 < max(gaps) < 16.0)
+check("300 s is at least 15x the worst of the two", 300.0 >= 15 * max(gaps))
+
+# --------------------------------------------------------------------------- #
+# 2b. TEL-05's case, reconstructed, because the capture cannot contain it
+# --------------------------------------------------------------------------- #
+# ⚠️ BE HONEST ABOUT WHAT THE CAPTURE ABOVE PROVES AND WHAT IT DOES NOT. On this
+# house's meter the power figure jitters at 1 W, so the worst `unchanged_s` any
+# sample sees is 8 s - which means the capture alone does NOT refute a bare
+# `unchanged_s > 300` threshold, and reporting it as though it did would be the
+# confident explanation nobody checked. The case that refutes the bare threshold
+# is the one p1.py describes and no capture of THIS meter contains: a converged
+# meter whose power figure simply repeats, where the 1 Wh export register needs
+# 360 s to advance at -10 W and the fingerprint therefore stands still.
+#
+# So it is constructed, from the operating point the capture measures (mean grid
+# -14.2 W) rather than invented: one hour of a perfectly healthy converged meter
+# that happens not to move.
+print("TEL-05's low-power case - a converged meter that legitimately repeats")
+tel05 = FreezeWatchdog(FreezeWatchdogConfig(hold_s=300))
+t5 = tuning(LIVE_MAX_W)
+tgt, iw, sc = 0.0, 0.0, 0
+bare_would_fire = False
+tel05_cmd = 0.0
+for k in range(3600):
+    if k % 15 == 0:                       # cycle_floor_s, the only trigger left
+        d = compute(prev_w=tgt, grid_w=-14.2, actual_w=tgt, tuning=t5,
+                    sat_count=sc, i_w=iw)
+        tgt, iw, sc = d.target_w, d.i_w, d.sat_count
+    tel05_cmd = max(tel05_cmd, abs(tgt))
+    # The REJECTED design, written out so the case can be shown to be real.
+    bare_would_fire = bare_would_fire or float(k) >= 300
+    tel05.evaluate(float(k), tgt, LIVE_MAX_W, T0 + timedelta(seconds=k))
+print(f"    an hour at -14.2 W: worst |command| {tel05_cmd:.0f} W, "
+      f"unchanged_s reaches 3599 s, episodes {tel05.episodes}")
+check("the bare unchanged_s threshold TEL-05 rejected WOULD fire here",
+      bare_would_fire)
+check("the conjunction does not - this is what the rail term buys",
+      tel05.episodes == 0)
+check("...and the command stayed nowhere near the rail",
+      tel05_cmd < rail_w(LIVE_MAX_W))
+
+# The structural version of the same point, re-derived rather than asserted in
+# prose: the slowest register a HEALTHY meter can have while still being seen as
+# unchanged for hold_s is 3600/hold_s watts, and at the shipped defaults that
+# figure is inside the deadband, so the command there is parked at 0 W. If
+# someone lowers meter_freeze_s or narrows the deadband, this is the check that
+# should stop them.
+DEADBAND_W = 15.0
+slowest_healthy_w = 3600.0 / 300.0
+check("a healthy meter slow enough to look unchanged is inside the deadband",
+      slowest_healthy_w < DEADBAND_W)
+_park = compute(prev_w=0.0, grid_w=-slowest_healthy_w, actual_w=0.0,
+                tuning=tuning(LIVE_MAX_W), sat_count=0, i_w=0.0)
+check("...and the shipped law really does park the command there",
+      _park.target_w == 0.0)
+
+# ⚠️ THE PROOF THAT THE REPLAY IS CAPABLE OF FIRING AT ALL. Without this, "the
+# converged capture is silent" is satisfied by a detector that is wired to
+# nothing. Drop the hold to 1 s and the rail to nothing, and the SAME replay
+# must alarm - so the silence above is the data's doing, not the harness's.
+wd_hot, _, _, fired_hot = replay(1.0, 20.0)
+check("...and the same replay DOES alarm once both terms are made reachable",
+      fired_hot is not None and wd_hot.episodes > 0)
+
+
+# --------------------------------------------------------------------------- #
+# 3. a genuinely frozen meter, over real HTTP, through the real transport
+# --------------------------------------------------------------------------- #
+def find_hwsim():
+    """The rig's own fake meter, if the infra repo is reachable."""
+    cands = []
+    if os.environ.get("GOODWE_SIM"):
+        cands.append(Path(os.environ["GOODWE_SIM"]) / "hwsim.py")
+    cands.append(HERE.parents[1] / "goodwe" / "sim" / "hwsim.py")
+    for c in cands:
+        if c.exists():
+            return c
+    return None
+
+
+STUB = r'''
+import http.server, json, sys, threading, time
+FROZEN = {"active_power_w": 700.0, "active_power_l1_w": 700.0,
+          "total_power_import_kwh": 1234.567, "total_power_export_kwh": 890.123}
+moving = len(sys.argv) > 2 and sys.argv[2] == "moving"
+t0 = time.monotonic()
+class H(http.server.BaseHTTPRequestHandler):
+    def do_GET(self):
+        d = dict(FROZEN)
+        if moving:
+            # A REAL railed condition: a big steady import, so the power figure
+            # jitters and the 1 Wh registers advance the way physics makes them.
+            el = time.monotonic() - t0
+            d["active_power_w"] = 7000.0 + (int(el * 10) % 7)
+            d["active_power_l1_w"] = d["active_power_w"]
+            d["total_power_import_kwh"] = round(1234.567 + 7000 * el / 3.6e6, 3)
+        raw = json.dumps(d).encode()
+        self.send_response(200)
+        self.send_header("Content-Type", "application/json")
+        self.send_header("Content-Length", str(len(raw)))
+        self.end_headers()
+        self.wfile.write(raw)
+    def log_message(self, *a): pass
+http.server.ThreadingHTTPServer(("127.0.0.1", int(sys.argv[1])), H).serve_forever()
+'''
+
+HWSIM_DRIVER = r'''
+import sys, threading, time
+sys.path.insert(0, sys.argv[3])
+import hwsim
+hwsim.serve(int(sys.argv[1]))
+mode = sys.argv[2]
+hwsim.set_grid(7000.0)
+if mode == "freeze":
+    hwsim.fault = "freeze"          # exactly `hwsim.py --fault freeze`
+while True:
+    # The plant keeps moving underneath either way. Under `freeze` hwsim's own
+    # set_grid() returns early, which is the whole point of that fault.
+    hwsim.set_grid(7000.0 + (int(time.monotonic() * 10) % 7))
+    time.sleep(0.2)
+'''
+
+
+async def live_run(port, mode, hold_s=10.0, seconds=16.0, max_w=LIVE_MAX_W):
+    """Poll a real HTTP meter through the real transport and drive the detector."""
+    ingest = P1Ingest(phases=1, max_age_s=30)
+    wd = FreezeWatchdog(FreezeWatchdogConfig(hold_s=hold_s))
+    t = tuning(max_w)
+    target, i_w, sat = 0.0, 0.0, 0
+    fired_at, polls, worst_unchanged, worst_cmd = None, 0, 0.0, 0.0
+    async with aiohttp.ClientSession() as session:
+        src = HomeWizardLocalSource(session, ingest, "127.0.0.1", port=port,
+                                    poll_s=1.0)
+        start = time.monotonic()
+        while time.monotonic() - start < seconds:
+            if await src.poll_once():
+                polls += 1
+                grid = ingest.net_w
+                d = compute(prev_w=target, grid_w=grid, actual_w=target,
+                            tuning=t, sat_count=sat, i_w=i_w)
+                target, i_w, sat = d.target_w, d.i_w, d.sat_count
+                worst_unchanged = max(worst_unchanged, src.unchanged_s or 0.0)
+                worst_cmd = max(worst_cmd, abs(target))
+                if wd.evaluate(src.unchanged_s, target, max_w,
+                               datetime.now(timezone.utc)) and fired_at is None:
+                    fired_at = time.monotonic() - start
+            await asyncio.sleep(1.0)
+    return fired_at, polls, worst_unchanged, worst_cmd
+
+
+def with_server(argv, port, fn):
+    proc = subprocess.Popen([sys.executable, "-c"] + argv,
+                            stdout=subprocess.DEVNULL, stderr=subprocess.PIPE)
+    try:
+        deadline = time.monotonic() + 10
+        while time.monotonic() < deadline:
+            try:
+                import socket
+                with socket.create_connection(("127.0.0.1", port), 0.3):
+                    break
+            except OSError:
+                time.sleep(0.1)
+        else:
+            raise RuntimeError("the fake meter never came up")
+        return fn()
+    finally:
+        proc.kill()
+        proc.wait()
+
+
+hw = find_hwsim()
+print(f"frozen meter over HTTP - using {'the rig hwsim at ' + str(hw) if hw else 'the local stub'}")
+if hw:
+    def argv_for(mode):
+        return [HWSIM_DRIVER, "8791" if mode == "freeze" else "8792", mode,
+                str(hw.parent)]
+else:
+    def argv_for(mode):
+        return [STUB, "8791" if mode == "freeze" else "8792",
+                "frozen" if mode == "freeze" else "moving"]
+
+fired, polls, unch, cmd = with_server(
+    argv_for("freeze"), 8791,
+    lambda: asyncio.run(live_run(8791, "freeze")))
+print(f"    freeze: {polls} polls, worst unchanged {unch:.1f} s, "
+      f"worst |command| {cmd:.0f} W, alarm at "
+      f"{'never' if fired is None else f'{fired:.1f} s'}")
+check("the transport really polled a live server", polls >= 10)
+check("a frozen meter raises the alarm", fired is not None)
+check("...and only after the hold, not on the first railed poll",
+      fired is None or fired >= 10.0)
+
+fired2, polls2, unch2, cmd2 = with_server(
+    argv_for("moving"), 8792,
+    lambda: asyncio.run(live_run(8792, "moving")))
+print(f"    moving: {polls2} polls, worst unchanged {unch2:.1f} s, "
+      f"worst |command| {cmd2:.0f} W, alarm at "
+      f"{'never' if fired2 is None else f'{fired2:.1f} s'}")
+check("the moving meter also drove the command to the rail", cmd2 >= rail_w(LIVE_MAX_W))
+check("a REAL railed condition against a live meter stays silent", fired2 is None)
+check("...because the meter kept moving", unch2 < 10.0)
+
+
+# --------------------------------------------------------------------------- #
+# 4. the wiring, because a correct detector nobody calls is not a detector
+# --------------------------------------------------------------------------- #
+# ⚠️ EVERYTHING ABOVE PASSES WITH `app/freeze.py` IMPORTED BY NOTHING. That is
+# the shape of defect this project keeps finding: the mechanism is right, the
+# suite is green, and the shipped path never reaches it. So the real
+# `Controller.cycle()` is driven here, against the real arbiter and the real
+# control law, with a stand-in transport that reports `unchanged_s` the way
+# HomeWizardLocalSource does - and the assertion is on the SERVICE CALL that
+# leaves the process, not on the watchdog's own flag.
+print("the wiring - Controller.cycle() actually raises the notification")
+
+
+class _Store:
+    data: dict = {}
+
+    def set(self, *a):
+        pass
+
+    def get_time(self, *a):
+        return None
+
+
+class _Pub:
+    enabled = False
+
+    def publish(self, *a, **k):
+        pass
+
+    def close(self):
+        pass
+
+
+class _Hass:
+    def __init__(self, grid):
+        self.grid = grid
+        self.calls = []
+        self.writes = []
+        # The plant tracks the command instantly, as in test_loop.py. Without
+        # it the saturation freeze pins the command short of the rail and the
+        # runaway under test never happens - which would have made this a check
+        # that passes for the wrong reason.
+        self.batt = 0.0
+
+    async def limits(self, entity):
+        return (-5000.0, 5000.0, 1.0)
+
+    async def number(self, entity, invert=False):
+        return {"sensor.grid": self.grid, "sensor.soc": 50.0,
+                "sensor.batt": self.batt}.get(entity)
+
+    async def set_number(self, entity, value):
+        self.writes.append(float(value))
+        self.batt = float(value)
+        return True
+
+    async def call(self, domain, service, data):
+        self.calls.append((domain, service, data))
+        return True
+
+
+class _Source:
+    """Only the attribute the controller reads. Duck-typed like the real one."""
+
+    def __init__(self, unchanged_s):
+        self.unchanged_s = unchanged_s
+
+
+def wired(unchanged_s, grid, cycles=60, **over):
+    async def go():
+        hass = _Hass(grid)
+        c = Controller(dict(
+            {"setpoint_entity": "number.sp", "meter_entity": "sensor.grid",
+             "soc_entity": "sensor.soc", "batt_entity": "sensor.batt",
+             "meter_source": "off", "max_w": LIVE_MAX_W, "gain": 0.6,
+             "slew_w": 1000, "deadband_w": 15, "target_grid_w": -10,
+             "step_w": 10, "heartbeat_s": 10, "stale_input_s": 15},
+            **over), hass, _Store(), _Pub(), stop=asyncio.Event())
+        c.auto = True
+        c.dev_min, c.dev_max = -5000.0, 5000.0
+        c.p1_source = _Source(unchanged_s)
+        for _ in range(cycles):
+            await c.read_inputs()
+            await c.cycle()
+        return hass, c
+    return asyncio.run(go())
+
+
+hass_f, ctl_f = wired(3600.0, 4000.0)
+notes = [d for dom, svc, d in hass_f.calls
+         if (dom, svc) == ("persistent_notification", "create")]
+# The status row lives behind `p1_enabled`, which is what a homewizard_local
+# install has. Flipped here rather than plumbing a whole P1 transport in - the
+# row's own content is what is under test.
+ctl_f.p1_enabled = True
+rows = [c for c in ctl_f.checks() if "METER MAY BE FROZEN" in c["text"]]
+print(f"    frozen at +4000 W: command ran to {ctl_f.target:.0f} W, "
+      f"{len(notes)} notification(s), {len(rows)} red status row(s)")
+check("the shipped cycle() raises exactly one HA notification", len(notes) == 1)
+check("...with a fixed notification_id so repeats replace, not stack",
+      notes and notes[0].get("notification_id") == "goodwe_meter_frozen")
+check("...and it says the controller is still running",
+      bool(notes) and "STILL RUNNING" in notes[0]["message"])
+check("the status page carries a failed row saying so",
+      len(rows) == 1 and not rows[0]["ok"] and not rows[0]["warn"])
+check("the event log names it", any("METER FROZEN" in e for e in ctl_f.events))
+# ⚠️ NOTIFY, NOT TRIP. If a later cut turns this into a trip it must come here
+# and change this expectation deliberately, not discover it in the field.
+check("and it does NOT command 0 W - this cut is an alarm only",
+      abs(ctl_f.target) >= rail_w(LIVE_MAX_W))
+
+hass_n, ctl_n = wired(3600.0, -14.2)
+check("wired up, TEL-05's converged case still raises nothing",
+      not [1 for dom, svc, _ in hass_n.calls if svc == "create"])
+hass_m, ctl_m = wired(2.0, 8000.0)
+check("wired up, a real railed load against a moving meter raises nothing",
+      not [1 for dom, svc, _ in hass_m.calls if svc == "create"]
+      and abs(ctl_m.target) >= rail_w(LIVE_MAX_W))
+check("an uncovered transport (no unchanged_s) raises nothing, and says so",
+      not [1 for dom, svc, _ in wired(None, 4000.0)[0].calls if svc == "create"])
+
+print()
+if fails:
+    print(f"{len(fails)} FAILED: {', '.join(fails)}")
+    sys.exit(1)
+print("all checks passed")

goodwe_controller/test_validate.py

@@ -26,9 +26,15 @@ def check(name, cond):
 
 def base(**over):
     """A configuration that must start. Everything else is this, spoilt."""
+    # ⚠️ The maintenance rates are named EXPLICITLY, at the values config.yaml
+    # ships (MAINT-04). They are not decoration: with the key absent, rule 6
+    # falls back to main.py's 2500 W, which against this 2000 W ceiling is a
+    # genuine refusal - so a base() without them would be a config that does
+    # not start, and every check below would be measuring the wrong thing.
     o = {"setpoint_entity": "number.goodwe_setpoint", "max_w": 2000,
          "soc_entity": "sensor.soc", "batt_entity": "sensor.batt",
-         "meter_source": "off"}
+         "meter_source": "off",
+         "maintenance_charge_w": 2000, "maintenance_discharge_w": 2000}
     o.update(over)
     return o
 
@@ -151,6 +157,170 @@ check("with meter_source off the number governs nothing and is not refused",
 check("the constant is the firmware's, not a rounded guess",
       FIRMWARE_INGEST_VETO_S == 30.0)
 
+# --------------------------------------------------------------------------- #
+print("6. a maintenance charge the ceiling can actually accommodate (MAINT-04)")
+# ⚠️ THE SHIPPED BUG. config.yaml shipped max_w 2000 against
+# maintenance_charge_w 2500, so the cheap-window shaping asked for hi=-2500
+# against the supervised lo=-2000 - lo > hi, arbiter clause 3, 0 W. Maintenance
+# silently never charged in a cheap window on a default install.
+p = validate_startup_config(base(max_w=2000, maintenance_charge_w=2500),
+                            -5000, 5000)
+check("maintenance_charge_w above max_w is refused", len(p) == 1)
+check("...and the message names the charge rate", why(p, "2500"))
+check("...and the ceiling", why(p, "2000"))
+check("...and says which one wins", why(p, "THE CEILING WINS"))
+# ⚠️ Equality is REACHABLE, not a near miss: lo=-2000, hi=-2000 is the single
+# point -2000 W. Refusing it would be exactly the trivia that gets a validator
+# deleted, and it is the boundary the rule is written `>` for.
+check("maintenance_charge_w exactly at max_w starts",
+      validate_startup_config(base(max_w=2000, maintenance_charge_w=2000),
+                              -5000, 5000) == [])
+check("below it starts",
+      validate_startup_config(base(max_w=2000, maintenance_charge_w=1500),
+                              -5000, 5000) == [])
+# Not scoped to maintenance_enabled: the pair is contradictory either way, and
+# scoping would leave the trap armed for the one action - ticking the box - that
+# cannot be expected to change what a charge rate means.
+check("...and it is refused with maintenance_enabled off, as shipped",
+      why(validate_startup_config(
+          base(max_w=2000, maintenance_charge_w=2500,
+               maintenance_enabled=False), -5000, 5000), "THE CEILING WINS"))
+
+# ⚠️ THE SIBLING, CHECKED RATHER THAN ASSUMED. The shaping is NOT symmetric:
+# drain files Claim.set at P_MAINTENANCE and owns the actuator, so the ceiling
+# CLAMPS it (+2000 W) instead of contradicting it, and the arbiter's explain()
+# names the clamp every cycle. Loud, and it still moves energy - so warned, not
+# refused. If someone later "fixes the asymmetry" by making this a refusal,
+# this check goes red and they have to justify it.
+check("maintenance_discharge_w above max_w WARNS but starts",
+      validate_startup_config(base(max_w=2000, maintenance_discharge_w=2500),
+                              -5000, 5000) == [])
+
+# The demonstration the rule is derived from, asserted rather than described.
+from app.arbiter import (                   # noqa: E402
+    Claim, P_LOOP, P_MAINTENANCE, P_MAINT_SHAPE, P_SAFETY, resolve,
+)
+
+def _charge(max_w, charge_w):
+    return resolve([Claim.limit("supervised", P_SAFETY, -max_w, max_w, "max_w"),
+                    Claim.limit("maintenance", P_MAINT_SHAPE, hi=-charge_w,
+                                reason="cheap-window charge"),
+                    Claim.set("loop", P_LOOP, 500.0, "grid")])
+
+def _drain(max_w, disch_w):
+    return resolve([Claim.limit("supervised", P_SAFETY, -max_w, max_w, "max_w"),
+                    Claim.set("maintenance", P_MAINTENANCE, disch_w, "drain"),
+                    Claim.set("loop", P_LOOP, 500.0, "grid")])
+
+r = _charge(2000, 2500)
+check("arbiter: the refused pair really does emit 0 W",
+      r.target_w == 0.0 and r.contradiction)
+r = _charge(2000, 2000)
+check("arbiter: the permitted equality really does charge",
+      r.target_w == -2000.0 and not r.contradiction)
+r = _charge(3000, 2500)
+check("arbiter: raising max_w above the rate charges at the rate",
+      r.target_w == -2500.0 and not r.contradiction)
+r = _drain(2000, 2500)
+check("arbiter: the drain SET is clamped, not contradicted",
+      r.target_w == 2000.0 and not r.contradiction)
+check("...and the clamp names itself, which is why it is not refused",
+      "supervised" in (r.bound_by or "") and "limited by" in r.explain())
+
+# --------------------------------------------------------------------------- #
+print("the SHIPPED defaults must pass the rule they are governed by (AC3)")
+# ⚠️ Shipping a default the validator refuses would be worse than the bug it
+# refuses. Read config.yaml itself rather than a transcription of it - a
+# transcription is what lets the two drift apart silently. Regex, not PyYAML:
+# the add-on image has no PyYAML (Dockerfile installs py3-aiohttp/py3-paho-mqtt
+# only) and a check that skips on ImportError is not a check.
+import os                                   # noqa: E402
+import re                                   # noqa: E402
+
+_CFG = os.path.join(os.path.dirname(os.path.abspath(__file__)), "config.yaml")
+with open(_CFG, encoding="utf-8") as _fh:
+    _txt = _fh.read()
+_shipped = {k: float(v) for k, v in re.findall(
+    r"^  (max_w|maintenance_charge_w|maintenance_discharge_w|sign_disagree_w): "
+    r"(-?\d+(?:\.\d+)?)\s*$", _txt, re.M)}
+check("config.yaml really was read (all four defaults found)",
+      set(_shipped) == {"max_w", "maintenance_charge_w",
+                        "maintenance_discharge_w", "sign_disagree_w"})
+check(f"the shipped defaults are accepted {_shipped}",
+      validate_startup_config(base(**_shipped), -5000, 5000) == [])
+check("...and the shipped charge rate is at or under the shipped ceiling",
+      _shipped["maintenance_charge_w"] <= _shipped["max_w"])
+check("...and the shipped discharge rate too, so it warns about nothing",
+      _shipped["maintenance_discharge_w"] <= _shipped["max_w"])
+
+# --------------------------------------------------------------------------- #
+print("the KNOWN cross-file default divergence, pinned rather than commented")
+# ⚠️ WHAT THIS GUARDS, AND WHY IT ASSERTS THE BUG RATHER THAN THE FIX.
+# config.yaml and validate.py now default maintenance_charge_w to 2000, while
+# main.py's two `opts.get(..., 2500)` fallbacks and MaintConfig's dataclass
+# default still say 2500. So an options dict with the key ABSENT is ACCEPTED by
+# rule 6 at 2000 and then built by main.py at 2500 - which is a contradiction:
+#
+#     validate_startup_config -> []            (accepted)
+#     MaintConfig().charge_w  -> 2500.0
+#     arbiter                 -> 0.0 W, contradiction=True
+#
+# That is the bug rule 6 exists to catch, passing rule 6. It is unreachable on a
+# Supervisor install (every key is always supplied from config.yaml) but fully
+# reachable from sim/inject.py and from tests - which is exactly where anyone
+# debugging maintenance works.
+#
+# The fix is ONE SOURCE OF TRUTH for option defaults. That is a bigger change
+# than this ticket and it lands in main.py, which another ticket is live in - so
+# the divergence is RECORDED here instead of closed. The check therefore passes
+# on the mismatch and FAILS when either side moves, in EITHER direction:
+#
+#   - config.yaml moves           -> FAIL: re-decide what the fallback should be
+#   - main.py is fixed to match   -> FAIL: the divergence is gone, DELETE this
+#                                    check and the ⚠️ block in validate.py
+#
+# A comment cannot do that, and "a comment where a check belonged" is this
+# repo's most repeated defect.
+_APP = os.path.join(os.path.dirname(os.path.abspath(__file__)), "app")
+
+def _read(*parts):
+    with open(os.path.join(*parts), encoding="utf-8") as fh:
+        return fh.read()
+
+# Every literal fallback for this key in main.py, whatever the call shape.
+_main_falls = [float(m) for m in re.findall(
+    r'\.get\(\s*"maintenance_charge_w"\s*,\s*(-?\d+(?:\.\d+)?)\s*\)',
+    _read(_APP, "main.py"))]
+# ...and MaintConfig's own dataclass default, which is the one that bites when
+# main.py is bypassed entirely (a Maintenance built straight from defaults).
+_dc_falls = [float(m) for m in re.findall(
+    r"^\s*charge_w:\s*float\s*=\s*(-?\d+(?:\.\d+)?)\s*$",
+    _read(_APP, "maintenance.py"), re.M)]
+
+check(f"main.py's fallbacks are still found and still 2500 {_main_falls}",
+      len(_main_falls) == 2 and set(_main_falls) == {2500.0})
+check(f"MaintConfig's default is still found and still 2500 {_dc_falls}",
+      len(_dc_falls) == 1 and set(_dc_falls) == {2500.0})
+check(f"...and config.yaml still ships 2000, so the divergence is UNCHANGED "
+      f"(shipped {_shipped['maintenance_charge_w']:.0f}, code 2500)",
+      _shipped["maintenance_charge_w"] == 2000.0)
+
+# ⚠️ And the consequence itself, through the REAL code rather than through the
+# numbers above - so that if someone "fixes" this by changing a literal without
+# understanding it, the thing that goes red is the behaviour, not the transcript.
+from app.maintenance import MaintConfig      # noqa: E402
+
+_absent = {k: v for k, v in base().items() if k != "maintenance_charge_w"}
+_built = MaintConfig().charge_w
+check("with the key ABSENT the validator accepts...",
+      validate_startup_config(_absent, -5000, 5000) == [])
+check(f"...while the code would build {_built:.0f} W against a "
+      f"{_absent['max_w']:.0f} W ceiling...", _built > _absent["max_w"])
+_r = _charge(_absent["max_w"], _built)
+check("...which the arbiter resolves to 0 W as a contradiction - the hole, "
+      "asserted so it cannot widen unnoticed",
+      _r.target_w == 0.0 and _r.contradiction)
+
 # --------------------------------------------------------------------------- #
 print("max_w must be a positive magnitude")
 # Schema-blocked on a real install, but validate_startup_config() is also
@@ -168,7 +338,8 @@ check("...and the message explains it would read as a trip, not a mistake",
 # threshold the ceiling can actually reach, and the interaction gets its own
 # check below.
 check("the smallest sane max_w still starts",
-      validate_startup_config(base(max_w=1, sign_disagree_w=0.5), -5000, 5000) == [])
+      validate_startup_config(base(max_w=1, sign_disagree_w=0.5,
+                                   maintenance_charge_w=1), -5000, 5000) == [])
 check("...but that same 1 W ceiling with the DEFAULT sign threshold is refused",
       why(validate_startup_config(base(max_w=1), -5000, 5000), "never fire"))
 

goodwe_controller/test_watchdog.py

@@ -145,8 +145,13 @@ check("300 W under a 2000 W ceiling is accepted", p == [])
 p = validate_startup_config({**base, "max_w": 2000, "sign_disagree_w": 2000},
                             -5000, 5000)
 check("a threshold AT max_w is refused", len(p) == 1 and "never fire" in p[0])
-p = validate_startup_config({**base, "max_w": 500, "sign_disagree_w": 3000},
-                            -5000, 5000)
+# ⚠️ maintenance_charge_w is named here only to keep this case about the SIGN
+# rule. MAINT-04 added a second rule against the same ceiling, and a 500 W
+# max_w is also below the 2000 W shipped maintenance charge - so without this
+# the dict is refused twice, for two correct but different reasons, and the
+# `len(p) == 1` below would be measuring the interaction rather than this rule.
+p = validate_startup_config({**base, "max_w": 500, "sign_disagree_w": 3000,
+                             "maintenance_charge_w": 500}, -5000, 5000)
 check("a threshold above max_w is refused", len(p) == 1 and "never fire" in p[0])
 p = validate_startup_config({**base, "max_w": 2000, "sign_disagree_w": 1999},
                             -5000, 5000)