adminandClaude Opus 5
0a1e61dbc9
Turns the reference RS485 controller into something a technician can install at a client site: a typed config form instead of YAML, an ingress UI that names misconfiguration in words, and persistent state that cannot be broken by a timezone. Why an add-on rather than YAML packages or blueprints: - Blueprints cannot create helpers, and the maintenance cycle is a state machine whose phase and completion date must survive restarts. - YAML packages need filesystem access, a configuration.yaml edit and a restart - none of which belong in a client install. - Add-ons authenticate with SUPERVISOR_TOKEN, so there is no long-lived token to generate, store or leak on someone else's machine. - Requires HA OS/Supervised. Container and Core installs cannot run add-ons at all, which is a market decision, not an oversight. The control law and the maintenance machine are pure functions with no Home Assistant imports, and both ship with runnable checks (22 and 22 assertions). Every assertion corresponds to a rule whose absence caused an observed failure on hardware - the saturation duration term, the clamp-before-slew ordering, the deadband, the sign convention. One behaviour deliberately differs from the implementation it replaces: when its inputs go missing this commands 0 W rather than replaying the last setpoint. The reference version kept replaying, which the hardware watchdog cannot catch - from the ESP32's side, Home Assistant is still talking to it. Includes the ESPHome firmware (now parameterised: node name, inverter rating, watchdog timeout) and the optional RS485 e-stop. FIELD-GUIDE.md carries the commissioning gates, all judged on the wire rather than on how Home Assistant looks, plus the written statement a site without an e-stop needs signed. Co-Authored-By: Claude Opus 5 <noreply@anthropic.com> Claude-Session: https://claude.ai/code/session_016NckgXecasQb2eSsPYNSW6
424 lines
17 KiB
Python
424 lines
17 KiB
Python
"""GoodWe RS485 Controller add-on - entry point and orchestration.
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WHAT THIS THING DOES, in one paragraph: it reads the house's net grid power from
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Home Assistant, decides how hard the battery should charge or discharge to hold
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that at zero, and writes that figure to an ESP32 which puts it on the inverter's
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RS485 meter bus. Once a month it runs a full low->full battery cycle so the BMS
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can balance cells and recalibrate its coulomb counter.
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⚠️ THE ONE THING TO UNDERSTAND BEFORE CHANGING ANY OF THIS: the inverter holds
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the last command it understood FOREVER. It has no meter-timeout of its own.
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Measured on real hardware: a controller died mid-command and the inverter held
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5 kW of discharge for 113 s until a human noticed. Every failsafe in this system
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exists because of that one fact:
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layer 1 the ESP32's own watchdog - if we stop refreshing for ~30 s it
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commands 0 W and KEEPS WRITING it. Stopping is the failure, not the
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fix. This add-on's heartbeat is what feeds it.
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layer 2 wind-down before a firmware update, in the ESP32.
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layer 3 the optional RS485 e-stop, which writes 0 W after 30 s of total bus
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silence. It is the ONLY thing that covers this add-on's host dying.
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So: when in doubt, this process stops writing, and the hardware takes the
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battery to zero on its own. Never "hold the last value to be safe".
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"""
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import asyncio
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import contextlib
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import json
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import logging
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import signal
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from datetime import datetime, timezone
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import aiohttp
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from .control import Tuning, compute, maintenance_charge_floor, peak_at_risk
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from .hass import HomeAssistant
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from .maintenance import IDLE, MaintConfig, Maintenance
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from .mqtt import MqttPublisher
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from . import web
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OPTIONS_PATH = "/data/options.json"
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_LOG = logging.getLogger("goodwe")
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def load_options() -> dict:
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try:
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with open(OPTIONS_PATH, "r", encoding="utf-8") as fh:
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return json.load(fh)
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except (OSError, json.JSONDecodeError) as err:
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_LOG.error("cannot read %s (%s) - using defaults", OPTIONS_PATH, err)
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return {}
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class Controller:
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def __init__(self, opts: dict, hass: HomeAssistant, store, mqtt_pub):
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self.o = opts
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self.hass = hass
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self.store = store
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self.mqtt = mqtt_pub
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self.tuning = Tuning(
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gain=float(opts.get("gain", 0.6)),
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max_w=float(opts.get("max_w", 2000)),
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slew_w=float(opts.get("slew_w", 1000)),
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deadband_w=float(opts.get("deadband_w", 15)),
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step_w=int(opts.get("step_w", 10)),
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saturation_w=float(opts.get("saturation_w", 500)),
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saturation_cycles=int(opts.get("saturation_cycles", 3)),
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)
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self.maint = Maintenance(
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MaintConfig(
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enabled=bool(opts.get("maintenance_enabled", False)),
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interval_days=int(opts.get("maintenance_interval_days", 28)),
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start_hour=int(opts.get("maintenance_start_hour", 10)),
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discharge_w=float(opts.get("maintenance_discharge_w", 2500)),
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charge_w=float(opts.get("maintenance_charge_w", 2500)),
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soc_floor=float(opts.get("maintenance_soc_floor", 11)),
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soc_target=float(opts.get("maintenance_soc_target", 99)),
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hold_min=int(opts.get("maintenance_hold_min", 120)),
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),
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store,
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)
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# live state
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self.auto = bool(store.data.get("auto", opts.get("auto_start", False)))
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self.target = 0.0
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self.sat_count = 0
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self.reason = "starting"
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self.grid = self.soc = self.batt = None
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self.peak_fc = None
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self.cheap = False
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self.last_write = None
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self.last_write_at = None
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self.last_write_ok = None
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self.inputs_bad_since = None
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self.dev_min = self.dev_max = None
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self.events: list[str] = []
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self.stopping = False
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# -- helpers -------------------------------------------------------------
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def log_event(self, msg: str) -> None:
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stamp = datetime.now(timezone.utc).strftime("%H:%M:%S")
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self.events.insert(0, f"{stamp} {msg}")
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del self.events[40:]
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@property
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def inputs_ok(self) -> bool:
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return None not in (self.grid, self.soc, self.batt)
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# -- io ------------------------------------------------------------------
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async def read_inputs(self) -> None:
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o = self.o
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self.grid = await self.hass.number(o.get("meter_entity", ""),
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bool(o.get("meter_invert")))
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self.soc = await self.hass.number(o.get("soc_entity", ""))
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self.batt = await self.hass.number(o.get("batt_entity", ""),
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bool(o.get("batt_invert")))
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if o.get("peak_forecast_entity"):
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raw = await self.hass.number(o["peak_forecast_entity"])
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# Accept kW or W - nobody's quarter-hour forecast is 50 W.
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self.peak_fc = None if raw is None else (raw * 1000 if abs(raw) < 50 else raw)
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else:
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self.peak_fc = None
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now_e, avg_e = o.get("price_now_entity"), o.get("price_avg_entity")
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if now_e and avg_e:
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now_p = await self.hass.number(now_e)
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avg_p = await self.hass.number(avg_e)
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self.cheap = (now_p is not None and avg_p is not None and now_p <= avg_p)
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else:
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# Fixed-tariff site: never force a paid grid top-up, wait for sun.
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self.cheap = False
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if self.inputs_ok:
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if self.inputs_bad_since is not None:
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self.log_event("inputs recovered")
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self.inputs_bad_since = None
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elif self.inputs_bad_since is None:
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self.inputs_bad_since = datetime.now(timezone.utc)
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async def write_setpoint(self, value: float, *, force: bool = False) -> None:
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entity = self.o.get("setpoint_entity", "")
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if not entity:
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return
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# Never send a value the device will reject outright. A rejected write is
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# silent from the controller's point of view, and the inverter then keeps
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# doing whatever it was already doing.
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if self.dev_min is not None and self.dev_max is not None:
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value = max(self.dev_min, min(self.dev_max, value))
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changed = (self.last_write is None or value != self.last_write)
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if not (changed or force):
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return
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ok = await self.hass.set_number(entity, value)
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self.last_write_ok = ok
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if ok:
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self.last_write = value
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self.last_write_at = datetime.now(timezone.utc)
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# -- the cycle -----------------------------------------------------------
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async def cycle(self) -> None:
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now = datetime.now(timezone.utc)
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result = self.maint.tick(now, self.soc)
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for msg in result.events:
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self.log_event(msg)
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# ⚠️ Fail toward inaction, and do it ACTIVELY. If the inputs are missing
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# we command 0 rather than replaying the last value. The YAML
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# implementation this replaces kept replaying its last setpoint when the
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# meter died - which the hardware watchdog cannot catch, because from the
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# ESP32's point of view Home Assistant is still talking to it.
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stale_after = float(self.o.get("stale_input_s", 15))
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if not self.inputs_ok:
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bad_for = (now - self.inputs_bad_since).total_seconds() if self.inputs_bad_since else 0.0
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if bad_for < stale_after:
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# A single missed poll is not a fault. Hold, keep the heartbeat
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# going, and give it a few seconds to come back.
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self.reason = f"inputs missing {bad_for:.0f}s"
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return
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if self.target != 0.0:
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self.log_event(f"inputs missing for {bad_for:.0f}s - commanding 0 W")
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self.target, self.reason = 0.0, "inputs-missing"
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await self.write_setpoint(0.0)
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return
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if result.owns_setpoint:
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# drain / hold / abort: maintenance drives directly.
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self.target = float(result.setpoint_w or 0.0)
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self.reason = f"maintenance:{result.phase}"
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self.sat_count = 0
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await self.write_setpoint(self.target)
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return
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if not self.auto:
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self.target, self.reason = 0.0, "stopped"
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await self.write_setpoint(0.0)
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return
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charge_floor = 0.0
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charge_only = result.charge_only
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if charge_only:
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# Money outranks the maintenance schedule (see control.peak_at_risk).
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if peak_at_risk(self.peak_fc, float(self.o.get("peak_cap_w", 3500))):
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charge_only = False
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self.log_event("peak at risk - suspending charge-only clamp")
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elif self.cheap:
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charge_floor = maintenance_charge_floor(
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float(self.o.get("maintenance_charge_w", 2500)),
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self.peak_fc,
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float(self.o.get("peak_cap_w", 3500)),
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)
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decision = compute(
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prev_w=self.target,
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grid_w=self.grid,
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actual_w=self.batt,
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tuning=self.tuning,
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sat_count=self.sat_count,
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charge_only=charge_only,
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charge_floor_w=charge_floor,
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)
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if decision.frozen and self.sat_count < self.tuning.saturation_cycles:
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self.log_event(f"saturation freeze ({self.target:.0f} W vs {self.batt:.0f} W)")
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self.target, self.sat_count, self.reason = (
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decision.target_w, decision.sat_count, decision.reason)
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await self.write_setpoint(self.target)
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# -- tasks ---------------------------------------------------------------
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async def run_control(self) -> None:
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entity = self.o.get("setpoint_entity", "")
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if entity:
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self.dev_min, self.dev_max, _ = await self.hass.limits(entity)
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if self.dev_max is not None and self.tuning.max_w > self.dev_max:
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self.log_event(
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f"clamp {self.tuning.max_w:.0f} W exceeds the device maximum "
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f"{self.dev_max:.0f} W - the device wins")
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last_grid = object()
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heartbeat = float(self.o.get("heartbeat_s", 10))
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last_beat = 0.0
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while not self.stopping:
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await self.read_inputs()
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# A cycle is one meter update, exactly as on the reference install.
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if self.grid != last_grid:
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last_grid = self.grid
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await self.cycle()
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# ⚠️ The heartbeat is not an optimisation. The ESP32 treats silence
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# longer than ~30 s as "the controller is gone" and zeroes the
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# inverter. Refreshing the SAME value is what proves we are alive.
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loop_now = asyncio.get_running_loop().time()
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if loop_now - last_beat >= heartbeat:
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last_beat = loop_now
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await self.write_setpoint(self.target, force=True)
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self.publish()
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await asyncio.sleep(1)
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def publish(self) -> None:
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self.mqtt.publish({
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"setpoint": self.target,
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"grid": self.grid,
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"battery": self.batt,
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"soc": self.soc,
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"phase": self.maint.phase,
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"status": "running" if self.auto else "stopped",
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})
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async def shutdown(self) -> None:
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"""Deterministic wind-down. Do not skip this."""
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self.stopping = True
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_LOG.info("shutting down - commanding 0 W")
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await self.write_setpoint(0.0, force=True)
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self.mqtt.close()
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# -- UI ------------------------------------------------------------------
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def checks(self) -> list:
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o = self.o
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out = []
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for label, value, entity in (
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("grid power", self.grid, o.get("meter_entity")),
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("battery SoC", self.soc, o.get("soc_entity")),
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("battery power", self.batt, o.get("batt_entity")),
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):
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if not entity:
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out.append({"ok": False, "warn": False, "text": f"{label}: no entity configured"})
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elif value is None:
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out.append({"ok": False, "warn": False,
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"text": f"{label}: {entity} is missing or not numeric"})
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else:
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out.append({"ok": True, "warn": False, "text": f"{label}: {entity} = {value:g}"})
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sp = o.get("setpoint_entity")
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if not sp:
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out.append({"ok": False, "warn": False, "text": "setpoint entity not configured"})
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elif self.dev_max is None:
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out.append({"ok": False, "warn": False,
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"text": f"setpoint entity {sp} not found"})
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else:
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out.append({"ok": True, "warn": False,
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"text": f"setpoint {sp} (range {self.dev_min:g}…{self.dev_max:g} W)"})
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if self.last_write_ok is False:
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out.append({"ok": False, "warn": False,
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"text": "last write to the inverter was REJECTED - check the log"})
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if not o.get("estop_fitted", False):
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out.append({"ok": False, "warn": True,
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"text": "no e-stop fitted: if this host dies the battery stays "
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"latched at its last command"})
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else:
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out.append({"ok": True, "warn": False, "text": "e-stop fitted"})
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if not o.get("peak_forecast_entity"):
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# ok=False + warn=True renders as a caution, not a pass. A check that
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# is both is a check nobody reads.
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out.append({"ok": False, "warn": True,
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"text": "no peak forecast: maintenance charging is not capacity-capped"})
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return out
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def status_payload(self) -> dict:
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checks = self.checks()
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bad = [c for c in checks if not c["ok"] and not c["warn"]]
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if bad:
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level, banner = "bad", f"NOT READY — {bad[0]['text']}"
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elif not self.auto:
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level, banner = "warn", "Stopped — inverter commanded to 0 W"
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elif self.maint.phase != IDLE:
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level, banner = "warn", f"Maintenance: {self.maint.phase}"
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else:
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level, banner = "ok", "Running — holding grid at zero"
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def w(v):
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return "—" if v is None else f"{v:,.0f} W".replace(",", " ")
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next_due = self.maint.next_due(datetime.now(timezone.utc))
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rows = [
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("Grid", w(self.grid)),
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("Battery", w(self.batt)),
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("State of charge", "—" if self.soc is None else f"{self.soc:g} %"),
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("Commanded", w(self.target)),
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("Why", self.reason),
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("Maintenance phase", self.maint.phase),
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("Maintenance due", "now" if next_due is None else next_due.strftime("%Y-%m-%d")),
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("Cheap window", "yes" if self.cheap else "no"),
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]
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return {
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"banner": banner, "level": level, "rows": rows, "checks": checks,
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"hint": self.events[0] if self.events else "",
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}
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async def handle_action(self, what: str):
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now = datetime.now(timezone.utc)
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if what == "auto_toggle":
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self.auto = not self.auto
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self.store.set("auto", self.auto)
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self.log_event("control started" if self.auto else "control stopped")
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if not self.auto:
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self.target = 0.0
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await self.write_setpoint(0.0, force=True)
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return {"auto": self.auto}
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if what == "maint_start":
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for msg in self.maint.force_start(now):
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self.log_event(msg)
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return {"phase": self.maint.phase}
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if what == "maint_abort":
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for msg in self.maint.abort(now, "operator"):
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self.log_event(msg)
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self.target = 0.0
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await self.write_setpoint(0.0, force=True)
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return {"phase": self.maint.phase}
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return None
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async def amain() -> None:
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opts = load_options()
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logging.basicConfig(
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level=getattr(logging, str(opts.get("log_level", "info")).upper(), logging.INFO),
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format="%(asctime)s %(levelname)-7s %(name)s: %(message)s",
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)
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_LOG.info("GoodWe RS485 Controller starting")
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from .store import Store
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store = Store()
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async with aiohttp.ClientSession() as session:
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hass = HomeAssistant(session)
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broker = await hass.mqtt_service()
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pub = MqttPublisher(
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broker.get("host") if broker else None,
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broker.get("port", 1883) if broker else 1883,
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broker.get("username") if broker else None,
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broker.get("password") if broker else None,
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)
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controller = Controller(opts, hass, store, pub)
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runner = await web.start(controller, port=8099)
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stop = asyncio.Event()
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loop = asyncio.get_running_loop()
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for sig in (signal.SIGTERM, signal.SIGINT):
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with contextlib.suppress(NotImplementedError):
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loop.add_signal_handler(sig, stop.set)
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task = asyncio.create_task(controller.run_control())
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await stop.wait()
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await controller.shutdown()
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task.cancel()
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with contextlib.suppress(asyncio.CancelledError):
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await task
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await runner.cleanup()
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_LOG.info("stopped")
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def main() -> None:
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try:
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asyncio.run(amain())
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except KeyboardInterrupt:
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pass
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if __name__ == "__main__":
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main()
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