Fix: Graceful Startup Config Retries & ML Load Fallback

apps/predbat/fetch.py

@@ -1986,6 +1986,11 @@ def fetch_ml_load_forecast(self, now_utc):
         and returns it as a minute_data dictionary
         """
         # Use ML Model for load prediction
+        status = self.get_state_wrapper("sensor." + self.prefix + "_load_ml_forecast")
+        if status and status != "active":
+            self.log("ML load forecast is not active (status: {}), falling back to historical data".format(status))
+            return {}
+
         load_ml_forecast = self.get_state_wrapper("sensor." + self.prefix + "_load_ml_forecast", attribute="results")
         if load_ml_forecast:
             self.log("Loading ML load forecast from sensor.{}_load_ml_forecast".format(self.prefix))

apps/predbat/load_ml_component.py

@@ -22,8 +22,9 @@
 import asyncio
 import os
 from datetime import datetime, timezone, timedelta
+import math
 from component_base import ComponentBase
-from utils import get_now_from_cumulative, dp2, dp4, minute_data
+from utils import get_now_from_cumulative, dp2, dp4, minute_data, safe_float
 from load_predictor import LoadPredictor, MODEL_VERSION
 from const import TIME_FORMAT, PREDICT_STEP
 import json
@@ -1054,9 +1055,10 @@ def _publish_entity(self):
             },
             app="load_ml",
         )
+
         self.dashboard_item(
             "sensor." + self.prefix + "_load_ml_stats",
-            state=round(total_kwh, 2),
+            state=safe_float(round(total_kwh, 2)),
             attributes={
                 "load_today": dp2(self.load_minutes_now),
                 "load_today_h1": dp2(load_today_h1),
@@ -1065,10 +1067,10 @@ def _publish_entity(self):
                 "power_today_now": dp2(power_today_now),
                 "power_today_h1": dp2(power_today_h1),
                 "power_today_h8": dp2(power_today_h8),
-                "mae_kwh": round(float(self.predictor.validation_mae), 4) if self.predictor and self.predictor.validation_mae is not None else None,
-                "bias_kwh": round(self.predictor.validation_bias, 4) if self.predictor and self.predictor.validation_bias is not None else None,
+                "mae_kwh": safe_float(self.predictor.validation_mae) if self.predictor else None,
+                "bias_kwh": safe_float(self.predictor.validation_bias) if self.predictor else None,
                 "last_trained": self.last_train_time.isoformat() if self.last_train_time else None,
-                "model_age_hours": round(model_age_hours, 1) if model_age_hours is not None else None,
+                "model_age_hours": safe_float(model_age_hours),
                 "training_days": self.load_data_age_days,
                 "status": self.model_status,
                 "model_version": MODEL_VERSION,

apps/predbat/predbat.py

@@ -1585,7 +1585,7 @@ def initialize(self):
                 self.record_status("Error: Some components failed to start (phase 2)", had_errors=True)
 
             self.load_user_config(quiet=False, register=True)
-            self.auto_config(final=True)
+            self.auto_config(final=False)
             self.validate_config()
 
             # Restore the last saved plan so it is immediately active before the first calculation
@@ -1753,6 +1753,12 @@ def run_time_loop(self, cb_args):
                     self.validate_config()
                     config_changed = True
 
+                # Retry auto config if we have unmatched regexes
+                if hasattr(self, 'unmatched_args') and len(self.unmatched_args) > 0:
+                    # Give HA 10 minutes from startup to fully load entities before final disable
+                    time_since_start = (self.now_utc_real - self.started_time).total_seconds() / 60.0
+                    self.auto_config(final=(time_since_start > 10))
+
                 # Run the prediction
                 self.update_pred(scheduled=True)
 

apps/predbat/tests/open_meteo_live.py

@@ -159,7 +159,7 @@ def print_comparison_table(label: str, sources: dict, day_str: str, tz_name: str
     """Print a side-by-side comparison table for one day.
 
     sources is an ordered dict of {source_name: hourly_dict} where each hourly_dict
-    maps 'YYYY-MM-DDTHH' → (kwh_p50, kwh_p10) as returned by _aggregate_to_hourly().
+    maps 'YYYY-MM-DDTHH' -> (kwh_p50, kwh_p10) as returned by _aggregate_to_hourly().
     Hours are shown in local time (tz_name).
     """
     source_names = list(sources.keys())
@@ -211,8 +211,8 @@ def print_comparison_table(label: str, sources: dict, day_str: str, tz_name: str
 async def run(fs_api_key: str = None, solcast_api_key: str = None, solcast_host: str = None) -> None:
     """Fetch live data via fetch_pv_forecast() for each source and print comparison.
 
-    Runs the full Predbat PV fetch pipeline (download → minute_data → pv_calibration
-    → publish_pv_stats) for each enabled source, then reads the detailedForecast that
+    Runs the full Predbat PV fetch pipeline (download -> minute_data -> pv_calibration
+    -> publish_pv_stats) for each enabled source, then reads the detailedForecast that
     Predbat would store in sensor.predbat_pv_today.
     """
     now_local = datetime.now(tz=LOCAL_TZ)
@@ -228,10 +228,10 @@ async def run(fs_api_key: str = None, solcast_api_key: str = None, solcast_host:
     _tmp = SolarAPI.__new__(SolarAPI)
     for i, a in enumerate(ARRAYS, 1):
         az_api = SolarAPI.convert_azimuth(_tmp, a["azimuth"])
-        print(f"  [{i}] postcode={a['postcode']}  kwp={a['kwp']}  declination={a['declination']}°  azimuth={a['azimuth']}° (→API: {az_api:.0f}°)  efficiency={a.get('efficiency', 1.0):.0%}")
+        print(f"  [{i}] postcode={a['postcode']}  kwp={a['kwp']}  declination={a['declination']}°  azimuth={a['azimuth']}° (->API: {az_api:.0f}°)  efficiency={a.get('efficiency', 1.0):.0%}")
     print(f"  cache: {_CACHE_ROOT}/cache/")
 
-    # results maps source_name → {"today": hourly_dict, "tomorrow": hourly_dict}
+    # results maps source_name -> {"today": hourly_dict, "tomorrow": hourly_dict}
     results: dict = {}
 
     # ── Open-Meteo ────────────────────────────────────────────────────────────

apps/predbat/tests/test_auto_config.py

@@ -0,0 +1,82 @@
+# -----------------------------------------------------------------------------
+# Predbat Home Battery System
+# -----------------------------------------------------------------------------
+
+def run_auto_config_tests(my_predbat):
+    """
+    Test auto_config retry logic and list/dict matching
+    """
+    failed = False
+    print("\n============================================================")
+    print("Running auto_config tests")
+    print("============================================================")
+
+    # Backup original
+    original_args = my_predbat.args.copy()
+    original_unmatched = getattr(my_predbat, "unmatched_args", {}).copy()
+
+    try:
+        # Test 1: List matching retains 're:' elements if they fail
+        print("\n=== Test 1: List regex matching ===")
+        my_predbat.args = {
+            "pv_forecast_raw": ["sensor.inv1", "re:.*inv2"]
+        }
+        my_predbat.unmatched_args = {}
+
+        # This simulates < 10 mins, so final=False
+        my_predbat.auto_config(final=False)
+
+        # It should still be in args exactly as it was, because matched=True for lists
+        val = my_predbat.args.get("pv_forecast_raw")
+        if val != ["sensor.inv1", "re:.*inv2"]:
+            print(f"FAIL: List regex matching failed to retain string. Got {val}")
+            failed = True
+        else:
+            print("PASS: List regex retained.")
+
+        # Test 2: Dict matching retains 're:' elements if they fail
+        print("\n=== Test 2: Dict regex matching ===")
+        my_predbat.args = {
+            "my_dict": {"foo": "sensor.foo", "bar": "re:.*bar"}
+        }
+        my_predbat.unmatched_args = {}
+
+        my_predbat.auto_config(final=False)
+
+        val = my_predbat.args.get("my_dict")
+        if val != {"foo": "sensor.foo", "bar": "re:.*bar"}:
+            print(f"FAIL: Dict regex matching failed to retain string. Got {val}")
+            failed = True
+        else:
+            print("PASS: Dict regex retained.")
+
+        # Test 3: Standard unmatched arg is moved to unmatched_args after 10 mins (final=True)
+        print("\n=== Test 3: Final=True moves unmatched args ===")
+        my_predbat.args = {
+            "inverter_limit": "re:.*missing_limit.*"
+        }
+        my_predbat.unmatched_args = {}
+
+        my_predbat.auto_config(final=True)
+
+        if "inverter_limit" in my_predbat.args:
+            print(f"FAIL: inverter_limit still in args: {my_predbat.args['inverter_limit']}")
+            failed = True
+        elif "inverter_limit" not in my_predbat.unmatched_args:
+            print(f"FAIL: inverter_limit not in unmatched_args")
+            failed = True
+        else:
+            print("PASS: Final=True moved unmatched arg correctly.")
+
+    finally:
+        my_predbat.args = original_args
+        my_predbat.unmatched_args = original_unmatched
+
+    print("============================================================")
+    if failed:
+        print("FAIL: SOME TESTS FAILED")
+    else:
+        print("PASS: ALL TESTS PASSED")
+    print("============================================================")
+
+    return failed