kkelomatic_home/docs/redesign/redesign-implementation-roadmap.md

Redesign Implementation Roadmap

Overview

This document provides a step-by-step roadmap for implementing the redesigned structure based on the light naming configuration.

Phase 1: Configuration & Planning

Step 1.1: Review Light Naming Configuration

• Review light-naming-configuration.md
• Modify light names per room based on actual installation
• Remove unused lights from structure
• Add any missing lights
• Document relay-to-light mapping

Step 1.2: Map Relays to Lights

• Create mapping table: Relay # → Room → Light Name
• Document in relay-mapping.md
• Verify all relays are accounted for

Example Mapping:

Relay 1  → kitchen → main
Relay 2  → kitchen → under_cabinet
Relay 3  → kitchen → island
Relay 4  → master_bedroom → main
Relay 5  → master_bedroom → bedside_left
...

Step 1.3: Water Boiler Configuration

• Review water boiler safety requirements
• Configure temperature limits
• Configure time limits (max ON, min OFF)
• Identify sensor inputs (temperature, flow, pressure)
• Map boiler relay output

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Phase 2: CODESYS Structure Implementation

Step 2.1: Create New Data Structures

• Create struct_light_control type
• Create struct_water_boiler type
• Create room-specific structures
• Create global rooms structure

Step 2.2: Create Function Blocks

• Create fb_lightControl function block
• Create fb_waterBoiler function block
• Test function blocks in simulation

Step 2.3: Update Network Variables

• Update NVL_Sender with new structure
• Update NVL_Receiver with new structure
• Add water boiler network variables
• Configure network variable properties

Step 2.4: Implement Control Logic

• Replace fb_switch with new structure
• Implement light control per room
• Implement water boiler control
• Add relay output mapping
• Add relay status readback

Step 2.5: Testing

• Test in simulation
• Test individual light control
• Test water boiler control
• Test safety measures
• Verify network variable transmission

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Phase 3: Node-RED Integration

Step 3.1: Update Network Variable Nodes

• Update CODESYS network variable nodes
• Configure new variable structure
• Test bidirectional communication

Step 3.2: Create Transformation Functions

• Create function to flatten room structure for HA
• Create function to convert HA commands to CODESYS format
• Create function for Zigbee edge detection
• Test transformations

Step 3.3: Update MQTT Flows

• Update MQTT topics to new naming convention
• Configure Home Assistant auto-discovery
• Update Zigbee switch flows
• Add water boiler MQTT flows

Step 3.4: Testing

• Test HA → CODESYS commands
• Test Zigbee → CODESYS commands
• Test CODESYS → HA status updates
• Test water boiler control
• Verify MQTT message flow

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Phase 4: Home Assistant Configuration

Step 4.1: Entity Configuration

• Create light entities for all lights
• Configure entity names and icons
• Set up areas/rooms in HA
• Create water boiler entity

Step 4.2: Dashboard Setup

• Create lighting dashboard
• Group lights by room
• Add water boiler control
• Add status indicators

Step 4.3: Automations

• Update existing automations
• Create new automations if needed
• Test automations

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Phase 5: Migration & Deployment

Step 5.1: Backup Current System

• Backup CODESYS project
• Export Node-RED flows
• Backup Home Assistant configuration
• Document current state

Step 5.2: Parallel Testing

• Deploy new structure in test mode
• Run parallel with old system
• Compare behavior
• Fix any issues

Step 5.3: Gradual Migration

• Migrate one room at a time
• Test each room thoroughly
• Migrate water boiler
• Complete migration

Step 5.4: Validation

• Test all lights from HA
• Test all lights from Zigbee switches
• Verify status feedback
• Test water boiler control
• Test all safety measures
• Verify no regressions

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Implementation Checklist

CODESYS

• New data structures defined
• Function blocks created and tested
• Network variables updated
• Control logic implemented
• Relay mapping configured
• Status readback implemented
• Water boiler safety measures implemented
• Code tested in simulation

Node-RED

• Network variable nodes updated
• Transformation functions created
• MQTT flows updated
• HA auto-discovery configured
• Zigbee integration updated
• Water boiler flows added
• All flows tested

Home Assistant

• All light entities created
• Water boiler entity created
• Areas/rooms configured
• Dashboard updated
• Automations updated
• All entities tested

Documentation

• Light naming configuration finalized
• Relay mapping documented
• Network variable structure documented
• MQTT topics documented
• Safety measures documented
• Troubleshooting guide updated

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Key Files Reference

1. Light Configuration: light-naming-configuration.md
2. Structure Analysis: structure-redesign-analysis.md
3. Visual Comparison: structure-comparison-visual.md
4. Function Block Redesign: fb_switch-redesign-recommendation.md
5. This Roadmap: redesign-implementation-roadmap.md

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Estimated Timeline

• Phase 1 (Planning): 1-2 days
• Phase 2 (CODESYS): 2-3 days
• Phase 3 (Node-RED): 1-2 days
• Phase 4 (Home Assistant): 1 day
• Phase 5 (Migration): 2-3 days

Total: ~7-11 days (depending on complexity and testing)

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Risk Mitigation

Risks

1. Network Variable Changes: May break existing Node-RED flows

   • Mitigation: Test thoroughly, have rollback plan

2. State Synchronization: During migration, states may be inconsistent

   • Mitigation: Migrate during low-usage period, verify all states

3. Water Boiler Safety: Critical system, must work correctly

   • Mitigation: Extensive testing, manual override available

4. Home Assistant Entities: May need to recreate entities

   • Mitigation: Use unique_id to preserve entity history

Rollback Plan

• Keep old CODESYS project as backup
• Keep old Node-RED flows as backup
• Document rollback procedure
• Test rollback procedure

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Status: Planning Phase
Next Step: Review and modify light-naming-configuration.md with actual light configuration