fix: Treat charger as 0A when OFF to enable proper start logic in EV_FREE mode (v0.9.10)

CRITICAL FIX: Charger now starts correctly when OFF during EV_FREE priority with solar surplus.

USER INSIGHT:
User correctly identified: "If priority switches from HOME to EV_FREE it should start charging"
This revealed that v0.9.9 was incomplete - only fixed early return, not the comparison logic.

ROOT CAUSE:
When charger is OFF, the system was reading the stored amperage setting (e.g., 16A from
previous session) instead of treating the OFF state as 0A for comparison purposes.

Scenario that failed:
1. Priority = HOME → EV charger STOPPED (home battery charging)
2. Priority switches to EV_FREE → both targets met, solar surplus available (6000W)
3. System reads current_amps = 16A (stored setting)
4. Calculates target_amps = 26A (from solar surplus)
5. Comparison: 26A > 16A = TRUE → should start (CORRECT)

BUT if surplus was lower:
3. System reads current_amps = 16A (stored setting)
4. Calculates target_amps = 6A (low solar surplus)
5. Comparison: 6A > 16A = FALSE → no action taken (WRONG - should have started at 6A)

THE COMPLETE FIX:
Modified solar_surplus.py lines 557-573 to check charger switch state BEFORE reading amperage:
- If charger is ON: Read actual amperage from sensor (normal operation)
- If charger is OFF: Set current_amps = 0 (allows any surplus to trigger start)

Now the comparison at line 677 works correctly:
- target_amps (6A or 26A) > current_amps (0A) = TRUE
- Calls _set_amperage() which starts charger at target amperage

IMPACT:
✅ Priority transitions HOME → EV_FREE now start charging automatically
✅ Fresh installations with charger OFF now work correctly
✅ ALL surplus levels (even 6A minimum) trigger charger start when OFF
✅ Proper state machine: OFF (0A) → any surplus → ON at calculated amperage

This completes the fix started in v0.9.9 (fall-through logic) with proper amperage handling.

Files Changed:
- custom_components/ev_smart_charger/solar_surplus.py (lines 557-573)
- custom_components/ev_smart_charger/manifest.json (version 0.9.10)
- README.md (version + detailed changelog explaining both fixes)

🎯 Generated with [Claude Code](https://claude.com/claude-code)

Co-Authored-By: Claude <noreply@anthropic.com>

Author: Antonio ...

README.md

@@ -2,7 +2,7 @@
 
 A Home Assistant integration for intelligent EV charging control based on solar production, time of day, and battery levels.
 
-## Current Version: 0.9.9
+## Current Version: 0.9.10
 
 [![GitHub Release](https://img.shields.io/github/v/release/antbald/ha-ev-smart-charger)](https://github.com/antbald/ha-ev-smart-charger/releases)
 [![hacs_badge](https://img.shields.io/badge/HACS-Custom-orange.svg)](https://github.com/custom-components/hacs)
@@ -729,7 +729,42 @@ Then restart Home Assistant.
 
 ## Changelog
 
-### v0.9.9 (2025-10-29) - Current - EV_FREE Solar Surplus Charging Fix
+### v0.9.10 (2025-10-29) - Current - Critical: Charger Start Fix in EV_FREE Mode
+- **FIX: Charger now treats amperage as 0 when OFF, enabling proper start logic**
+  - **Critical Issue**: When charger was OFF, `current_amps` was read from charger setting (e.g., 16A from previous session)
+  - Solar surplus logic compared `target_amps` (e.g., 26A) vs `current_amps` (16A) → triggered increase (correct)
+  - BUT if `target_amps` (6A) < `current_amps` (16A), charger would NOT start despite having surplus
+  - **v0.9.9 incomplete fix**: Only removed early return, didn't fix amperage comparison
+
+- **Root Cause Identified:**
+  - User correctly pointed out: "If priority switches from HOME to EV_FREE, it should start charging"
+  - When Priority Balancer transitions HOME → EV_FREE, charger is OFF (was stopped for home battery)
+  - Solar surplus available (6000W = 26A), but comparison logic failed because charger OFF state not handled
+  - System read stored amperage setting instead of treating OFF charger as 0A
+
+- **Complete Fix:**
+  - Modified amperage detection logic (lines 557-573) to check charger switch state FIRST
+  - If charger is **ON**: Read actual amperage from sensor (normal operation)
+  - If charger is **OFF**: Set `current_amps = 0` (allows ANY surplus to trigger start)
+  - Now comparison works correctly: `target_amps (26A) > current_amps (0A)` = TRUE → starts charger
+
+- **Impact:**
+  - **Priority transitions now work**: HOME → EV_FREE automatically starts charging with available solar
+  - **Fresh installations work**: Charger OFF + solar surplus → starts automatically
+  - **All surplus levels work**: Even low surplus (6A) will start charger when OFF
+  - **Proper state machine**: OFF (0A) → any surplus → ON at target amperage
+
+- **Technical Details:**
+  - Added charger switch state check before reading amperage
+  - Treats OFF charger as 0A for comparison logic
+  - Ensures line 677 condition `target_amps > current_amps` always evaluates correctly
+  - Complements v0.9.9 EV_FREE fall-through fix
+
+- **Files Modified:**
+  - `solar_surplus.py` - Amperage detection logic (lines 557-573)
+  - `manifest.json` - Version 0.9.10
+
+### v0.9.9 (2025-10-29) - EV_FREE Solar Surplus Charging Fix (Incomplete)
 - **FIX: EV_FREE priority now allows solar surplus charging when charger is OFF**
   - Previously, when Priority Balancer set priority to EV_FREE (both EV and home battery targets met), the automation would stop charging if charger was ON and then exit early
   - This prevented the charger from starting when it was OFF, even with abundant solar surplus available

custom_components/ev_smart_charger/manifest.json

@@ -1,7 +1,7 @@
 {
   "domain": "ev_smart_charger",
   "name": "EV Smart Charger",
-  "version": "0.9.9",
+  "version": "0.9.10",
   "documentation": "https://github.com/antbald/ha-ev-smart-charger",
   "issue_tracker": "https://github.com/antbald/ha-ev-smart-charger/issues",
   "codeowners": ["@antbald"],

custom_components/ev_smart_charger/solar_surplus.py

@@ -554,15 +554,23 @@ async def _async_periodic_check(self, now=None) -> None:
             _LOGGER.info("=" * 80)
             return
 
-        # Get current amperage setting
-        current_setting_state = self.hass.states.get(self._charger_current)
-        if current_setting_state:
-            try:
-                current_amps = int(float(current_setting_state.state))
-            except (ValueError, TypeError):
+        # Get current amperage - treat as 0 if charger is OFF
+        charger_state = self.hass.states.get(self._charger_switch)
+        charger_is_on = charger_state and charger_state.state == "on"
+
+        if charger_is_on:
+            # Charger is ON, get actual amperage setting
+            current_setting_state = self.hass.states.get(self._charger_current)
+            if current_setting_state:
+                try:
+                    current_amps = int(float(current_setting_state.state))
+                except (ValueError, TypeError):
+                    current_amps = 6
+            else:
                 current_amps = 6
         else:
-            current_amps = 6
+            # Charger is OFF, treat as 0A (allows any surplus to start it)
+            current_amps = 0
 
         # Calculate surplus
         surplus_watts = fv_production - home_consumption