Merge #602(S7)/#610.2: S7 connect backoff, write-path worst-state-wins, Volatile health, factory logging, driver-side array writes

Claude-Session: https://claude.ai/code/session_01Ef2ozxS7QPanGT8uoATbTe
2026-10-08 07:01:32 -04:00
parent 6a5e804eca 82372f1672
commit 80ed056d41
12 changed files with 845 additions and 75 deletions
@@ -115,6 +115,8 @@ public sealed class S7Driver
    private const uint StatusBadNodeIdUnknown = 0x80340000u;
    /// <summary>OPC UA StatusCode used when the tag's data type isn't implemented yet.</summary>
    private const uint StatusBadNotSupported = 0x803D0000u;
+    /// <summary>OPC UA StatusCode used when a written value has the wrong shape / length / element type.</summary>
+    private const uint StatusBadTypeMismatch = 0x80740000u;
    /// <summary>OPC UA StatusCode used when the tag is declared read-only.</summary>
    private const uint StatusBadNotWritable = 0x803B0000u;
    /// <summary>OPC UA StatusCode used when write fails validation (e.g. out-of-range value).</summary>
@@ -179,6 +181,38 @@ public sealed class S7Driver
    private bool _plcDead;

    private DriverHealth _health = new(DriverState.Unknown, null, null);
+
+    /// <summary>
+    ///     The health snapshot, accessed with volatile semantics: it is written from the gate-holding
+    ///     read/write passes, the poll engine's error sink and the lifecycle methods, and read lock-free
+    ///     by <see cref="GetHealth"/> (the health tick) — the same Volatile idiom <c>ModbusDriver</c> uses.
+    ///     <see cref="DriverHealth"/> is an immutable record, so a reference swap is a complete update.
+    /// </summary>
+    private DriverHealth Health
+    {
+        get => Volatile.Read(ref _health);
+        set => Volatile.Write(ref _health, value);
+    }
+
+    /// <summary>
+    ///     Per-device connect-attempt throttle (STAB-21): a dead PLC costs one connect attempt per
+    ///     backoff window (1 s doubling to 30 s) instead of one per data call / poll tick / probe tick.
+    ///     Not internally synchronized — only touched from <see cref="EnsureConnectedAsync"/> (under
+    ///     <see cref="_gate"/>) and from init/shutdown, which run with every loop drained.
+    /// </summary>
+    private readonly ConnectionBackoff _connectBackoff =
+        new(TimeSpan.FromSeconds(1), TimeSpan.FromSeconds(30));
+
+    /// <summary>Clock the connect backoff is measured on. Internal so tests step it deterministically.</summary>
+    internal Func<DateTime> BackoffClock { get; set; } = static () => DateTime.UtcNow;
+
+    /// <summary>
+    ///     The sticky write-side config fault (access denied / PUT-GET disabled), or null. A read
+    ///     pass that finds everything readable must NOT erase it (reads can succeed while writes are
+    ///     protected); it is cleared by the next write pass that writes something successfully.
+    ///     Guarded by <see cref="_gate"/>.
+    /// </summary>
+    private (DriverState State, string Message)? _writeFault;
    private bool _disposed;

    /// <inheritdoc />
@@ -189,7 +223,7 @@ public sealed class S7Driver
    /// <inheritdoc />
    public async Task InitializeAsync(string driverConfigJson, CancellationToken cancellationToken)
    {
-        _health = new DriverHealth(DriverState.Initializing, null, null);
+        Health = new DriverHealth(DriverState.Initializing, null, null);
        try
        {
            // Re-parse the supplied DriverConfig JSON so a config change delivered through the
@@ -263,6 +297,7 @@ public sealed class S7Driver

            Plc = plc;
            _plcDead = false;
+            _connectBackoff.RecordSuccess();

            // Parse every tag's address once at init so config typos fail fast here instead
            // of surfacing as BadInternalError on every Read against the bad tag. The parser
@@ -274,7 +309,7 @@ public sealed class S7Driver
            }

            _initialized = true;
-            _health = new DriverHealth(DriverState.Healthy, DateTime.UtcNow, null);
+            Health = new DriverHealth(DriverState.Healthy, DateTime.UtcNow, null);
            _logger.LogInformation("S7Driver connected. Driver={DriverInstanceId} Host={Host} CPU={CpuType} Tags={TagCount}",
                _driverInstanceId, _options.Host, _options.CpuType, _tagsByRawPath.Count);

@@ -299,7 +334,7 @@ public sealed class S7Driver
            Plc = null;
            _initialized = false;
            _plcDead = false;
-            _health = new DriverHealth(DriverState.Faulted, null, ex.Message);
+            Health = new DriverHealth(DriverState.Faulted, null, ex.Message);
            _logger.LogError(ex, "S7Driver connect failed. Driver={DriverInstanceId} Host={Host}", _driverInstanceId, _options.Host);
            throw;
        }
@@ -346,13 +381,15 @@ public sealed class S7Driver

        _initialized = false;
        _plcDead = false;
+        _writeFault = null;
+        _connectBackoff.RecordSuccess();
        try { Plc?.Dispose(); } catch { /* best-effort — tearing down anyway */ }
        Plc = null;
-        _health = new DriverHealth(DriverState.Unknown, _health.LastSuccessfulRead, null);
+        Health = new DriverHealth(DriverState.Unknown, Health.LastSuccessfulRead, null);
    }

    /// <inheritdoc />
-    public DriverHealth GetHealth() => _health;
+    public DriverHealth GetHealth() => Health;

    /// <summary>
    ///     True when <paramref name="driverConfigJson"/> carries a real config body. The
@@ -453,19 +490,18 @@ public sealed class S7Driver
                    "Timer/Counter are read-only this phase; set Writable=false.");
            }

-            // (e) Array tag declared Writable — WriteOneAsync has no WriteArrayAsync path yet.
-            // Without this guard a writable array node is discovered and
-            // accepted, then every write returns BadCommunicationError (InvalidCastException from
-            // BoxValueForWrite receiving a typed array) instead of the informative BadNotSupported
-            // the caller could act on. Wide-type arrays are already rejected above (guard-a); this
-            // targets non-wide types (Int16[], Byte[], Float32[], etc.) that ARE supported for
-            // reading but not yet for writing.
-            if (t.ArrayCount is >= 1 && t.Writable)
+            // (e) Bool array declared Writable — element writes are byte-granular (one byte per
+            // element, mirroring the read), so a write would overwrite the 7 neighbouring bits of
+            // every byte it touches; a safe bit-packed write needs read-modify-write and is not
+            // implemented. Every other supported element type (Byte/Int16/UInt16/Int32/UInt32/
+            // Float32) writes as ONE contiguous block (EncodeArrayBlock) — S7-016. Wide-type arrays
+            // are already rejected above (guard-a).
+            if (t.ArrayCount is >= 1 && t.Writable && t.DataType == S7DataType.Bool)
            {
                throw new NotSupportedException(
-                    $"S7 tag '{t.Name}' is a {t.DataType} array (ArrayCount={t.ArrayCount}) declared Writable — " +
-                    "array writes are not yet supported by the S7 driver. Set Writable=false for read-only array tags, " +
-                    "or split into individual scalar tags until array-write support lands.");
+                    $"S7 tag '{t.Name}' is a Bool array (ArrayCount={t.ArrayCount}) declared Writable — " +
+                    "Bool array writes are not supported (a byte-granular write would clobber the neighbouring " +
+                    "bits). Set Writable=false, or write the bits as individual scalar Bool tags.");
            }
        }
    }
@@ -567,7 +603,7 @@ public sealed class S7Driver
            {
                for (var i = 0; i < fullReferences.Count; i++)
                    results[i] = new DataValueSnapshot(null, StatusBadCommunicationError, null, now);
-                _health = new DriverHealth(DriverState.Degraded, _health.LastSuccessfulRead, ex.Message);
+                Health = new DriverHealth(DriverState.Degraded, Health.LastSuccessfulRead, ex.Message);
                return results;
            }

@@ -683,12 +719,23 @@ public sealed class S7Driver
            //
            // LastSuccessfulRead advances whenever ANYTHING read, even into a Degraded/Faulted
            // state — see ReadPassOutcome for why that is load-bearing.
+            //
+            // A sticky write-side Faulted (PUT/GET denied) outranks a read pass that found less
+            // wrong: reads can succeed against a CPU whose writes are protected, and a clean read
+            // must not erase the config alert. The write pass clears it on its next success.
            if (outcome.HasObservations)
            {
-                _health = new DriverHealth(
-                    outcome.WorstFailure,
-                    outcome.AnySuccess ? now : _health.LastSuccessfulRead,
-                    outcome.WorstFailure == DriverState.Healthy ? null : outcome.WorstError);
+                var state = outcome.WorstFailure;
+                var error = state == DriverState.Healthy ? null : outcome.WorstError;
+                if (_writeFault is { } wf && ReadPassOutcome.Rank(wf.State) > ReadPassOutcome.Rank(state))
+                {
+                    state = wf.State;
+                    error = wf.Message;
+                }
+                Health = new DriverHealth(
+                    state,
+                    outcome.AnySuccess ? now : Health.LastSuccessfulRead,
+                    error);
            }

            _gate.Release();
@@ -698,7 +745,7 @@ public sealed class S7Driver

    /// <summary>
    ///     The outcomes ONE <see cref="ReadAsync"/> pass observed, accumulated so the pass writes
-    ///     <see cref="_health"/> exactly once — <b>worst state wins</b>.
+    ///     <see cref="Health"/> exactly once — <b>worst state wins</b>.
    /// </summary>
    /// <remarks>
    ///     <para>
@@ -780,7 +827,7 @@ public sealed class S7Driver
        /// <summary>Severity order the pass ranks by: Healthy (none) &lt; Degraded &lt; Faulted.</summary>
        /// <param name="state">The state to rank.</param>
        /// <returns>Its severity, higher being worse.</returns>
-        private static int Rank(DriverState state) => state switch
+        internal static int Rank(DriverState state) => state switch
        {
            DriverState.Faulted => 2,
            DriverState.Degraded => 1,
@@ -1129,7 +1176,7 @@ public sealed class S7Driver
    /// <remarks>
    ///     <para>
    ///         <b>The health state is recorded, not applied.</b> It goes into
-    ///         <paramref name="outcome"/> so the pass can write <see cref="_health"/> once at the
+    ///         <paramref name="outcome"/> so the pass can write <see cref="Health"/> once at the
    ///         end, worst-state-wins — writing it here is what let a later good tag erase this
    ///         failure. The <c>_plcDead</c> / <see cref="MarkConnectionDeadIfFatal"/> side effects
    ///         stay IMMEDIATE: they govern whether the very next read reopens the handle, which
@@ -1691,6 +1738,8 @@ public sealed class S7Driver
        ArgumentNullException.ThrowIfNull(writes);
        RequireInitialized();
        var results = new WriteResult[writes.Count];
+        // Health is decided ONCE, at the end of the batch, worst-state-wins — see WritePassOutcome.
+        var outcome = new WritePassOutcome();

        await _gate.WaitAsync(cancellationToken).ConfigureAwait(false);
        try
@@ -1709,7 +1758,7 @@ public sealed class S7Driver
            {
                for (var i = 0; i < writes.Count; i++)
                    results[i] = new WriteResult(StatusBadCommunicationError);
-                _health = new DriverHealth(DriverState.Degraded, _health.LastSuccessfulRead, ex.Message);
+                outcome.RecordFailure(DriverState.Degraded, ex.Message);
                return results;
            }

@@ -1746,6 +1795,7 @@ public sealed class S7Driver
                {
                    await WriteOneAsync(plc, tag, w.Value, cancellationToken).ConfigureAwait(false);
                    results[i] = new WriteResult(0u);
+                    outcome.RecordSuccess();
                }
                catch (OperationCanceledException)
                {
@@ -1761,13 +1811,18 @@ public sealed class S7Driver
                {
                    results[i] = new WriteResult(StatusBadNotSupported);
                }
+                catch (S7WriteValueException)
+                {
+                    // Client-supplied value of the wrong shape — not a device or comms fault.
+                    results[i] = new WriteResult(StatusBadTypeMismatch);
+                }
                catch (PlcException pex) when (IsAccessDenied(pex))
                {
                    // PUT/GET-disabled / access-protection on write — same permanent
                    // configuration fault as on read. BadNotSupported +
                    // a config-alert health state, not a transient device failure.
                    results[i] = new WriteResult(StatusBadNotSupported);
-                    _health = new DriverHealth(DriverState.Faulted, _health.LastSuccessfulRead,
+                    outcome.RecordFailure(DriverState.Faulted,
                        "S7 access denied — enable PUT/GET communication in TIA Portal " +
                        $"(Protection & Security) for this CPU. PLC reported: {pex.Message}");
                }
@@ -1779,7 +1834,7 @@ public sealed class S7Driver
                    // dead so the next call reopens.
                    MarkConnectionDeadIfFatal(pex);
                    results[i] = new WriteResult(StatusBadDeviceFailure);
-                    _health = new DriverHealth(DriverState.Degraded, _health.LastSuccessfulRead, pex.Message);
+                    outcome.RecordFailure(DriverState.Degraded, pex.Message);
                }
                catch (Exception ex)
                {
@@ -1788,25 +1843,84 @@ public sealed class S7Driver
                    // dead when it's a connection loss.
                    MarkConnectionDeadIfFatal(ex);
                    results[i] = new WriteResult(StatusBadCommunicationError);
-                    _health = new DriverHealth(DriverState.Degraded, _health.LastSuccessfulRead, ex.Message);
+                    outcome.RecordFailure(DriverState.Degraded, ex.Message);
                }
            }
        }
-        finally { _gate.Release(); }
+        finally
+        {
+            // THE single health write of the batch (a finally, so an OCE mid-batch still flushes the
+            // evidence gathered so far — a pass that observed nothing writes nothing).
+            ApplyWritePassHealth(outcome);
+            _gate.Release();
+        }
        return results;
    }

+    /// <summary>
+    ///     Publishes one write batch's verdict (STAB-22): worst state wins over every outcome the
+    ///     batch recorded, so a Faulted access-denied item is not erased by a later Degraded or
+    ///     successful sibling. Maintains <see cref="_writeFault"/>, the sticky Faulted a read pass
+    ///     must not erase. Caller holds <see cref="_gate"/>.
+    /// </summary>
+    /// <param name="outcome">The batch's accumulated outcomes.</param>
+    private void ApplyWritePassHealth(WritePassOutcome outcome)
+    {
+        if (!outcome.HasObservations) return;
+
+        var worst = outcome.WorstFailure;
+        if (worst == DriverState.Faulted)
+            _writeFault = (DriverState.Faulted, outcome.WorstError!);
+        else if (outcome.AnySuccess)
+            _writeFault = null; // a write got through — the protection fault is gone
+
+        if (worst == DriverState.Healthy)
+        {
+            // Success-only batch: no health write, except to retire a Faulted that WE (the write
+            // side) were holding — a clean write is the only evidence the alert has cleared.
+            if (outcome.AnySuccess && _writeFault is null && Health.State == DriverState.Faulted)
+                Health = new DriverHealth(DriverState.Healthy, Health.LastSuccessfulRead, null);
+            return;
+        }
+
+        var state = worst;
+        var error = outcome.WorstError;
+        // A Degraded-only batch must not downgrade a still-sticky Faulted.
+        if (_writeFault is { } wf && ReadPassOutcome.Rank(wf.State) > ReadPassOutcome.Rank(state))
+        {
+            state = wf.State;
+            error = wf.Message;
+        }
+        Health = new DriverHealth(state, Health.LastSuccessfulRead, error);
+    }
+
+    /// <summary>
+    ///     The outcomes ONE <see cref="WriteAsync"/> batch observed — the write-side sibling of
+    ///     <see cref="ReadPassOutcome"/> (same worst-state-wins ranking and severity-pinned message),
+    ///     accumulated so the batch writes <see cref="Health"/> once instead of per item.
+    /// </summary>
+    private sealed class WritePassOutcome
+    {
+        private readonly ReadPassOutcome _inner = new();
+
+        /// <summary>True once any item in the batch wrote successfully.</summary>
+        public bool AnySuccess => _inner.AnySuccess;
+        /// <summary>The worst failure recorded; Healthy means none.</summary>
+        public DriverState WorstFailure => _inner.WorstFailure;
+        /// <summary>The message explaining <see cref="WorstFailure"/>.</summary>
+        public string? WorstError => _inner.WorstError;
+        /// <summary>True once the batch observed a success or a failure.</summary>
+        public bool HasObservations => _inner.HasObservations;
+        /// <summary>Records one successful write.</summary>
+        public void RecordSuccess() => _inner.RecordSuccess();
+        /// <summary>Records one failed write.</summary>
+        /// <param name="state">The state the failure would have stamped alone.</param>
+        /// <param name="message">The operator-facing message.</param>
+        public void RecordFailure(DriverState state, string message) => _inner.RecordFailure(state, message);
+    }
+
    private async Task WriteOneAsync(IS7Plc plc, S7TagDefinition tag, object? value, CancellationToken ct)
    {
-        // Defence-in-depth guard: authored array tags are rejected at init
-        // (RejectUnsupportedTagConfigs guard-e), but a transient equipment-tag ref resolved by
-        // _resolver bypasses that path. Both should fail with NotSupportedException → BadNotSupported,
-        // not InvalidCastException → BadCommunicationError from BoxValueForWrite receiving an array.
-        if (tag.ArrayCount is >= 1)
-            throw new NotSupportedException(
-                $"S7 array writes are not yet supported (tag '{tag.Name}'). " +
-                "Use individual scalar tags or set Writable=false for read-only arrays.");
-
        // Parse the address the same way ReadOneAsync does: every tag pre-parses at init
        // (_parsedByRawPath), with an on-demand parse as a defensive fallback. Needed here so the
        // wide-type write can byte-address the block (the narrow path below addresses by the raw
@@ -1815,6 +1929,17 @@ public sealed class S7Driver
            ? parsed
            : S7AddressParser.Parse(tag.Address);

+        // Array path (S7-016): ONE contiguous WriteBytesAsync of count × element-bytes — the inverse
+        // of ReadArrayAsync. Bool / wide-type arrays throw NotSupportedException (→ BadNotSupported);
+        // a wrong-shaped value throws S7WriteValueException (→ BadTypeMismatch, no health impact).
+        if (tag.ArrayCount is >= 1)
+        {
+            var arrayBytes = EncodeArrayBlock(tag, addr, value);
+            await plc.WriteBytesAsync(ToS7NetArea(addr.Area), addr.DbNumber, addr.ByteOffset, arrayBytes, ct)
+                .ConfigureAwait(false);
+            return;
+        }
+
        // Wide/structured scalar path: encode the value to a big-endian byte block and write it
        // at the start byte via S7.Net's buffer-based WriteBytesAsync. Mirrors the read seam;
        // the narrow string-based write below stays unchanged for 1/2/4-byte types.
@@ -1832,6 +1957,90 @@ public sealed class S7Driver
        await plc.WriteAsync(tag.Address, boxed, ct).ConfigureAwait(false);
    }

+    /// <summary>
+    ///     Pure encode loop — the inverse of <see cref="DecodeArrayBlock"/>: turns the caller's array
+    ///     into the contiguous big-endian block for a single <c>WriteBytesAsync</c>. No network I/O.
+    ///     Accepts any non-string <see cref="System.Collections.IEnumerable"/> (OPC UA hands the server
+    ///     a typed array, but a boxed <c>object[]</c> is equally fine); each element is coerced with
+    ///     <c>Convert.To*</c> like the scalar path.
+    /// </summary>
+    /// <param name="tag">Tag definition carrying the element type and declared array length.</param>
+    /// <param name="addr">Parsed address carrying the access <see cref="S7Size"/>.</param>
+    /// <param name="value">The array to encode; must hold exactly <c>ArrayCount</c> elements.</param>
+    /// <returns>The big-endian block, <c>count × element-bytes</c> long.</returns>
+    /// <exception cref="NotSupportedException">Bool or wide-type element arrays.</exception>
+    /// <exception cref="S7WriteValueException">The value is not an array, has the wrong length, or an
+    /// element does not convert to the element type.</exception>
+    internal static byte[] EncodeArrayBlock(S7TagDefinition tag, S7ParsedAddress addr, object? value)
+    {
+        var count = tag.ArrayCount!.Value;
+
+        switch (tag.DataType, addr.Size)
+        {
+            case (S7DataType.Bool, _):
+                throw new NotSupportedException(
+                    $"S7 Bool array writes are not supported (tag '{tag.Name}'): a byte-granular write would clobber neighbouring bits.");
+            case (S7DataType.Int64, _):
+            case (S7DataType.UInt64, _):
+            case (S7DataType.Float64, _):
+            case (S7DataType.String, _):
+            case (S7DataType.DateTime, _):
+                throw new NotSupportedException($"S7 array writes of {tag.DataType} are not supported (tag '{tag.Name}').");
+            case (S7DataType.Byte, S7Size.Byte):
+            case (S7DataType.UInt16, S7Size.Word):
+            case (S7DataType.Int16, S7Size.Word):
+            case (S7DataType.UInt32, S7Size.DWord):
+            case (S7DataType.Int32, S7Size.DWord):
+            case (S7DataType.Float32, S7Size.DWord):
+                break;
+            default:
+                throw new System.IO.InvalidDataException(
+                    $"S7 array Write type-mismatch: tag '{tag.Name}' declared {tag.DataType} but address " +
+                    $"'{tag.Address}' parsed as Size={addr.Size}");
+        }
+
+        if (value is string || value is not System.Collections.IEnumerable items)
+            throw new S7WriteValueException($"S7 array tag '{tag.Name}' requires an array value.");
+
+        var elements = new List<object?>(count);
+        foreach (var e in items) elements.Add(e);
+        if (elements.Count != count)
+            throw new S7WriteValueException(
+                $"S7 array tag '{tag.Name}' has {count} elements but the write supplied {elements.Count}.");
+
+        var elementBytes = ElementByteSize(addr.Size);
+        var block = new byte[count * elementBytes];
+        try
+        {
+            for (var i = 0; i < count; i++)
+            {
+                var span = block.AsSpan(i * elementBytes, elementBytes);
+                var element = elements[i];
+                switch (tag.DataType)
+                {
+                    case S7DataType.Byte: span[0] = Convert.ToByte(element); break;
+                    case S7DataType.UInt16: System.Buffers.Binary.BinaryPrimitives.WriteUInt16BigEndian(span, Convert.ToUInt16(element)); break;
+                    case S7DataType.Int16: System.Buffers.Binary.BinaryPrimitives.WriteInt16BigEndian(span, Convert.ToInt16(element)); break;
+                    case S7DataType.UInt32: System.Buffers.Binary.BinaryPrimitives.WriteUInt32BigEndian(span, Convert.ToUInt32(element)); break;
+                    case S7DataType.Int32: System.Buffers.Binary.BinaryPrimitives.WriteInt32BigEndian(span, Convert.ToInt32(element)); break;
+                    case S7DataType.Float32: System.Buffers.Binary.BinaryPrimitives.WriteSingleBigEndian(span, Convert.ToSingle(element)); break;
+                }
+            }
+        }
+        catch (Exception ex) when (ex is FormatException or InvalidCastException or OverflowException)
+        {
+            throw new S7WriteValueException(
+                $"S7 array tag '{tag.Name}': an element does not convert to {tag.DataType} ({ex.Message}).");
+        }
+        return block;
+    }
+
+    /// <summary>
+    ///     A caller-supplied write value the driver cannot encode (wrong shape / length / element
+    ///     type). A client error — maps to <c>BadTypeMismatch</c> and does not touch driver health.
+    /// </summary>
+    internal sealed class S7WriteValueException(string message) : Exception(message);
+
    /// <summary>
    ///     Writes a wide/structured scalar as ONE contiguous byte block via S7.Net's
    ///     buffer-based <c>Plc.WriteBytesAsync(DataType, db, startByteAdr, byte[] value, ct)</c>.
@@ -1893,18 +2102,15 @@ public sealed class S7Driver
    ///     <see cref="_plcDead"/> and reuses the single-connection-per-PLC invariant the gate
    ///     enforces. The read / write / probe paths all take the gate before calling it.
    ///     <para>
-    ///         While the PLC is down every data call and probe tick pays a full connect attempt
+    ///         While the PLC is down every data call and probe tick would pay a full connect attempt
    ///         bounded only by <c>_options.Timeout</c> (STAB-8). This method is the single
    ///         choke-point all S7 reconnects flow through (already gate-serialized), so the
-    ///         fleet-wide connect-attempt throttle plugs in here. R2-09 (sub-batch B3/B4) shipped the
-    ///         shared <see cref="ConnectionBackoff"/> primitive
-    ///         (<c>src/Core/…/Core.Abstractions/ConnectionBackoff.cs</c>) — the S7 wiring is a
-    ///         per-driver <c>ConnectionBackoff</c> field consulted with <c>ShouldAttempt(now)</c> at
-    ///         the top of the slow path (fail fast + degrade inside the window) plus
-    ///         <c>RecordFailure</c>/<c>RecordSuccess</c> around the connect, all under <c>_gate</c>
-    ///         (which satisfies the primitive's caller-synchronized contract; TwinCAT/FOCAS/AbCip
-    ///         already wire it this way). Deliberately NOT implemented driver-locally here — owned by
-    ///         <c>archreview/plans/R2-01-s7-fault-hardening-plan.md</c> Finding 3.
+    ///         connect-attempt throttle lives here (STAB-21): the shared <see cref="ConnectionBackoff"/>
+    ///         primitive is consulted with <c>ShouldAttempt(now)</c> at the top of the slow path —
+    ///         inside the window the call fails fast with no connect attempt, which every caller
+    ///         already degrades on — with <c>RecordFailure</c>/<c>RecordSuccess</c> around the connect.
+    ///         A successful connect clears the window, so recovery is never delayed past the first
+    ///         attempt that finds the PLC back; the 30 s cap bounds the worst case.
    ///     </para>
    /// </remarks>
    /// <param name="ct">Cancellation token for the (re)connect attempt.</param>
@@ -1922,6 +2128,12 @@ public sealed class S7Driver
        }
        _plcDead = false;

+        // STAB-21: inside the backoff window fail fast WITHOUT a connect attempt. A plain
+        // InvalidOperationException (not an OCE) so the read/write/probe catch ladders degrade on it.
+        if (!_connectBackoff.ShouldAttempt(BackoffClock()))
+            throw new InvalidOperationException(
+                $"S7 reconnect to {_options.Host}:{_options.Port} suppressed — backing off after a failed connect attempt.");
+
        var plc = _plcFactory.Create(
            _options.CpuType, _options.Host, _options.Port, _options.Rack, _options.Slot, _options.Timeout);
        try
@@ -1932,6 +2144,7 @@ public sealed class S7Driver
        }
        catch (OperationCanceledException) when (!ct.IsCancellationRequested)
        {
+            _connectBackoff.RecordFailure(BackoffClock());
            // The linked CancelAfter fired — a connect TIMEOUT, not a caller cancellation.
            // Surface it as a connection FAILURE (TimeoutException) so callers route it through
            // their degrade paths: an escaping OCE reads as teardown and permanently killed the
@@ -1941,12 +2154,16 @@ public sealed class S7Driver
                $"S7 connect to {_options.Host}:{_options.Port} timed out after " +
                $"{(int)_options.Timeout.TotalMilliseconds} ms.");
        }
-        catch
+        catch (Exception ex)
        {
+            // Caller cancellation is teardown, not a dead PLC — it must not open a window.
+            if (!(ex is OperationCanceledException && ct.IsCancellationRequested))
+                _connectBackoff.RecordFailure(BackoffClock());
            try { plc.Dispose(); } catch { /* best-effort */ }
            throw;
        }

+        _connectBackoff.RecordSuccess();
        Plc = plc;
        _logger.LogInformation("S7Driver reconnected. Driver={DriverInstanceId} Host={Host} CPU={CpuType}",
            _driverInstanceId, _options.Host, _options.CpuType);
@@ -2114,8 +2331,8 @@ public sealed class S7Driver
    private void HandlePollError(Exception ex)
    {
        _logger.LogWarning(ex, "S7 poll reader failed. Driver={DriverInstanceId}", _driverInstanceId);
-        if (_health.State != DriverState.Faulted)
-            _health = new DriverHealth(DriverState.Degraded, _health.LastSuccessfulRead, ex.Message);
+        if (Health.State != DriverState.Faulted)
+            Health = new DriverHealth(DriverState.Degraded, Health.LastSuccessfulRead, ex.Message);
    }

    // ---- IHostConnectivityProbe ----
@@ -2257,8 +2474,10 @@ public sealed class S7Driver

        _initialized = false;
        _plcDead = false;
+        _writeFault = null;
+        _connectBackoff.RecordSuccess();
        try { Plc?.Dispose(); } catch { /* best-effort — tearing down anyway */ }
        Plc = null;
-        _health = new DriverHealth(DriverState.Unknown, _health.LastSuccessfulRead, null);
+        Health = new DriverHealth(DriverState.Unknown, Health.LastSuccessfulRead, null);
    }
 }
@@ -1,5 +1,6 @@
 using System.Text.Json;
 using System.Text.Json.Serialization;
+using Microsoft.Extensions.Logging;
 using ZB.MOM.WW.OtOpcUa.Core.Abstractions;
 using ZB.MOM.WW.OtOpcUa.Core.Hosting;

@@ -16,22 +17,32 @@ public static class S7DriverFactoryExtensions
    public const string DriverTypeName = "S7";

    /// <summary>Registers the S7 driver factory with the registry.</summary>
+    /// <remarks>
+    ///     The optional <paramref name="loggerFactory"/> is captured at registration time and used to
+    ///     build an <see cref="ILogger{S7Driver}"/> per driver instance — without it the driver runs on
+    ///     the null logger and none of its diagnostics (connect/reconnect, skipped tags, poll faults)
+    ///     reach the node log (CONV-3).
+    /// </remarks>
    /// <param name="registry">The driver factory registry.</param>
-    public static void Register(DriverFactoryRegistry registry)
+    /// <param name="loggerFactory">Optional logger factory for driver instances.</param>
+    public static void Register(DriverFactoryRegistry registry, ILoggerFactory? loggerFactory = null)
    {
        ArgumentNullException.ThrowIfNull(registry);
-        registry.Register(DriverTypeName, CreateInstance);
+        registry.Register(DriverTypeName, (id, json) => CreateInstance(id, json, loggerFactory));
    }

    /// <summary>Creates a new S7 driver instance from configuration.</summary>
    /// <param name="driverInstanceId">The unique identifier for the driver instance.</param>
    /// <param name="driverConfigJson">The JSON configuration for the driver.</param>
    /// <returns>A newly created S7 driver instance.</returns>
-    internal static S7Driver CreateInstance(string driverInstanceId, string driverConfigJson)
+    /// <param name="loggerFactory">Optional logger factory for the driver instance.</param>
+    internal static S7Driver CreateInstance(
+        string driverInstanceId, string driverConfigJson, ILoggerFactory? loggerFactory = null)
    {
        ArgumentException.ThrowIfNullOrWhiteSpace(driverInstanceId);
        ArgumentException.ThrowIfNullOrWhiteSpace(driverConfigJson);
-        return new S7Driver(ParseOptions(driverInstanceId, driverConfigJson), driverInstanceId);
+        return new S7Driver(ParseOptions(driverInstanceId, driverConfigJson), driverInstanceId,
+            logger: loggerFactory?.CreateLogger<S7Driver>());
    }

    /// <summary>
@@ -112,6 +112,26 @@ public sealed class S7TagConfigModel
                + string.Join(", ", Enum.GetNames<S7DataType>()) + ".";
        }

+        // S7-016: array shape is judged against the driver's INIT guards, which THROW (failing the whole
+        // driver's init, not just this tag) for a wide-type array and for a writable Bool array. The
+        // isArray / arrayLength keys themselves belong to the TagModal's generic array controls
+        // (TagArrayConfig) and are intentionally not fields of this model, so read them off the key bag.
+        if (TagConfigJson.GetBool(_bag, "isArray"))
+        {
+            var dt = DataType;
+            if (dt is S7DataType.Int64 or S7DataType.UInt64 or S7DataType.Float64
+                   or S7DataType.String or S7DataType.DateTime)
+            {
+                return $"S7 does not support {dt} arrays — use Bool (read-only), Byte, Int16, UInt16, Int32, "
+                    + "UInt32 or Float32 for an array tag, or a scalar tag.";
+            }
+            if (dt == S7DataType.Bool && (Writable ?? true))
+            {
+                return "A Bool array cannot be writable (a byte-granular write would clobber neighbouring bits) — "
+                    + "uncheck Writable, or use scalar Bool tags.";
+            }
+        }
+
        // Gitea #554: the reader's remaining, non-enum refusal — a String tag whose 'stringLength' is
        // negative or above 254 (S7 REJECTS it rather than clamping) — is not restated here. The verdict and
        // the wording both come from the driver's own reader, via TagConfigParseGate.
@@ -226,7 +226,7 @@ public static class DriverFactoryBootstrap
        // task, so the Tier A 5s Subscribe budget never covers the stream's lifetime.
        Driver.MTConnect.MTConnectDriverFactoryExtensions.Register(registry, loggerFactory);
        Driver.OpcUaClient.OpcUaClientDriverFactoryExtensions.Register(registry, loggerFactory, secretResolver);
-        Driver.S7.S7DriverFactoryExtensions.Register(registry);
+        Driver.S7.S7DriverFactoryExtensions.Register(registry, loggerFactory);
        Driver.Sql.SqlDriverFactoryExtensions.Register(registry, loggerFactory);
        Driver.TwinCAT.TwinCATDriverFactoryExtensions.Register(registry, loggerFactory);
    }