# GL-S200 Thread Border Router Integration Plan

Planning notes for adding a GL.iNet GL-S200 as a Thread Border Router for Home Assistant on concord NUC.

## Device Overview

**GL-S200** ([product page](https://www.gl-inet.com/products/gl-s200/))

| Spec | Value |
|------|-------|
| CPU | QCA9531 @ 650 MHz |
| RAM / Flash | 128 MB DDR2 / 128 MB NAND |
| OS | GL.iNet firmware (OpenWrt 21.02, kernel 5.4) |
| Radios | Thread + BLE 5.0 + Wi-Fi 2.4 GHz b/g/n (150 Mbps) |
| Ports | 1x WAN, 1x LAN (10/100 Mbps) |
| Power | USB-C 5V / 2A |
| Role | Thread Border Router (OTBR) — not a Matter controller; Matter runs on top via python-matter-server already deployed on the NUC |

## Where to Plug It In

**Must land on the same L2 segment as Home Assistant.**

HA runs as a Docker container on `vish-concord-nuc` with `network_mode: host`. The NUC sits on `192.168.68.0/22` (gateway `192.168.68.1`) — **deliberately separated** from the main homelab LAN (`192.168.0.0/24`).

Thread/Matter border router discovery uses mDNS (`_meshcop._udp`), which is link-local. Cross-subnet discovery would require an mDNS reflector (not currently deployed). So:

- ✅ Plug S200 WAN into a switch/AP on `192.168.68.0/22` (same segment as the NUC).
- ❌ Do not plug into the main 192.168.0.0/24 LAN — HA will not see it.

## Existing Stack on Concord NUC

Compose: `concord_nuc/homeassistant.yaml`

| Service | Purpose | Status |
|---------|---------|--------|
| `homeassistant` | HA Core (host networking) | Running |
| `matter-server` | python-matter-server (host networking) | Running |
| `piper` | Wyoming TTS (port 10200) | Running |
| `whisper` | Wyoming STT (port 10300) | Running |
| `openwakeword` | Wyoming wake word (port 10400) | Running |

The Matter server is already in place — the S200 plugs in as the *radio* layer for Thread. No compose changes needed to add the S200 itself.

## Integration Steps (When Device Arrives)

1. **Physical setup**
   - Connect S200 WAN to the 192.168.68.0/22 network.
   - Power via USB-C (5V/2A).
   - First-boot admin UI reachable at `192.168.8.1` until reconfigured, then at the DHCP-assigned 192.168.68.x address.
   - Update firmware, set an admin password.

2. **Verify mDNS discovery from the NUC**
   ```bash
   # Run on concord NUC (Tailscale: 100.72.55.21)
   avahi-browse -rt _meshcop._udp
   ```
   Should list the S200 as a Thread Border Router with a TXT record containing `rv=1`, `tv=1.3.0`, etc.

3. **Add to Home Assistant**
   - Settings → Devices & Services → Add Integration → **Thread**
   - S200 should auto-discover. Add it as an External Thread Border Router.
   - Settings → Devices & Services → Add Integration → **Matter (BETA)** (already configured to talk to the local matter-server container).

4. **Pair Matter devices**
   - Use the Home Assistant Companion app (iOS/Android) to pair.
   - The app hands off Thread commissioning credentials to each device so it joins the S200's mesh.

## Gotchas

- **Firmware lag**: GL.iNet's OTBR implementation trails upstream OpenThread. Check the admin UI for firmware updates before committing to the device.
- **No Zigbee**: S200 is Thread-only. Existing Zigbee devices (if any) still need a separate coordinator (e.g., a Zigbee stick on the NUC via Zigbee2MQTT or ZHA).
- **Thread credential backup**: Once the S200 forms an operational dataset (network name, PAN ID, network key), export and back it up — losing it means re-commissioning every Thread device.
- **HA network_mode: host is load-bearing**: If HA is ever migrated to bridge networking, Matter/Thread discovery breaks. Keep host networking.

## Status

- [ ] S200 acquired
- [ ] Plugged into 192.168.68.0/22 segment
- [ ] mDNS discovery verified from NUC
- [ ] Added to HA Thread integration
- [ ] First Matter device paired
- [ ] Thread operational dataset backed up