diff --git a/opensearch-master/rootfs/etc/opensearch/opensearch.yml.template b/opensearch-master/rootfs/etc/opensearch/opensearch.yml.template
index 489ec03..0d7d89e 100644
--- a/opensearch-master/rootfs/etc/opensearch/opensearch.yml.template
+++ b/opensearch-master/rootfs/etc/opensearch/opensearch.yml.template
@@ -1,5 +1,5 @@
-cluster.name: ${CLUSTER_NAME}
-node.name: ${NODE_NAME}
+cluster.name: "${CLUSTER_NAME}"
+node.name: "${NODE_NAME}"
 node.roles: [${NODE_ROLE}]
 
 path.data: /usr/share/opensearch/data
diff --git a/opensearch-master/rootfs/usr/bin/configure-opensearch b/opensearch-master/rootfs/usr/bin/configure-opensearch
index 4c1c24e..00ed47e 100644
--- a/opensearch-master/rootfs/usr/bin/configure-opensearch
+++ b/opensearch-master/rootfs/usr/bin/configure-opensearch
@@ -5,8 +5,7 @@ read_config() {
     if command -v bashio >/dev/null 2>&1; then
         bashio::config "$1"
     else
-        # Fallback for testing outside Home Assistant
-        echo "Testing mode - using default values"
+        # Fallback for testing outside Home Assistant - return empty to avoid issues
         case "$1" in
             "node_role") echo "master" ;;
             "cluster_name") echo "hass-opensearch-cluster" ;;
@@ -14,7 +13,7 @@ read_config() {
             "heap_size") echo "1g" ;;
             "http_port") echo "9200" ;;
             "transport_port") echo "9300" ;;
-            "discovery_seed_hosts") echo '["os-master:9300", "os-data-1:9300"]' ;;
+            "discovery_seed_hosts") echo '["os-master:9300"]' ;;
             "initial_master_nodes") echo '["os-master"]' ;;
             "security_enabled") echo "true" ;;
             "admin_password") echo "SecurePass123!" ;;
@@ -31,8 +30,8 @@ NODE_NAME=$(read_config 'node_name')
 HEAP_SIZE=$(read_config 'heap_size')
 HTTP_PORT=$(read_config 'http_port')
 TRANSPORT_PORT=$(read_config 'transport_port')
-DISCOVERY_SEEDS=$(read_config 'discovery_seed_hosts' | tr -d '[]" ' | tr ',' ' ')
-INITIAL_MASTERS=$(read_config 'initial_master_nodes' | tr -d '[]" ' | tr ',' ' ')
+DISCOVERY_SEEDS=$(read_config 'discovery_seed_hosts' | tr -d '[]"' | tr ',' ' ')
+INITIAL_MASTERS=$(read_config 'initial_master_nodes' | tr -d '[]"' | tr ',' ' ')
 SECURITY_ENABLED=$(read_config 'security_enabled')
 ADMIN_PASSWORD=$(read_config 'admin_password')
 
@@ -40,27 +39,42 @@ ADMIN_PASSWORD=$(read_config 'admin_password')
 export OPENSEARCH_INITIAL_ADMIN_PASSWORD="${ADMIN_PASSWORD}"
 export DISCOVERY_TYPE="multi-node"
 
-# Set heap size
-echo "-Xms${HEAP_SIZE}" > /usr/share/opensearch/config/jvm.options.d/heap.options
-echo "-Xmx${HEAP_SIZE}" >> /usr/share/opensearch/config/jvm.options.d/heap.options
+# Set heap size with proper format (remove any extra spaces or invalid characters)
+CLEAN_HEAP_SIZE=$(echo "$HEAP_SIZE" | tr -d ' ' | grep -oE '[0-9]+[mg]')
+if [ -z "$CLEAN_HEAP_SIZE" ]; then
+    CLEAN_HEAP_SIZE="1g"  # Default if invalid
+fi
 
-# Export variables for envsubst
-export CLUSTER_NAME NODE_NAME NODE_ROLE HTTP_PORT TRANSPORT_PORT
-export DISCOVERY_SEEDS INITIAL_MASTERS SECURITY_ENABLED
+# Set heap size in jvm.options.d (proper format)
+mkdir -p /usr/share/opensearch/config/jvm.options.d
+echo "-Xms${CLEAN_HEAP_SIZE}" > /usr/share/opensearch/config/jvm.options.d/heap.options
+echo "-Xmx${CLEAN_HEAP_SIZE}" >> /usr/share/opensearch/config/jvm.options.d/heap.options
+
+# Export variables for envsubst (ensure they have proper values)
+export CLUSTER_NAME="${CLUSTER_NAME:-hass-opensearch-cluster}"
+export NODE_NAME="${NODE_NAME:-os-node-1}"
+export NODE_ROLE="${NODE_ROLE:-master}"
+export HTTP_PORT="${HTTP_PORT:-9200}"
+export TRANSPORT_PORT="${TRANSPORT_PORT:-9300}"
+export DISCOVERY_SEEDS="${DISCOVERY_SEEDS:-os-master:9300}"
+export INITIAL_MASTERS="${INITIAL_MASTERS:-os-master}"
+export SECURITY_ENABLED="${SECURITY_ENABLED:-false}"
 
 # Generate opensearch.yml from template
 envsubst < /etc/opensearch/opensearch.yml.template > /usr/share/opensearch/config/opensearch.yml
 
-# Install plugins if specified
+# Install plugins if specified (only if not in test mode)
 PLUGINS_JSON=$(read_config 'plugins')
-if [ -n "$PLUGINS_JSON" ] && [ "$PLUGINS_JSON" != "[]" ]; then
-    # Extract plugins from JSON array
-    PLUGINS=$(echo "$PLUGINS_JSON" | tr -d '[]"' | tr ',' '\n' | sed 's/^ *//;s/ *$//')
-    for plugin in $PLUGINS; do
-        echo "Installing plugin: $plugin"
-        /usr/share/opensearch/bin/opensearch-plugin install --batch "$plugin" || true
-    done
+if [ -n "$PLUGINS_JSON" ] && [ "$PLUGINS_JSON" != "[]" ] && command -v bashio >/dev/null 2>&1; then
+    # Extract plugins from JSON array properly
+    PLUGINS=$(echo "$PLUGINS_JSON" | jq -r '.[]' 2>/dev/null || echo "")
+    if [ -n "$PLUGINS" ]; then
+        for plugin in $PLUGINS; do
+            echo "Installing plugin: $plugin"
+            /usr/share/opensearch/bin/opensearch-plugin install --batch "$plugin" || true
+        done
+    fi
 fi
 
-# Start OpenSearch (use exec to replace the current process)
+# Start OpenSearch
 exec /usr/share/opensearch/bin/opensearch
\ No newline at end of file