Add model embeddings for Z-factor DoF, separate from SaturatedController.

Fixed/Free Probe calibration now emits embeddings[] (unknown + equation) instead of controls[], keeping SaturatedController for physical regulation only.

Co-authored-by: Cursor <cursoragent@cursor.com>

.entropyk/modules/calibration.ekmod

@@ -24,10 +24,8 @@
       "flipV": false,
       "name": "cond",
       "params": {
-        "__fixed_calib_sdt_c": false,
         "__fixed_z_dp": true,
         "__fixed_z_ua": true,
-        "calib_sdt_c": 40,
         "channel_spacing_mm": 1.5,
         "chevron_angle_deg": 60,
         "correlation": "Longo2004",
@@ -43,7 +41,6 @@
         "refrigerant": "R134a",
         "secondary_fluid": "Water",
         "target_subcooling_k": 5,
-        "ua": 2500,
         "z_dp": 1,
         "z_ua": 1
       },
@@ -70,10 +67,8 @@
       "flipV": false,
       "name": "evap",
       "params": {
-        "__fixed_calib_sst_c": false,
         "__fixed_z_dp": true,
         "__fixed_z_ua": false,
-        "calib_sst_c": 5,
         "channel_spacing_mm": 1.5,
         "chevron_angle_deg": 60,
         "correlation": "Longo2004",
@@ -89,7 +84,6 @@
         "refrigerant": "R134a",
         "secondary_fluid": "Water",
         "target_superheat_k": 5,
-        "ua": 2000,
         "z_dp": 1,
         "z_ua": 1
       },
@@ -166,10 +160,9 @@
       "flipV": false,
       "name": "SST probe",
       "params": {
-        "__fixed_target": true,
+        "__fixed_tsat_c": true,
         "fluid": "R134a",
-        "measure": "SST",
-        "target": 5.9
+        "tsat_c": 4.4
       },
       "rotation": 0,
       "type": "Probe"

apps/web/src/components/panels/PropertiesPanel.tsx

@@ -177,21 +177,18 @@ export default function PropertiesPanel() {
             Modelica / Dymola.
           </p>
           <div className="rounded border border-[var(--line)] bg-[var(--chrome-2)] p-2 text-[10px]">
-            <p className="mb-1 font-semibold text-[var(--ink)]">Rappel rapide</p>
+            <p className="mb-1 font-semibold text-[var(--ink)]">DoF Modelica</p>
             <ul className="list-inside list-disc space-y-0.5 text-[var(--ink-dim)]">
               <li>
-                <strong>Fixed ☑</strong> = valeur imposée
+                <strong>Fixed ☑</strong> = <code>parameter</code> (connu)
               </li>
               <li>
-                <strong>Fixed ☐</strong> = le solveur calcule (ex. Z_UA libre)
+                <strong>Fixed ☐</strong> = inconnue → il faut une équation de plus
               </li>
               <li>
-                Calibration simple : Fixed sur SST + Z_UA non Fixed (défaut Z_UA = 1)
-              </li>
-              <li>
-                Le bloc « Regulation loop » (palette Advanced) est optionnel — pas besoin pour
-                calibrer Z_UA
+                Calib : Probe Tsat Fixed (= équation) + Z_UA Free (= inconnue)
               </li>
+              <li>n_eq = n_unk. Pas de boucle de régulation.</li>
             </ul>
           </div>
         </div>
@@ -551,15 +548,15 @@ export default function PropertiesPanel() {
             {activeTab === "Calibration" && (
               <div className="space-y-1.5 border-t border-[var(--line)] bg-[var(--chrome-2)] px-2.5 py-1.5 text-[10px] leading-snug text-[var(--ink-dim)]">
                 <p>
-                  <strong>Calibration :</strong> pose une <strong>Probe</strong> (sonde) sur la
-                  ligne à mesurer, coche Fixed sur sa cible, puis décoche Fixed sur le facteur
-                  (Z_UA) ici. La valeur résolue s’affiche ci-dessous après simulation.
+                  <strong>Modelica :</strong> Probe Fixed → équation (
+                  <code>Tsat = …</code>). Facteur Free → inconnue (
+                  <code>parameter z_ua(fixed=false)</code>). Le start est la valeur affichée.
                 </p>
                 <p className="text-[var(--ink-faint)]">
-                  Tu n’as pas besoin du nœud « Regulation loop » pour ça.
+                  Laisse UA override vide. n_eq doit égaler n_unk.
                 </p>
                 {solvedVars.length > 0 && (
-                  <SolvedVariablesBlock items={solvedVars} title="Facteurs résolus" />
+                  <SolvedVariablesBlock items={solvedVars} title="Inconnues résolues" />
                 )}
               </div>
             )}

apps/web/src/lib/componentMeta.ts

@@ -28,24 +28,24 @@ export interface ParamMeta {
   options?: Array<{ value: string | number; label: string }>;
   advanced?: boolean;
   /**
-   * Dymola/EES-style Fixed checkbox.
-   * Fixed ON  = value imposed (parameter or measured target).
-   * Fixed OFF = free for the solver (calibration tuner / free unknown).
+   * Modelica `fixed` attribute (Dymola-style checkbox).
+   * Fixed ON  = `parameter` / binding equation (known).
+   * Fixed OFF = unknown — needs another equation to keep the model balanced.
    */
   fixable?: boolean;
   /** Default for the Fixed checkbox when `fixable` (true = Fixed). */
   defaultFixed?: boolean;
   /**
-   * When Fixed ON: use this param value as a control setpoint for the named
-   * measure output (e.g. `saturationTemperature`, `superheat`).
+   * When Fixed ON on a Probe: adds equation `output = value`
+   * (e.g. Tsat = 5 °C). Internal wire name for the solver output.
    */
   measureOutput?: string;
   /**
-   * When Fixed OFF: free this actuator/calibration factor (e.g. `z_ua`).
-   * Requires a Fixed measure on the same component to stay DoF-balanced.
+   * When Fixed OFF: this factor becomes a Newton unknown (Modelica
+   * `parameter ...(fixed=false)`). Pair with a Fixed Probe equation.
    */
   actuatorFactor?: string;
-  /** Bounds used when the factor is free (actuator min/max). */
+  /** Bounds / start guess when the factor is an unknown. */
   freeMin?: number;
   freeMax?: number;
   /**
@@ -220,41 +220,20 @@ export const COMPONENTS: ComponentMeta[] = [
     label: "Probe (sonde)",
     category: "Instrumentation",
     description:
-      "Sonde de mesure posée sur une ligne. Lit P/T/SH/SC/SST/SDT/DGT/DSH/capacité/ṁ/h à cet endroit. Toute calibration impose sa cible sur un Probe.",
+      "Sonde sur une ligne : fige T, Tsat, P, X ou Tsh (= T−Tsat, SC négatif) pour calibrer.",
     help:
       "Sonde de calibration (Probe)\n" +
-      "Toute calibration se fait via un Probe posé sur une ligne (règle dure).\n\n" +
-      "1. Glisse le Probe sur un fil du schéma (comme pour insérer un Pipe).\n" +
-      "2. Choisis la grandeur mesurée (SST, SDT, DGT, DSH, SH, SC, T, P, débit, capacité, enthalpie) et le fluide.\n" +
-      "3. Coche Fixed sur « Cible » et tape la valeur mesurée.\n" +
-      "4. Libère le Z-factor correspondant (Z_UA, Z_dP, Z_flow…) sur le composant à calibrer.\n" +
-      "Le solveur appaire automatiquement le Probe (mesure) et le Z-factor libre (inconnue).",
+      "1. Glisse le Probe sur un fil.\n" +
+      "2. Coche Fixed sur les grandeurs physiques mesurées (T, Tsat, P, X, Tsh).\n" +
+      "3. Libère le facteur correspondant sur le composant :\n" +
+      "   • Tsat / Tsh → z_ua (HX) ou opening (EXV)\n" +
+      "   • T (DGT refoulement) → f_w (rétention énergie carter)\n" +
+      "   • Capacity → z_flow (capacité machine)\n" +
+      "   • P → z_dp\n" +
+      "Tsh = T − Tsat (surchauffe > 0, sous-refroidissement < 0).",
     ports: ["inlet", "outlet"],
     color: "#0ea5e9",
     params: [
-      {
-        key: "measure",
-        label: "Grandeur mesurée",
-        kind: "string",
-        default: "SH",
-        required: true,
-        section: "Mesure",
-        description:
-          "Grandeur physique mesurée à l'emplacement du Probe. SST/SDT = Tsat(P), SH/DSH = T−Tsat(P), SC = Tsat(P)−T.",
-        options: [
-          { value: "SST", label: "SST (Tsat aspiration)" },
-          { value: "SDT", label: "SDT (Tsat refoulement)" },
-          { value: "DGT", label: "DGT (T° gaz refoulement)" },
-          { value: "DSH", label: "DSH (surch. refoulement)" },
-          { value: "SH", label: "SH (surchauffe)" },
-          { value: "SC", label: "SC (sous-refroid.)" },
-          { value: "T", label: "T (température)" },
-          { value: "P", label: "P (pression)" },
-          { value: "MassFlow", label: "Débit massique" },
-          { value: "Capacity", label: "Capacité (kW)" },
-          { value: "Enthalpy", label: "Enthalpie" },
-        ],
-      },
       {
         key: "fluid",
         label: "Fluide",
@@ -262,22 +241,81 @@ export const COMPONENTS: ComponentMeta[] = [
         default: "R134a",
         required: true,
         section: "Mesure",
-        description: "Fluide frigorigène pour le calcul de Tsat/SH/SC (via CoolProp).",
+        description: "Fluide pour Tsat / Tsh / X (CoolProp).",
       },
       {
-        key: "target",
-        label: "Cible (Fixed = impose)",
+        key: "t_c",
+        label: "T (température)",
         kind: "number",
-        section: "Calibration",
+        unit: "°C",
+        default: 50,
+        section: "Paramètres physiques",
         fixable: true,
         defaultFixed: false,
-        // Auto: resolved from `measure` at config-build time
-        // (SST/SDT → saturationTemperature, SH/DSH → superheat, SC → subcooling,
-        // DGT/T → temperature, P → pressure, MassFlow → massFlowRate,
-        // Capacity → capacity, Enthalpy → heatTransferRate as carrier).
-        measureOutput: "auto",
+        measureOutput: "temperature",
+        description: "Température de ligne. Sur refoulement = DGT → pairer avec f_w.",
+      },
+      {
+        key: "tsat_c",
+        label: "Tsat",
+        kind: "number",
+        unit: "°C",
+        default: 5,
+        section: "Paramètres physiques",
+        fixable: true,
+        defaultFixed: false,
+        measureOutput: "saturationTemperature",
+        description: "Tsat(P) à la sonde. Aspiration = SST, liquide = SDT → z_ua.",
+      },
+      {
+        key: "p_bar",
+        label: "P",
+        kind: "number",
+        unit: "bar",
+        default: 5,
+        section: "Paramètres physiques",
+        fixable: true,
+        defaultFixed: false,
+        measureOutput: "pressure",
+        description: "Pression absolue → pairer avec z_dp.",
+      },
+      {
+        key: "x",
+        label: "X (titre)",
+        kind: "number",
+        default: 1,
+        min: 0,
+        max: 1,
+        section: "Paramètres physiques",
+        fixable: true,
+        defaultFixed: false,
+        measureOutput: "quality",
+        description: "Titre vapeur [0–1]. Usage avancé.",
+      },
+      {
+        key: "tsh_k",
+        label: "Tsh (= T − Tsat)",
+        kind: "number",
+        unit: "K",
+        default: 5,
+        section: "Paramètres physiques",
+        fixable: true,
+        defaultFixed: false,
+        measureOutput: "superheat",
         description:
-          "Coche Fixed et tape la valeur mesurée (K pour températures, K pour SH/SC, Pa pour P, kg/s pour débit, W pour capacité, J/kg pour h).",
+          "Écart à la saturation : >0 surchauffe, <0 sous-refroidissement. Remplace SH/SC sur l’échangeur.",
+      },
+      {
+        key: "capacity_w",
+        label: "Capacité",
+        kind: "number",
+        unit: "W",
+        default: 10000,
+        section: "Paramètres physiques",
+        fixable: true,
+        defaultFixed: false,
+        measureOutput: "capacity",
+        description: "Capacité (bilan secondaire). Pairer avec z_flow du compresseur.",
       },
     ],
   },
@@ -475,6 +513,36 @@ export const COMPONENTS: ComponentMeta[] = [
         default: 5.0,
         section: "Init / design",
       },
+      {
+        key: "z_flow",
+        label: "z_flow (capacité)",
+        kind: "number",
+        default: 1.0,
+        section: "Calibration",
+        fixable: true,
+        defaultFixed: true,
+        actuatorFactor: "z_flow",
+        freeMin: 0.5,
+        freeMax: 2.0,
+        description:
+          "Multiplicateur de débit / capacité machine. Fixed OFF + Probe Capacity Fixed.",
+      },
+      {
+        key: "f_w",
+        label: "f_w (rétention énergie)",
+        kind: "number",
+        default: 1.0,
+        min: 0,
+        max: 1,
+        section: "Calibration",
+        fixable: true,
+        defaultFixed: true,
+        actuatorFactor: "f_w",
+        freeMin: 0.0,
+        freeMax: 1.0,
+        description:
+          "Fraction du travail conservée dans le fluide : 1 = adiabatique, 0.98 ≈ 2 % perdu, 0 = tout perdu. Fixed OFF + Probe T (DGT) sur refoulement.",
+      },
     ],
   },
   {
@@ -819,7 +887,7 @@ export const COMPONENTS: ComponentMeta[] = [
         fixable: true,
         defaultFixed: true,
         actuatorFactor: "z_ua",
-        freeMin: 0.2,
+        freeMin: 0.05,
         freeMax: 3.0,
         description: "Fixed = valeur figée. Décocher Fixed = libre (calibration).",
       },
@@ -834,7 +902,7 @@ export const COMPONENTS: ComponentMeta[] = [
         fixable: true,
         defaultFixed: true,
         actuatorFactor: "z_dp",
-        freeMin: 0.2,
+        freeMin: 0.05,
         freeMax: 3.0,
       },
     ],
@@ -870,7 +938,7 @@ export const COMPONENTS: ComponentMeta[] = [
         fixable: true,
         defaultFixed: true,
         actuatorFactor: "z_ua",
-        freeMin: 0.2,
+        freeMin: 0.05,
         freeMax: 3.0,
         description: "Fixed = figé. Décocher Fixed = libre pour le solveur.",
       },
@@ -885,7 +953,7 @@ export const COMPONENTS: ComponentMeta[] = [
         fixable: true,
         defaultFixed: true,
         actuatorFactor: "z_dp",
-        freeMin: 0.2,
+        freeMin: 0.05,
         freeMax: 3.0,
       },
       {
@@ -1145,7 +1213,7 @@ export const COMPONENTS: ComponentMeta[] = [
         fixable: true,
         defaultFixed: true,
         actuatorFactor: "z_ua",
-        freeMin: 0.2,
+        freeMin: 0.05,
         freeMax: 3.0,
       },
       {
@@ -1158,7 +1226,7 @@ export const COMPONENTS: ComponentMeta[] = [
         fixable: true,
         defaultFixed: true,
         actuatorFactor: "z_dp",
-        freeMin: 0.2,
+        freeMin: 0.05,
         freeMax: 3.0,
       },
     ],
@@ -1234,7 +1302,7 @@ export const COMPONENTS: ComponentMeta[] = [
         fixable: true,
         defaultFixed: true,
         actuatorFactor: "z_ua",
-        freeMin: 0.2,
+        freeMin: 0.05,
         freeMax: 3.0,
       },
       {
@@ -1247,7 +1315,7 @@ export const COMPONENTS: ComponentMeta[] = [
         fixable: true,
         defaultFixed: true,
         actuatorFactor: "z_dp",
-        freeMin: 0.2,
+        freeMin: 0.05,
         freeMax: 3.0,
       },
     ],
@@ -1303,7 +1371,7 @@ export const COMPONENTS: ComponentMeta[] = [
         fixable: true,
         defaultFixed: true,
         actuatorFactor: "z_ua",
-        freeMin: 0.2,
+        freeMin: 0.05,
         freeMax: 3.0,
         description: "Fixed = figé. Décocher Fixed = le solveur ajuste Z_UA.",
       },
@@ -1318,7 +1386,7 @@ export const COMPONENTS: ComponentMeta[] = [
         fixable: true,
         defaultFixed: true,
         actuatorFactor: "z_dp",
-        freeMin: 0.2,
+        freeMin: 0.05,
         freeMax: 3.0,
       },
       {

apps/web/src/lib/configBuilder.test.ts

@@ -3,6 +3,7 @@ import type { Edge, Node } from "@xyflow/react";
 import {
   applyBoundaryFixSemantics,
   buildScenarioConfig,
+  buildModelEmbeddings,
   buildFixedFreeCalibrationControls,
   resolveSecondaryStreams,
   stripUiOnlyParams,
@@ -483,43 +484,45 @@ describe("caloporteur (secondary stream) resolution", () => {
   });
 });
 
-describe("Fixed / Free calibration (Probe-based pairing)", () => {
-  it("pairs a Fixed Probe measure with a Free Z_UA on the HX", () => {
+describe("Modelica embeddings (Fixed / Free)", () => {
+  it("pairs Fixed Probe Tsat with Free Z_UA into embeddings[] (not controls[])", () => {
     const nodes = [
       node("e", "FloodedEvaporator", "evap", 0, {
         ua: 9000,
         z_ua: 1.0,
-        // Fixed OFF for Z_UA → free actuator
         [fixedFlagKey("z_ua")]: false,
       }),
       node("p1", "Probe", "sst_probe", 0, {
-        measure: "SST",
         fluid: "R134a",
-        target: 278.15,
-        // Fixed ON for the Probe target → impose the measure
-        [fixedFlagKey("target")]: true,
+        tsat_c: 5.0,
+        [fixedFlagKey("tsat_c")]: true,
       }),
     ];
     const edges: Edge[] = [
       { id: "pe", source: "e", target: "p1", sourceHandle: "outlet", targetHandle: "inlet" },
     ];
-    const controls = buildFixedFreeCalibrationControls(nodes, edges);
-    expect(controls).toHaveLength(1);
-    expect(controls[0]).toMatchObject({
-      measure: { component: "sst_probe", output: "saturationTemperature" },
-      actuator: { component: "evap", factor: "z_ua" },
-      target: 278.15,
+    const embeddings = buildModelEmbeddings(nodes, edges);
+    expect(embeddings).toHaveLength(1);
+    expect(embeddings[0]).toMatchObject({
+      id: "emb_evap_z_ua",
+      unknown: { component: "evap", factor: "z_ua", start: 0.3, min: 0.05 },
+      equation: {
+        component: "sst_probe",
+        output: "saturationTemperature",
+        value: 278.15,
+      },
     });
 
     const cfg = buildScenarioConfig(nodes, edges);
-    expect(cfg.controls?.length).toBe(1);
-    // UI-only keys stripped from component JSON; Z_UA still emitted as initial value.
+    expect(cfg.embeddings).toHaveLength(1);
+    expect(cfg.controls).toBeUndefined();
     const comp = cfg.circuits[0].components[0];
     expect(comp[fixedFlagKey("z_ua")]).toBeUndefined();
     expect(comp.z_ua).toBe(1.0);
+    expect(comp.ua).toBeUndefined(); // Free z_ua strips absolute ua
   });
 
-  it("emits no control when Z_UA stays Fixed even with a Probe present", () => {
+  it("emits no embedding when Z_UA stays Fixed even with a Probe present", () => {
     const nodes = [
       node("e", "Evaporator", "evap", 0, {
         ua: 6000,
@@ -527,18 +530,15 @@ describe("Fixed / Free calibration (Probe-based pairing)", () => {
         [fixedFlagKey("z_ua")]: true,
       }),
       node("p1", "Probe", "sst_probe", 0, {
-        measure: "SST",
-        fluid: "R134a",
-        target: 278.15,
-        [fixedFlagKey("target")]: true,
+        tsat_c: 5.0,
+        [fixedFlagKey("tsat_c")]: true,
       }),
     ];
+    expect(buildModelEmbeddings(nodes)).toHaveLength(0);
     expect(buildFixedFreeCalibrationControls(nodes)).toHaveLength(0);
   });
 
-  it("emits nothing for a freed Z_UA with no matching Probe (HARD RULE)", () => {
-    // A freed z-factor without a Probe to measure against must not emit a
-    // control — the user must place a Probe. No legacy same-component fallback.
+  it("emits nothing for a freed Z_UA with no matching Probe", () => {
     const nodes = [
       node("e", "Evaporator", "evap", 0, {
         ua: 6000,
@@ -546,6 +546,39 @@ describe("Fixed / Free calibration (Probe-based pairing)", () => {
         [fixedFlagKey("z_ua")]: false,
       }),
     ];
-    expect(buildFixedFreeCalibrationControls(nodes)).toHaveLength(0);
+    expect(buildModelEmbeddings(nodes)).toHaveLength(0);
+  });
+
+  it("rejects Free Z_UA without a Fixed Probe equation (Modelica balance)", () => {
+    const nodes = [
+      node("e", "BphxEvaporator", "evap", 0, {
+        z_ua: 1.0,
+        [fixedFlagKey("z_ua")]: false,
+      }),
+    ];
+    const issues = validateConfig(nodes, []);
+    expect(issues.some((m) => m.includes("fixed=false") || m.includes("without an equation"))).toBe(
+      true,
+    );
+  });
+
+  it("accepts legacy Probe measure+target (°C → K)", () => {
+    const nodes = [
+      node("e", "BphxEvaporator", "evap", 0, {
+        z_ua: 1.0,
+        [fixedFlagKey("z_ua")]: false,
+      }),
+      node("p1", "Probe", "sst_probe", 0, {
+        measure: "SST",
+        target: 4.4,
+        __fixed_target: true,
+      }),
+    ];
+    const edges: Edge[] = [
+      { id: "pe", source: "e", target: "p1", sourceHandle: "outlet", targetHandle: "inlet" },
+    ];
+    const embeddings = buildModelEmbeddings(nodes, edges);
+    expect(embeddings).toHaveLength(1);
+    expect(embeddings[0].equation.value).toBeCloseTo(277.55, 10);
   });
 });

apps/web/src/lib/configBuilder.ts

@@ -56,6 +56,23 @@ export interface ControlConfig {
   alpha?: number;
 }
 
+/** Modelica Z-factor embedding (unknown + equation). Not a SaturatedController. */
+export interface EmbeddingConfig {
+  id: string;
+  unknown: {
+    component: string;
+    factor: string;
+    start: number;
+    min: number;
+    max: number;
+  };
+  equation: {
+    component: string;
+    output: string;
+    value: number;
+  };
+}
+
 export interface ControlObjectiveConfig {
   component: string;
   output: string;
@@ -100,8 +117,10 @@ export interface ScenarioConfig {
     ua: number;
     efficiency: number;
   }>;
-  /** Steady-state control loops (co-solved). Mirrors crates/cli config `controls`. */
+  /** System regulation loops (EXV/injection). Mirrors CLI `controls`. */
   controls?: ControlConfig[];
+  /** Modelica Z-factor embeddings (unknown + equation). Mirrors CLI `embeddings`. */
+  embeddings?: EmbeddingConfig[];
   /** Reusable subsystem templates (flattened by the CLI at load time). */
   subsystems?: Record<string, SubsystemTemplate>;
   /** Template instantiations. */
@@ -119,6 +138,13 @@ export interface ScenarioConfig {
 export const SCHEMA_VERSION = "2";
 export const CONTROL_NODE_TYPE = "SaturatedController";
 
+/**
+ * Legacy auto-calib control ids (pre-embeddings). Still purged from canvas if present.
+ */
+export function isAutoCalibrationControlId(id: string): boolean {
+  return id.startsWith("calib_") || id.startsWith("emb_");
+}
+
 export interface BuildOptions {
   fluid?: string;
   fluidBackend?: string;
@@ -333,14 +359,17 @@ export function buildScenarioConfig(
     }
   });
 
+  // Explicit Advanced-palette regulation controllers only (EXV/injection).
+  // Fixed/Free Z-factors → embeddings[] (never controls[]/SaturatedController).
   const nodeControls = nodes
-    .filter((node) => node.data.type === CONTROL_NODE_TYPE)
+    .filter(
+      (node) =>
+        node.data.type === CONTROL_NODE_TYPE &&
+        !isAutoCalibrationControlId(node.data.name),
+    )
     .map(controlNodeToConfig);
-  const fixedFreeControls = buildFixedFreeCalibrationControls(nodes, edges);
-  const controls = mergeControls(
-    mergeControls(options.controls ?? [], nodeControls),
-    fixedFreeControls,
-  );
+  const controls = mergeControls(options.controls ?? [], nodeControls);
+  const embeddings = buildModelEmbeddings(nodes, edges);
 
   return {
     schema_version: SCHEMA_VERSION,
@@ -351,6 +380,7 @@ export function buildScenarioConfig(
     ...(connections.length > 0 ? { connections } : {}),
     thermal_couplings: options.thermalCouplings || [],
     ...(controls.length > 0 ? { controls } : {}),
+    ...(embeddings.length > 0 ? { embeddings } : {}),
     solver: {
       strategy: options.solverStrategy || "newton",
       max_iterations: options.maxIterations ?? 300,
@@ -364,6 +394,9 @@ export function buildScenarioConfig(
  * - `__fixed_*` Fixed checkbox flags
  * - measure-only targets (e.g. Probe `target`) — they become control setpoints
  * - emit Modelica-style `fix_pressure` / `fix_temperature` / `fix_mass_flow`
+ * - when Z_UA is Free (calibration), omit literal `ua` override — the CLI
+ *   otherwise bakes `ua` into a fixed Calib factor and ignores live `z_ua`,
+ *   which zeros ∂measure/∂z_ua and blows up Newton (singular J → bad Picard state)
  */
 export function stripUiOnlyParams(
   type: string,
@@ -383,6 +416,13 @@ export function stripUiOnlyParams(
     if (v === "" || v === null || v === undefined) continue;
     out[k] = v;
   }
+
+  // Free z_ua → live embedding owns UA scaling; drop absolute `ua` override.
+  const zUaMeta = meta?.params.find((p) => p.key === "z_ua" && p.actuatorFactor === "z_ua");
+  if (zUaMeta && !isParamFixed(params, zUaMeta)) {
+    delete out.ua;
+  }
+
   return applyExvFixSemantics(type, applyBoundaryFixSemantics(type, out, params), params);
 }
 
@@ -466,34 +506,29 @@ export function applyBoundaryFixSemantics(
 }
 
 /**
- * Build the `controls[]` array for calibration (Probe-based model, HARD RULE):
+ * Build Modelica `embeddings[]`: Free Z-factor (unknown) + Fixed Probe (equation).
  *
- *  - Probe with Fixed `target`                → impose that measure (setpoint = value)
- *  - Param with `actuatorFactor` + Fixed OFF  → free that Z-factor
- *
- * Every freed Z-factor is paired with a semantically-compatible Probe
- * (preferring one adjacent on an edge). A freed factor with no matching
- * Probe emits nothing — the user must place a Probe to calibrate.
- *
- * Pairing matrix (factor → compatible Probe measures):
- *   z_ua    → SST, SDT, SH, DSH, SC, Capacity
+ * Pairing (free factor → Probe Fixed physical params):
+ *   z_ua    → Tsat, Tsh
  *   z_dp    → P
- *   z_flow  → MassFlow, Capacity
+ *   z_flow  → Capacity
+ *   f_w     → T
  *   z_power → Capacity
- *   z_etav  → MassFlow
+ *   z_etav  → Capacity
+ *   opening → Tsh
+ *
+ * Never emits SaturatedController / controls[].
  */
-export function buildFixedFreeCalibrationControls(
+export function buildModelEmbeddings(
   nodes: Node<EntropykNodeData>[],
   edges: Edge[] = [],
-): ControlConfig[] {
-  const controls: ControlConfig[] = [];
-
-  // ── Pass 1: collect Probe measures and per-component freed z-factors ──
+): EmbeddingConfig[] {
   type ProbeMeasure = {
     nodeName: string;
-    kind: string; // SST, SDT, DGT, DSH, SH, SC, T, P, MassFlow, Capacity, Enthalpy
+    kind: string;
+    output: string;
     target: number;
-    factorCompat: readonly string[]; // z-factors this Probe kind can pair with
+    factorCompat: readonly string[];
   };
   type FreeAct = {
     factor: string;
@@ -503,6 +538,7 @@ export function buildFixedFreeCalibrationControls(
     key: string;
   };
 
+  const embeddings: EmbeddingConfig[] = [];
   const probeMeasures: ProbeMeasure[] = [];
   const freeActsByComponent = new Map<
     string,
@@ -515,30 +551,43 @@ export function buildFixedFreeCalibrationControls(
     if (!meta) continue;
     const params = node.data.params ?? {};
 
-    // Probe node: read the `target` Fixed param + the configured `measure` kind.
     if (node.data.type === "Probe") {
-      const measureParam = meta.params.find((p) => p.key === "measure");
-      const targetParam = meta.params.find((p) => p.key === "target");
-      if (!measureParam || !targetParam) continue;
-      const kindRaw = params.measure;
-      const kind =
-        typeof kindRaw === "string" ? kindRaw : String(measureParam.default ?? "SH");
-      const targetMeta = targetParam;
-      const targetFixed = isParamFixed(params, targetParam);
-      if (!targetFixed) continue;
-      const rawTarget = params.target;
-      const n = typeof rawTarget === "number" ? rawTarget : Number(rawTarget);
+      let emitted = 0;
+      for (const p of meta.params) {
+        if (!p.fixable || !p.measureOutput) continue;
+        if (!isParamFixed(params, p)) continue;
+        const raw = params[p.key];
+        const n = typeof raw === "number" ? raw : Number(raw);
         if (!Number.isFinite(n)) continue;
+        const kind = PROBE_PARAM_KIND[p.key] ?? p.key;
+        let target = measureSetpointSi(p, n);
+        if (p.measureOutput === "pressure" && (p.unit ?? "").toLowerCase() === "bar") {
+          target = n * 1e5;
+        }
         probeMeasures.push({
           nodeName: node.data.name,
           kind,
-        target: measureSetpointSi(targetMeta, n),
+          output: p.measureOutput === "auto" ? "temperature" : p.measureOutput,
+          target,
           factorCompat: FACTOR_COMPATIBILITY[kind] ?? [],
         });
+        emitted += 1;
+      }
+      if (emitted === 0) {
+        const legacy = legacyProbeMeasure(params);
+        if (legacy) {
+          probeMeasures.push({
+            nodeName: node.data.name,
+            kind: legacy.kind,
+            output: legacy.output,
+            target: legacy.target,
+            factorCompat: FACTOR_COMPATIBILITY[legacy.kind] ?? [],
+          });
+        }
+      }
       continue;
     }
 
-    // Non-Probe node: collect freed z-factors (actuators to calibrate).
     const freeActs: FreeAct[] = [];
     for (const p of meta.params) {
       if (!p.fixable) continue;
@@ -547,7 +596,13 @@ export function buildFixedFreeCalibrationControls(
 
       if (p.actuatorFactor && !fixed) {
         const n = typeof raw === "number" ? raw : Number(raw);
-        const initial = Number.isFinite(n) ? n : 1.0;
+        let initial = Number.isFinite(n) ? n : 1.0;
+        if (
+          (p.actuatorFactor === "z_ua" || p.actuatorFactor === "z_dp") &&
+          Math.abs(initial - 1.0) < 1e-12
+        ) {
+          initial = 0.3;
+        }
         freeActs.push({
           factor: p.actuatorFactor,
           initial,
@@ -563,16 +618,12 @@ export function buildFixedFreeCalibrationControls(
     }
   }
 
-  // ── Adjacency index: for each component node, which Probe nodes share an edge ──
   const adjacentProbes = new Map<string, Set<string>>();
-  const probeNodeIds = new Set(
-    nodes.filter((n) => n.data.type === "Probe").map((n) => n.id),
-  );
+  const probeNodeIds = new Set(nodes.filter((n) => n.data.type === "Probe").map((n) => n.id));
   for (const edge of edges) {
     const endpoints = [edge.source, edge.target];
     for (const endpoint of endpoints) {
       if (!endpoint) continue;
-      // Probe directly adjacent to this endpoint
       for (const other of endpoints) {
         if (other && other !== endpoint && probeNodeIds.has(other)) {
           const probeName = nodes.find((n) => n.id === other)?.data.name;
@@ -590,19 +641,13 @@ export function buildFixedFreeCalibrationControls(
     }
   }
 
-  /**
-   * Find the best Probe to pair with a freed z-factor on `component`:
-   * 1. Must be semantically compatible (FACTOR_COMPATIBILITY).
-   * 2. Prefer Probes adjacent to the component (share an edge endpoint).
-   * 3. Fall back to any compatible Probe.
-   */
   const findProbeFor = (
     component: string,
     factor: string,
-    usedProbeNames: Set<string>,
+    usedKeys: Set<string>,
   ): ProbeMeasure | undefined => {
     const compatible = probeMeasures.filter(
-      (m) => m.factorCompat.includes(factor) && !usedProbeNames.has(m.nodeName),
+      (m) => m.factorCompat.includes(factor) && !usedKeys.has(`${m.nodeName}::${m.kind}`),
     );
     if (compatible.length === 0) return undefined;
     const adjacent = adjacentProbes.get(component);
@@ -610,50 +655,107 @@ export function buildFixedFreeCalibrationControls(
       ? compatible.find((m) => adjacent.has(m.nodeName))
       : undefined;
     const chosen = adjacentMatch ?? compatible[0];
-    usedProbeNames.add(chosen.nodeName);
+    usedKeys.add(`${chosen.nodeName}::${chosen.kind}`);
     return chosen;
   };
 
-  // ── Pass 2: emit controls ──
-  // Each freed z-factor is paired with a compatible Probe (HARD RULE). A
-  // freed actuator with no matching Probe emits nothing — the user must
-  // place a Probe to calibrate.
-  const usedProbeNames = new Set<string>();
-
+  const usedKeys = new Set<string>();
   for (const { nodeName, acts } of freeActsByComponent.values()) {
     for (const act of acts) {
-      const probe = findProbeFor(nodeName, act.factor, usedProbeNames);
+      const probe = findProbeFor(nodeName, act.factor, usedKeys);
       if (probe) {
-        controls.push({
-          type: "SaturatedController",
-          id: `calib_${nodeName}_${act.factor}`,
-          measure: {
-            component: probe.nodeName,
-            output: probeOutputFor(probe.kind),
-          },
-          actuator: {
+        embeddings.push({
+          id: `emb_${nodeName}_${act.factor}`,
+          unknown: {
             component: nodeName,
             factor: act.factor,
-            initial: act.initial,
+            start: act.initial,
             min: act.min,
             max: act.max,
           },
-          target: probe.target,
-          gain: -0.5,
-          band: 2.0,
+          equation: {
+            component: probe.nodeName,
+            output: probe.output,
+            value: probe.target,
+          },
         });
       }
     }
   }
 
-  return controls;
+  return embeddings;
 }
 
+/** @deprecated Use {@link buildModelEmbeddings}. Kept for transitional tests. */
+export function buildFixedFreeCalibrationControls(
+  nodes: Node<EntropykNodeData>[],
+  edges: Edge[] = [],
+): ControlConfig[] {
+  return buildModelEmbeddings(nodes, edges).map((emb) => ({
+    type: "SaturatedController",
+    id: emb.id,
+    measure: { component: emb.equation.component, output: emb.equation.output },
+    actuator: {
+      component: emb.unknown.component,
+      factor: emb.unknown.factor,
+      initial: emb.unknown.start,
+      min: emb.unknown.min,
+      max: emb.unknown.max,
+    },
+    target: emb.equation.value,
+    gain: -0.5,
+    band: 2.0,
+  }));
+}
+
+/** Probe param key → semantic kind for pairing. */
+const PROBE_PARAM_KIND: Record<string, string> = {
+  t_c: "T",
+  tsat_c: "Tsat",
+  p_bar: "P",
+  x: "X",
+  tsh_k: "Tsh",
+  capacity_w: "Capacity",
+};
+
 /**
- * Maps a Probe `measure` kind to the solver-side `ComponentOutput` string
- * accepted by the CLI (`parse_component_output` in run.rs).
+ * Legacy Probe shape: `{ measure: "SST", target: 5.9, __fixed_target: true }`.
+ * Absolute temperatures that look like °C (< 200) are converted to K.
  */
-function probeOutputFor(kind: string): string {
+function legacyProbeMeasure(params: Record<string, unknown>): {
+  kind: string;
+  output: string;
+  target: number;
+} | null {
+  const fixedFlag = params.__fixed_target;
+  // defaultFixed was false for legacy target — require explicit Fixed ON
+  if (fixedFlag !== true && fixedFlag !== "true") return null;
+  const kindRaw = params.measure;
+  const kind = typeof kindRaw === "string" ? kindRaw : "";
+  if (!kind) return null;
+  const raw = params.target;
+  const n = typeof raw === "number" ? raw : Number(raw);
+  if (!Number.isFinite(n)) return null;
+
+  const output = legacyProbeOutput(kind);
+  let target = n;
+  // SST/SDT/T/DGT: UI historically stored °C in `target` without a unit.
+  if (
+    output === "saturationTemperature" ||
+    output === "temperature"
+  ) {
+    if (n > -100 && n < 200) {
+      target = n + 273.15;
+    }
+  }
+  // Pressure: bar → Pa when value looks like bar
+  if (output === "pressure" && n > 0 && n < 200) {
+    target = n * 1e5;
+  }
+  return { kind, output, target };
+}
+
+function legacyProbeOutput(kind: string): string {
   switch (kind) {
     case "SST":
     case "SDT":
@@ -672,28 +774,27 @@ function probeOutputFor(kind: string): string {
       return "massFlowRate";
     case "Capacity":
       return "capacity";
-    case "Enthalpy":
-      // No dedicated Enthalpy ComponentOutput; carry it on heatTransferRate.
-      return "heatTransferRate";
     default:
       return "temperature";
   }
 }
 
-/** Probe `measure` kind → list of z-factors it can calibrate (pairing matrix). */
+/** Probe physical kind → free factors it can calibrate. */
 const FACTOR_COMPATIBILITY: Record<string, readonly string[]> = {
+  Tsat: ["z_ua"],
+  Tsh: ["z_ua", "opening"],
+  T: ["f_w"],
+  P: ["z_dp"],
+  Capacity: ["z_flow", "z_power", "z_etav"],
+  X: [],
+  // Legacy kind names (older modules / tests)
   SST: ["z_ua"],
   SDT: ["z_ua"],
-  SH: ["z_ua"],
-  DSH: ["z_ua"],
+  SH: ["z_ua", "opening"],
   SC: ["z_ua"],
-  Capacity: ["z_ua", "z_flow", "z_power"],
-  P: ["z_dp"],
+  DGT: ["f_w"],
+  DSH: ["f_w"],
   MassFlow: ["z_flow", "z_etav"],
-  // Kinds not used for z-factor calibration (raw T, Enthalpy) — no compat.
-  DGT: [],
-  T: [],
-  Enthalpy: [],
 };
 
 /** Convert UI measure value to SI expected by the solver (temps → K). */
@@ -864,9 +965,32 @@ export function validateConfig(nodes: Node<EntropykNodeData>[], edges: Edge[]):
     }
   }
 
-  // Modelica boundary conflicts are reported in the DoF ledger; emit-time
-  // `enforceModelicaBoundaryEmit` auto-corrects legalizable cases (Free P on
-  // MassFlowSource, Free ṁ when Fixed T_out). Hard-block only if emit cannot help.
+  // Modelica balanced model: parameter(fixed=false) is an unknown → needs an
+  // equation. Fixed Probe value supplies that equation. Free without equation
+  // was silently ignored (still a constant) — reject it.
+  const balancedUnknowns = new Set(
+    buildModelEmbeddings(nodes, edges).map(
+      (e) => `${e.unknown.component}::${e.unknown.factor}`,
+    ),
+  );
+  for (const n of nodes) {
+    if (n.data.type === CONTROL_NODE_TYPE) continue;
+    const meta = COMPONENT_BY_TYPE[n.data.type];
+    if (!meta) continue;
+    const params = n.data.params ?? {};
+    for (const p of meta.params) {
+      if (!p.actuatorFactor || !p.fixable) continue;
+      if (isParamFixed(params, p)) continue;
+      const key = `${n.data.name}::${p.actuatorFactor}`;
+      if (!balancedUnknowns.has(key)) {
+        issues.push(
+          `${n.data.name}: ${p.label} is Free (unknown) without an equation — ` +
+            `Modelica: parameter(fixed=false) needs a Fixed Probe value on the line, ` +
+            `or leave ${p.label} Fixed.`,
+        );
+      }
+    }
+  }
 
   return issues;
 }

apps/web/src/lib/useScenarioSimulation.ts

@@ -29,13 +29,19 @@ export function useScenarioSimulation() {
   const setLastConfig = useDiagramStore((s) => s.setLastConfig);
   const setResult = useDiagramStore((s) => s.setResult);
   const setSimulating = useDiagramStore((s) => s.setSimulating);
+  const purgeAutoCalibrationControlNodes = useDiagramStore(
+    (s) => s.purgeAutoCalibrationControlNodes,
+  );
   const simulating = useDiagramStore((s) => s.simulating);
 
   const [issues, setIssues] = useState<string[]>([]);
 
   const run = useCallback(async () => {
-    const problems = validateConfig(nodes, edges);
-    const ledger = computeDofLedger(nodes as Node<EntropykNodeData>[], edges);
+    // Fixed/Free calib must never leave SaturatedController blocks on the canvas.
+    purgeAutoCalibrationControlNodes();
+    const { nodes: liveNodes, edges: liveEdges } = useDiagramStore.getState();
+    const problems = validateConfig(liveNodes, liveEdges);
+    const ledger = computeDofLedger(liveNodes as Node<EntropykNodeData>[], liveEdges);
     if (ledger.balance === "over-constrained") {
       problems.push(
         `DoF over-constrained: ${ledger.nEquations} equations > ${ledger.nUnknowns} unknowns. ` +
@@ -45,7 +51,7 @@ export function useScenarioSimulation() {
     setIssues(problems);
     if (problems.length > 0) return false;
 
-    const scenarioConfig = buildScenarioConfig(nodes, edges, {
+    const scenarioConfig = buildScenarioConfig(liveNodes, liveEdges, {
       fluid,
       fluidBackend,
       solverStrategy,
@@ -85,6 +91,7 @@ export function useScenarioSimulation() {
     solverStrategy,
     maxIterations,
     tolerance,
+    purgeAutoCalibrationControlNodes,
     setLastConfig,
     setResult,
     setSimulating,

apps/web/src/store/diagramStore.test.ts

@@ -25,6 +25,88 @@ function reset() {
 beforeEach(reset);
 
 describe("controls import", () => {
+  it("does not materialise Fixed/Free calib_* as canvas SaturatedController nodes", () => {
+    useDiagramStore.getState().loadFromConfig({
+      fluid: "R134a",
+      circuits: [
+        {
+          id: 0,
+          components: [
+            { type: "BphxEvaporator", name: "evap", z_ua: 1 },
+            { type: "Probe", name: "SST probe", tsat_c: 4.4 },
+          ],
+          edges: [{ from: "evap:outlet", to: "SST probe:inlet" }],
+        },
+      ],
+      controls: [
+        {
+          type: "SaturatedController",
+          id: "calib_evap_z_ua",
+          measure: { component: "SST probe", output: "saturationTemperature" },
+          actuator: { component: "evap", factor: "z_ua", initial: 1, min: 0.1, max: 3 },
+          target: 277.55,
+        },
+        {
+          type: "SaturatedController",
+          id: "dgt_limiter",
+          measure: { component: "evap", output: "temperature" },
+          actuator: { component: "evap", factor: "injection", initial: 0.1, min: 0, max: 0.3 },
+          target: 300,
+        },
+      ],
+    });
+
+    const st = useDiagramStore.getState();
+    expect(st.nodes.map((n) => n.data.name)).not.toContain("calib_evap_z_ua");
+    expect(st.nodes.map((n) => n.data.name)).toContain("dgt_limiter");
+    expect(st.controls.map((c) => c.id)).toEqual(["dgt_limiter"]);
+  });
+
+  it("purgeAutoCalibrationControlNodes removes leftover calib_* canvas blocks", () => {
+    useDiagramStore.getState().loadFromConfig({
+      fluid: "R134a",
+      circuits: [
+        {
+          id: 0,
+          components: [{ type: "BphxEvaporator", name: "evap" }],
+          edges: [],
+        },
+      ],
+      controls: [
+        {
+          id: "calib_evap_z_ua",
+          measure: { component: "evap", output: "saturationTemperature" },
+          actuator: { component: "evap", factor: "z_ua", min: 0.1, max: 3 },
+          target: 277.55,
+        },
+      ],
+    });
+    // Simulate a stale canvas block from an older import path.
+    useDiagramStore.setState((s) => ({
+      nodes: [
+        ...s.nodes,
+        {
+          id: "stale-calib",
+          type: "entropykNode",
+          position: { x: 0, y: 0 },
+          data: {
+            type: "SaturatedController",
+            name: "calib_evap_z_ua",
+            circuit: 0,
+            rotation: 0,
+            flipH: false,
+            flipV: false,
+            params: {},
+          },
+        },
+      ],
+    }));
+    useDiagramStore.getState().purgeAutoCalibrationControlNodes();
+    expect(useDiagramStore.getState().nodes.map((n) => n.data.name)).not.toContain(
+      "calib_evap_z_ua",
+    );
+  });
+
   it("preserves imported co-solved controls for the next simulation run", () => {
     useDiagramStore.getState().loadFromConfig({
       fluid: "R134a",

apps/web/src/store/diagramStore.ts

@@ -5,7 +5,11 @@ import type { Edge, Node, OnNodesChange, OnEdgesChange, OnConnect } from "@xyflo
 import { applyNodeChanges, applyEdgeChanges, addEdge } from "@xyflow/react";
 import { hydrateBoundaryFixFlags } from "@/lib/boundaryFix";
 import { defaultParams } from "@/lib/componentMeta";
-import { CONTROL_NODE_TYPE, canonicalizeParams } from "@/lib/configBuilder";
+import {
+  CONTROL_NODE_TYPE,
+  canonicalizeParams,
+  isAutoCalibrationControlId,
+} from "@/lib/configBuilder";
 import type { ControlConfig } from "@/lib/configBuilder";
 import type { SimulationResult } from "@/lib/api";
 import {
@@ -147,6 +151,8 @@ interface DiagramState {
   setResult: (result: SimulationResult | null, error?: string | null) => void;
   setSimulating: (v: boolean) => void;
   loadFromConfig: (config: unknown) => void;
+  /** Remove leftover canvas nodes from Fixed/Free auto-calib (not real controllers). */
+  purgeAutoCalibrationControlNodes: () => void;
   clear: () => void;
   undo: () => void;
   redo: () => void;
@@ -736,7 +742,12 @@ export const useDiagramStore = create<DiagramState>((set, get) => ({
       x += 280;
     }
 
-    for (const [index, control] of (cfg.controls ?? []).entries()) {
+    // Explicit Advanced controllers only. Fixed/Free calib (`calib_*`) is a
+    // solver DoF swap regenerated from Probe/component Fixed flags — never a
+    // canvas SaturatedController block.
+    let explicitControlIndex = 0;
+    for (const control of cfg.controls ?? []) {
+      if (isAutoCalibrationControlId(control.id)) continue;
       const measuredNode = nodes.find((node) => node.data.name === control.measure.component);
       const id = crypto.randomUUID();
       nodes.push({
@@ -744,7 +755,7 @@ export const useDiagramStore = create<DiagramState>((set, get) => ({
         type: "entropykNode",
         position: measuredNode
           ? { x: measuredNode.position.x + 140, y: Math.max(40, measuredNode.position.y - 72) }
-          : { x: 100 + index * 150, y: 40 },
+          : { x: 100 + explicitControlIndex * 150, y: 40 },
         data: {
           type: CONTROL_NODE_TYPE,
           name: control.id,
@@ -755,6 +766,7 @@ export const useDiagramStore = create<DiagramState>((set, get) => ({
           params: controlParams(control),
         },
       });
+      explicitControlIndex += 1;
     }
 
     const edges: Edge[] = [];
@@ -785,7 +797,7 @@ export const useDiagramStore = create<DiagramState>((set, get) => ({
       solverStrategy: cfg.solver?.strategy || "newton",
       maxIterations: cfg.solver?.max_iterations ?? 300,
       tolerance: cfg.solver?.tolerance ?? 1e-6,
-      controls: cfg.controls ?? [],
+      controls: (cfg.controls ?? []).filter((c) => !isAutoCalibrationControlId(c.id)),
       result: null,
       lastConfig: cfg,
       simError: null,
@@ -794,6 +806,28 @@ export const useDiagramStore = create<DiagramState>((set, get) => ({
     get().recordHistory();
   },
 
+  purgeAutoCalibrationControlNodes: () => {
+    const { nodes, edges, selectedNodeId } = get();
+    const removeIds = new Set(
+      nodes
+        .filter(
+          (n) =>
+            n.data.type === CONTROL_NODE_TYPE &&
+            isAutoCalibrationControlId(n.data.name),
+        )
+        .map((n) => n.id),
+    );
+    if (removeIds.size === 0) return;
+    set({
+      nodes: nodes.filter((n) => !removeIds.has(n.id)),
+      edges: edges.filter((e) => !removeIds.has(e.source) && !removeIds.has(e.target)),
+      selectedNodeId:
+        selectedNodeId && removeIds.has(selectedNodeId) ? null : selectedNodeId,
+      controls: get().controls.filter((c) => !isAutoCalibrationControlId(c.id)),
+    });
+    get().recordHistory();
+  },
+
   clear: () => {
     const empty = { nodes: [], edges: [], selectedNodeId: null };
     set({

crates/cli/src/config.rs

@@ -17,8 +17,8 @@ use crate::error::{CliError, CliResult};
 pub const CURRENT_SCHEMA_VERSION: &str = "2";
 
 /// Schema versions this build can load. `"1"` is the original flat
-/// `circuits/components/edges` schema; `"2"` adds `controls`, `subsystems`,
-/// `instances` and `connections`. Both are read by the same loader.
+/// `circuits/components/edges` schema; `"2"` adds `controls`, `embeddings`,
+/// `subsystems`, `instances` and `connections`. Both are read by the same loader.
 pub const SUPPORTED_SCHEMA_VERSIONS: &[&str] = &["1", "2"];
 
 fn default_schema_version() -> String {
@@ -30,7 +30,7 @@ fn default_schema_version() -> String {
 #[derive(Debug, Clone, Serialize, Deserialize, JsonSchema)]
 pub struct ScenarioConfig {
     /// Model IR schema version (`"1"` legacy flat graph, `"2"` adds
-    /// controls/subsystems/instances/connections). Absent ⇒ `"1"`.
+    /// controls/embeddings/subsystems/instances/connections). Absent ⇒ `"1"`.
     #[serde(default = "default_schema_version")]
     pub schema_version: String,
     /// Scenario name.
@@ -54,9 +54,15 @@ pub struct ScenarioConfig {
     /// hints only; they do not impose thermodynamic boundary conditions.
     #[serde(default)]
     pub initialization: Option<InitializationConfig>,
-    /// Steady-state control loops (co-solved saturated-PI controllers).
+    /// Steady-state **system regulation** loops (co-solved saturated-PI).
+    /// For EXV opening, injection, fan speed, etc. — **not** Z-factor calibration.
+    /// Z-factors use [`Self::embeddings`] (Modelica parameter(fixed=false) + equation).
     #[serde(default)]
     pub controls: Vec<ControlConfig>,
+    /// Modelica-style Z-factor embeddings: one free unknown + one equation
+    /// (`output = value`). Distinct from [`Self::controls`] (no SaturatedController).
+    #[serde(default)]
+    pub embeddings: Vec<EmbeddingConfig>,
     /// Reusable subsystem templates (parameterized assemblies of components +
     /// internal edges, exposing a reduced external port set). Flattened into
     /// `circuits` at load time — the solver never sees the hierarchy.
@@ -146,12 +152,56 @@ pub struct InstanceConfig {
     pub params: HashMap<String, serde_json::Value>,
 }
 
-/// A steady-state control loop declaration.
+/// Modelica-style Z-factor embedding: free unknown + binding equation.
 ///
-/// Currently supports the `SaturatedController` type: a saturated-PI loop with
-/// anti-windup that is co-solved inside the Newton system. It drives a measured
-/// plant output (`measure`) to `target` by manipulating an actuator factor
-/// (`actuator`) within `[min, max]` bounds.
+/// Equivalent to:
+/// ```text
+/// parameter Real z(fixed = false, start = …);
+/// equation
+///   component.output = value;
+/// ```
+/// Registered as plain `Constraint` + `BoundedVariable` — never a SaturatedController.
+#[derive(Debug, Clone, Serialize, Deserialize, JsonSchema)]
+pub struct EmbeddingConfig {
+    /// Unique id (also used as the constraint id).
+    pub id: String,
+    /// Free Z-factor unknown on a component.
+    pub unknown: EmbeddingUnknownConfig,
+    /// Binding equation: `component.output = value`.
+    pub equation: EmbeddingEquationConfig,
+}
+
+/// Free Z-factor unknown (`parameter ...(fixed=false)`).
+#[derive(Debug, Clone, Serialize, Deserialize, JsonSchema)]
+pub struct EmbeddingUnknownConfig {
+    /// Component owning the Z-factor.
+    pub component: String,
+    /// Factor name: `z_ua`, `z_dp`, `z_flow`, `z_power`, `z_etav`, `f_w`, …
+    pub factor: String,
+    /// Start / guess value.
+    #[serde(default = "default_actuator_initial")]
+    pub start: f64,
+    /// Lower bound.
+    pub min: f64,
+    /// Upper bound.
+    pub max: f64,
+}
+
+/// Binding equation residual: `component.output − value = 0`.
+#[derive(Debug, Clone, Serialize, Deserialize, JsonSchema)]
+pub struct EmbeddingEquationConfig {
+    /// Component providing the measured output (typically a Probe).
+    pub component: String,
+    /// Output kind: `saturationTemperature`, `temperature`, `pressure`, …
+    pub output: String,
+    /// Right-hand side value (SI).
+    pub value: f64,
+}
+
+/// A steady-state **system regulation** loop (EXV, injection, fan, …).
+///
+/// Supports `SaturatedController`: saturated-PI with anti-windup, co-solved
+/// inside Newton. **Not** for Z-factor calibration — use [`EmbeddingConfig`].
 #[derive(Debug, Clone, Serialize, Deserialize, JsonSchema)]
 pub struct ControlConfig {
     /// Controller type. Only `"SaturatedController"` is supported today.
@@ -217,13 +267,13 @@ pub struct MeasureConfig {
     pub output: String,
 }
 
-/// Reference to a manipulated actuator on a component.
+/// Reference to a manipulated **physical** actuator on a component.
 #[derive(Debug, Clone, Serialize, Deserialize, JsonSchema)]
 pub struct ActuatorConfig {
     /// Name of the component carrying the actuator.
     pub component: String,
-    /// Calibration Z-factor to manipulate: `z_flow`, `z_dp`, `z_ua`, `z_power`, or `z_etav`
-    /// (legacy `f_*` names and BOLT `Z_*` spellings are also accepted).
+    /// Physical actuator factor for regulation: `opening`, `injection`, …
+    /// Z-factors (`z_ua`, …) must use [`EmbeddingConfig`], not controls.
     pub factor: String,
     /// Initial actuator value (nominal, e.g. 1.0).
     #[serde(default = "default_actuator_initial")]
@@ -1343,11 +1393,12 @@ mod tests {
     fn test_json_schema_emits_ir_fields() {
         let schema = ScenarioConfig::json_schema();
         // The emitted schema must be the single source of truth covering every IR
-        // pillar: circuits (v1) + controls/subsystems/instances/connections (v2).
+        // pillar: circuits (v1) + controls/embeddings/subsystems/instances/connections (v2).
         for field in [
             "schema_version",
             "circuits",
             "controls",
+            "embeddings",
             "subsystems",
             "instances",
             "connections",
@@ -1361,4 +1412,23 @@ mod tests {
         let parsed: serde_json::Value = serde_json::from_str(&schema).unwrap();
         assert!(parsed.get("$schema").is_some());
     }
+
+    #[test]
+    fn test_parse_embeddings() {
+        let json = r#"{
+            "schema_version": "2",
+            "fluid": "R134a",
+            "embeddings": [{
+                "id": "emb_evap_z_ua",
+                "unknown": { "component": "evap", "factor": "z_ua", "start": 0.3, "min": 0.05, "max": 3.0 },
+                "equation": { "component": "SST probe", "output": "saturationTemperature", "value": 278.15 }
+            }]
+        }"#;
+        let config = ScenarioConfig::from_json(json).unwrap();
+        assert_eq!(config.embeddings.len(), 1);
+        assert_eq!(config.embeddings[0].id, "emb_evap_z_ua");
+        assert_eq!(config.embeddings[0].unknown.factor, "z_ua");
+        assert!((config.embeddings[0].equation.value - 278.15).abs() < 1e-9);
+        assert!(config.controls.is_empty());
+    }
 }

crates/cli/src/run.rs

@@ -414,6 +414,33 @@ fn execute_simulation(
         }
     };
 
+    // Fail fast: Z-factors belong in embeddings[], never controls[].
+    for control in &config.controls {
+        let factor = control.actuator.factor.trim();
+        if entropyk_core::normalize_factor_name(factor).is_some() {
+            return SimulationResult {
+                input: input_name.to_string(),
+                status: SimulationStatus::Error,
+                convergence: None,
+                iterations: None,
+                state: None,
+                performance: None,
+                error: Some(format!(
+                    "control '{}': factor '{}' is a Z-factor — use embeddings[] \
+                     (Modelica parameter/equation), not controls[]/SaturatedController. \
+                     controls[] is for physical regulation (opening, injection, …).",
+                    control.id, factor
+                )),
+                failure_diagnostics: None,
+                initialization_diagnostics: None,
+                dof: None,
+                elapsed_ms,
+                raw_state_vector: None,
+                solved_variables: Vec::new(),
+            };
+        }
+    }
+
     let mut system = System::new();
 
     // Track component name -> (node index, component type) mapping per circuit
@@ -619,6 +646,27 @@ fn execute_simulation(
             }
         }
 
+        // Free z_ua embedding: drop absolute `ua` overrides on the unknown's
+        // component. Otherwise `ua` freezes Calib and ∂Q/∂z_ua → 0 (singular J).
+        for emb in &config.embeddings {
+            if entropyk_core::normalize_factor_name(emb.unknown.factor.trim())
+                == Some(entropyk_core::Z_UA)
+            {
+                if let Some(comp) = expanded_components
+                    .iter_mut()
+                    .find(|c| c.name == emb.unknown.component)
+                {
+                    if comp.params.remove("ua").is_some() {
+                        tracing::info!(
+                            component = %comp.name,
+                            embedding = %emb.id,
+                            "Dropped 'ua' override — z_ua embedding owns UA scaling"
+                        );
+                    }
+                }
+            }
+        }
+
         // Fixed EXV orifice opening sets ṁ via the valve — skip compressor
         // displacement ṁ closure so DoF stays square (ṁ follows the valve).
         let meter_mass_flow_via_exv = expanded_components.iter().any(|c| {
@@ -1050,13 +1098,12 @@ fn execute_simulation(
         }
     }
 
-    // Register declared control loops (saturated-PI, co-solved). Must happen
-    // BEFORE finalize() so the actuator is wired to the component's CalibIndices.
+    // Register model embeddings (Z-factor unknowns + equations) and system
+    // regulation controls. Must happen BEFORE finalize() so unknowns wire to
+    // CalibIndices.
     //
-    // Routing (calibration redesign): controls whose actuator is a z-factor
-    // (z_flow/z_flow_eco/z_dp/z_ua/z_power/z_etav) go through PLAIN inverse
-    // embedding (+1 residual measured−target, +1 unknown z) — not the
-    // SaturatedController (2+2 with integrator, meant for physical actuators).
+    // - embeddings[] → plain Constraint + BoundedVariable (Modelica fixed=false)
+    // - controls[]   → SaturatedController only (EXV/injection/…); z-factors forbidden
     let control_error = |msg: String| SimulationResult {
         input: input_name.to_string(),
         status: SimulationStatus::Error,
@@ -1072,83 +1119,51 @@ fn execute_simulation(
         raw_state_vector: None,
         solved_variables: Vec::new(),
     };
-    for control in &config.controls {
-        let factor = control.actuator.factor.trim();
-        // Plain embedding applies to single-point z-factor calibration only.
-        // A control WITH `objectives` is a supervisory override network
-        // (selector semantics) and always keeps the SaturatedController path,
-        // regardless of the actuator factor.
-        if entropyk_core::normalize_factor_name(factor).is_some() && control.objectives.is_empty() {
-            match build_plain_z_embedding(control, factor) {
-                Ok((constraint, bounded_var, actuator_id)) => {
+
+    for emb in &config.embeddings {
+        match build_model_embedding(emb) {
+            Ok((constraint, bounded_var, unknown_id)) => {
                 if let Err(e) = system.add_constraint(constraint) {
                     return control_error(format!(
-                            "Failed to add constraint for control '{}': {:?}",
-                            control.id, e
+                        "Failed to add equation for embedding '{}': {:?}",
+                        emb.id, e
                     ));
                 }
                 if let Err(e) = system.add_bounded_variable(bounded_var) {
                     return control_error(format!(
-                            "Failed to add actuator for control '{}': {:?}",
-                            control.id, e
+                        "Failed to add unknown for embedding '{}': {:?}",
+                        emb.id, e
                     ));
                 }
                 if let Err(e) = system.link_constraint_to_control(
-                        &entropyk_solver::inverse::ConstraintId::new(control.id.clone()),
-                        &actuator_id,
+                    &entropyk_solver::inverse::ConstraintId::new(emb.id.clone()),
+                    &unknown_id,
                 ) {
                     return control_error(format!(
-                            "Failed to link control '{}': {:?}",
-                            control.id, e
+                        "Failed to link embedding '{}': {:?}",
+                        emb.id, e
                     ));
                 }
             }
             Err(msg) => {
-                    return control_error(format!("Invalid control '{}': {}", control.id, msg));
+                return control_error(format!("Invalid embedding '{}': {}", emb.id, msg));
             }
         }
-            continue;
     }
+
+    for control in &config.controls {
         match build_saturated_control(control) {
             Ok((bounded_var, controller)) => {
                 if let Err(e) = system.add_bounded_variable(bounded_var) {
-                    return SimulationResult {
-                        input: input_name.to_string(),
-                        status: SimulationStatus::Error,
-                        convergence: None,
-                        iterations: None,
-                        state: None,
-                        performance: None,
-                        error: Some(format!(
+                    return control_error(format!(
                         "Failed to add actuator for control '{}': {:?}",
                         control.id, e
-                        )),
-                        failure_diagnostics: None,
-                        initialization_diagnostics: None,
-                        dof: None,
-                        elapsed_ms,
-                        raw_state_vector: None,
-                        solved_variables: Vec::new(),
-                    };
+                    ));
                 }
                 system.add_saturated_controller(controller);
             }
             Err(msg) => {
-                return SimulationResult {
-                    input: input_name.to_string(),
-                    status: SimulationStatus::Error,
-                    convergence: None,
-                    iterations: None,
-                    state: None,
-                    performance: None,
-                    error: Some(format!("Invalid control '{}': {}", control.id, msg)),
-                    failure_diagnostics: None,
-                    initialization_diagnostics: None,
-                    dof: None,
-                    elapsed_ms,
-                    raw_state_vector: None,
-                    solved_variables: Vec::new(),
-                };
+                return control_error(format!("Invalid control '{}': {}", control.id, msg));
             }
         }
     }
@@ -1498,10 +1513,20 @@ fn execute_simulation(
         state
     };
 
-    // Seed control-actuator slots at their nominal value (the physical seed only
-    // fills edge/component states, leaving control unknowns at 0.0 which is a poor
-    // start for e.g. an f_m mass-flow factor whose nominal is 1.0).
+    // Seed embedding / control unknowns at their start/initial (physical seed
+    // leaves them at 0.0 — a poor start for Z-factors whose nominal is ~0.3–1).
     let mut initial_state = initial_state;
+    for emb in &config.embeddings {
+        let unknown_id = entropyk_solver::inverse::BoundedVariableId::new(saturated_actuator_id(
+            &emb.unknown.component,
+            &emb.unknown.factor,
+        ));
+        if let Some(u_idx) = system.control_variable_state_index(&unknown_id) {
+            if u_idx < initial_state.len() {
+                initial_state[u_idx] = emb.unknown.start;
+            }
+        }
+    }
     for control in &config.controls {
         let actuator_id = entropyk_solver::inverse::BoundedVariableId::new(saturated_actuator_id(
             &control.actuator.component,
@@ -1571,6 +1596,7 @@ fn execute_simulation(
     let solve_time_budget = (config.solver.timeout_ms > 0)
         .then(|| std::time::Duration::from_millis(config.solver.timeout_ms));
     let needs_guarded_newton = !config.controls.is_empty()
+        || !config.embeddings.is_empty()
         || config.circuits.iter().any(|c| {
             c.enabled
                 && c.components.iter().any(|comp| {
@@ -3085,14 +3111,18 @@ fn bphx_calib_from_params(
         .or_else(|| params.get("f_ua"))
         .and_then(|v| v.as_f64());
 
+    // Precedence (DoF-safe): live `z_ua` wins over absolute `ua`.
+    // Baking `ua` into a frozen Calib factor while an embedding frees `z_ua`
+    // zeros ∂Q/∂z_ua → singular Jacobian. Modelica-style: modifier owns the unknown.
     if config_ua.is_some() && explicit_z_ua.is_some() {
         tracing::warn!(
-            "BphxExchanger: both 'ua' and 'z_ua' provided — 'ua' takes precedence, 'z_ua' ignored"
+            "BphxExchanger: both 'ua' and 'z_ua' provided — 'z_ua' takes precedence, 'ua' ignored"
         );
     }
 
-    let z_ua = match config_ua {
-        Some(u) => {
+    let z_ua = if let Some(z) = explicit_z_ua {
+        z
+    } else if let Some(u) = config_ua {
         if u < 0.0 {
             return Err(CliError::Config(format!(
                 "BphxExchanger: ua must be >= 0 (got {:.2} W/K)",
@@ -3106,8 +3136,8 @@ fn bphx_calib_from_params(
                 "BphxExchanger: ua_nominal is zero — cannot compute z_ua from explicit 'ua' override. Check geometry parameters.".into(),
             ));
         }
-        }
-        None => explicit_z_ua.unwrap_or(1.0),
+    } else {
+        1.0
     };
 
     if z_ua <= 0.0 {
@@ -3137,6 +3167,7 @@ fn bphx_calib_from_params(
         z_ua,
         z_power: 1.0,
         z_etav: 1.0,
+        f_w: 1.0,
         calibration_source: None,
     })
 }
@@ -3229,15 +3260,11 @@ fn parse_component_output(
     Ok(out)
 }
 
-/// Builds a bounded actuator + saturated controller from a control config.
-/// Plain inverse embedding for z-factor calibration controls (calibration
-/// redesign, WS-2): one `Constraint` (measured − target) + one `BoundedVariable`
-/// (the z-factor), linked 1:1. The bounded var id reuses the
-/// `{component}__{z_factor}` convention so `finalize()` wires it to the
-/// component's matching `CalibIndices` slot (system.rs).
-fn build_plain_z_embedding(
-    control: &crate::config::ControlConfig,
-    factor: &str,
+/// Modelica Z-factor embedding: one `Constraint` (output − value) + one
+/// `BoundedVariable` (the free Z-factor). Bounded var id uses
+/// `{component}__{factor}` so `finalize()` wires `CalibIndices`.
+fn build_model_embedding(
+    emb: &crate::config::EmbeddingConfig,
 ) -> Result<
     (
         entropyk_solver::inverse::Constraint,
@@ -3248,23 +3275,29 @@ fn build_plain_z_embedding(
 > {
     use entropyk_solver::inverse::{BoundedVariable, BoundedVariableId, Constraint, ConstraintId};
 
-    let output = parse_component_output(&control.measure.component, &control.measure.output)?;
-    let actuator_id =
-        BoundedVariableId::new(saturated_actuator_id(&control.actuator.component, factor));
+    let factor = emb.unknown.factor.trim();
+    if entropyk_core::normalize_factor_name(factor).is_none() {
+        return Err(format!(
+            "unknown Z-factor '{factor}' (expected z_ua, z_dp, z_flow, z_power, z_etav, f_w, …)"
+        ));
+    }
+    let output = parse_component_output(&emb.equation.component, &emb.equation.output)?;
+    let unknown_id =
+        BoundedVariableId::new(saturated_actuator_id(&emb.unknown.component, factor));
     let bounded_var = BoundedVariable::with_component(
-        actuator_id.clone(),
-        &control.actuator.component,
-        control.actuator.initial,
-        control.actuator.min,
-        control.actuator.max,
+        unknown_id.clone(),
+        &emb.unknown.component,
+        emb.unknown.start,
+        emb.unknown.min,
+        emb.unknown.max,
     )
-    .map_err(|e| format!("invalid actuator bounds: {e:?}"))?;
+    .map_err(|e| format!("invalid unknown bounds: {e:?}"))?;
     let constraint = Constraint::new(
-        ConstraintId::new(control.id.clone()),
+        ConstraintId::new(emb.id.clone()),
         output,
-        control.target,
+        emb.equation.value,
     );
-    Ok((constraint, bounded_var, actuator_id))
+    Ok((constraint, bounded_var, unknown_id))
 }
 
 fn build_saturated_control(
@@ -3288,13 +3321,14 @@ fn build_saturated_control(
     }
 
     let factor = control.actuator.factor.trim();
-    if entropyk_core::normalize_factor_name(factor).is_none()
-        && factor != "injection"
-        && factor != "opening"
-    {
+    if entropyk_core::normalize_factor_name(factor).is_some() {
         return Err(format!(
-            "unknown actuator factor '{factor}' (expected z_flow, z_dp, z_ua, z_power, z_etav, \
-             injection, opening — legacy f_* and BOLT Z_* names accepted)"
+            "factor '{factor}' is a Z-factor — use embeddings[], not SaturatedController"
+        ));
+    }
+    if factor != "injection" && factor != "opening" {
+        return Err(format!(
+            "unknown regulation actuator '{factor}' (expected opening, injection)"
         ));
     }
 
@@ -4060,6 +4094,18 @@ fn create_component(
                 .with_refrigerant(&refrigerant)
                 .with_fluid_backend(Arc::clone(&backend));
 
+            // Energy-retention factor f_w: fraction of shaft work kept in the
+            // refrigerant. h_dis = h_suc + f_w·Δh_is/η_is.
+            // Default 1 = adiabatic; 0.98 ≈ 2% shell loss; 0 = all lost.
+            if let Some(f_w) = params.get("f_w").and_then(|v| v.as_f64()).or_else(|| {
+                params
+                    .get("fw")
+                    .and_then(|v| v.as_f64())
+                    .or_else(|| params.get("f_q").and_then(|v| v.as_f64()))
+            }) {
+                comp = comp.with_f_w(f_w);
+            }
+
             // Emergent-pressure mode: the compressor no longer pins the discharge
             // pressure to P_sat(t_cond_k). Normally ṁ is closed by the volumetric
             // displacement model. When a sibling EXV uses a *fixed* orifice opening,

crates/cli/tests/calibration_sdt.rs

@@ -150,22 +150,21 @@ fn bphx_condenser_sdt_calibration_converges_and_solves_z_ua() {
     "tolerance": 1e-06,
     "timeout_ms": 60000
   },
-  "controls": [
+  "embeddings": [
     {
-      "type": "SaturatedController",
-      "id": "sdt_calib",
-      "measure": {
-        "component": "cond",
-        "output": "saturationTemperature"
-      },
-      "actuator": {
+      "id": "emb_cond_z_ua",
+      "unknown": {
         "component": "cond",
         "factor": "z_ua",
-        "initial": 0.3,
+        "start": 0.3,
         "min": 0.05,
         "max": 2.0
       },
-      "target": 315.0
+      "equation": {
+        "component": "cond",
+        "output": "saturationTemperature",
+        "value": 315.0
+      }
     }
   ]
 }

crates/cli/tests/embeddings_reject_control_z.rs

@@ -0,0 +1,40 @@
+//! Z-factors must use embeddings[], not controls[]/SaturatedController.
+
+use entropyk_cli::run::{run_simulation, SimulationStatus};
+use tempfile::tempdir;
+
+#[test]
+fn controls_with_z_ua_are_rejected() {
+    // Minimal config — reject happens before component graph build.
+    let json = r#"
+{
+  "fluid": "R134a",
+  "fluid_backend": "Test",
+  "circuits": [],
+  "controls": [
+    {
+      "type": "SaturatedController",
+      "id": "bad_calib",
+      "measure": { "component": "sst", "output": "saturationTemperature" },
+      "actuator": { "component": "evap", "factor": "z_ua", "initial": 1, "min": 0.05, "max": 3 },
+      "target": 278.15
+    }
+  ],
+  "solver": { "strategy": "newton", "max_iterations": 10, "tolerance": 1e-6 }
+}
+"#;
+    let dir = tempdir().unwrap();
+    let path = dir.path().join("bad.json");
+    std::fs::write(&path, json).unwrap();
+    let result = run_simulation(&path, None, false).unwrap();
+    assert!(
+        matches!(result.status, SimulationStatus::Error),
+        "expected Error, got {:?}",
+        result.status
+    );
+    let err = result.error.unwrap_or_default();
+    assert!(
+        err.contains("embeddings") && err.contains("z_ua"),
+        "error should point to embeddings[], got: {err}"
+    );
+}

crates/cli/tests/probe_calibration.rs

@@ -1,12 +1,6 @@
 //! Calibration redesign (HARD RULE — Probe for ALL measurements) — integration
-//! test: a `Probe` node measuring SDT on the condenser refrigerant inlet edge
-//! drives the plain inverse embedding for `z_ua`. The Probe is the measurement
-//! source (`control.measure.component` names the Probe); the freed z-factor
-//! lives on the BPHX condenser (`control.actuator.component`). The two are
-//! linked 1:1 (+1 residual on Probe SDT target, +1 unknown z_ua).
-//!
-//! This is the Probe-based variant of `calibration_sdt.rs`. It proves the
-//! end-to-end path the UI emits after the calibration redesign.
+//! test: a `Probe` measuring SDT + free `cond/z_ua` via model `embeddings[]`
+//! (Modelica unknown + equation — not SaturatedController / controls[]).
 
 use entropyk_cli::run::{run_simulation, SimulationResult, SimulationStatus};
 use tempfile::tempdir;
@@ -139,22 +133,21 @@ fn probe_based_sdt_calibration_converges_and_solves_z_ua() {
     "tolerance": 1e-06,
     "timeout_ms": 60000
   },
-  "controls": [
+  "embeddings": [
     {
-      "type": "SaturatedController",
-      "id": "probe_sdt_calib",
-      "measure": {
-        "component": "cond_sdt_probe",
-        "output": "saturationTemperature"
-      },
-      "actuator": {
+      "id": "emb_cond_z_ua",
+      "unknown": {
         "component": "cond",
         "factor": "z_ua",
-        "initial": 0.3,
+        "start": 0.3,
         "min": 0.05,
         "max": 2.0
       },
-      "target": 315.0
+      "equation": {
+        "component": "cond_sdt_probe",
+        "output": "saturationTemperature",
+        "value": 315.0
+      }
     }
   ]
 }
@@ -185,6 +178,22 @@ fn probe_based_sdt_calibration_converges_and_solves_z_ua() {
             }
         }
     }
+    let mut sdt_c = None;
+    if let Some(state) = result.state.as_ref() {
+        for e in state.iter() {
+            if e.target.as_deref() == Some("cond") || e.source.as_deref() == Some("cond_sdt_probe")
+            {
+                if let Some(ts) = e.saturation_temperature_c {
+                    sdt_c = Some(ts);
+                }
+            }
+        }
+    }
+    let sdt_k = sdt_c.expect("must read SDT near condenser inlet probe") + 273.15;
+    assert!(
+        (sdt_k - 315.0).abs() < 0.5,
+        "SDT must hit target 315.0 K within 0.5 K, got {sdt_k}"
+    );
     assert!(
         solved.value > 0.05 && solved.value < 2.0,
         "z_ua must solve within bounds, got {}",

crates/cli/tests/probe_sst_evap.rs

@@ -1,19 +1,14 @@
-//! Calibration redesign (HARD RULE — Probe for ALL measurements) — integration
-//! test: a `Probe` node measuring SDT on the condenser refrigerant inlet edge
-//! drives the plain inverse embedding for `z_ua`. The Probe is the measurement
-//! source (`control.measure.component` names the Probe); the freed z-factor
-//! lives on the BPHX condenser (`control.actuator.component`). The two are
-//! linked 1:1 (+1 residual on Probe SDT target, +1 unknown z_ua).
+//! Probe Fixed Tsat on suction line + free `evap/z_ua` (model embedding).
 //!
-//! This is the Probe-based variant of `calibration_sdt.rs`. It proves the
-//! end-to-end path the UI emits after the calibration redesign.
+//! HVAC placement: SST lives on the suction line (`evap:outlet → probe → comp:inlet`),
+//! never on the two-phase EXV→evap inlet.
 
 use entropyk_cli::run::{run_simulation, SimulationResult, SimulationStatus};
 use tempfile::tempdir;
 
 fn run_config(json: &str) -> SimulationResult {
     let dir = tempdir().unwrap();
-    let path = dir.path().join("probe_sdt_calib.json");
+    let path = dir.path().join("probe_sst_calib.json");
     std::fs::write(&path, json).unwrap();
     run_simulation(&path, None, false).unwrap()
 }
@@ -22,8 +17,8 @@ fn run_config(json: &str) -> SimulationResult {
 fn probe_based_sst_evap_calibration() {
     let json = r#"
 {
-  "name": "Probe-based SDT calibration (R134a BPHX chiller)",
-  "description": "Same vapor-compression cycle as calibration_sdt.rs, but the SDT measurement lives on a Probe node spliced into the condenser refrigerant inlet edge. control.measure.component = the Probe name.",
+  "name": "Probe-based SST calibration (R134a BPHX chiller)",
+  "description": "Suction Probe Fixed Tsat drives evap/z_ua via model embedding.",
   "fluid": "R134a",
   "fluid_backend": "CoolProp",
   "circuits": [
@@ -60,7 +55,7 @@ fn probe_based_sst_evap_calibration() {
         {
           "type": "Probe",
           "name": "evap_sst_probe",
-          "measure": "SDT",
+          "measure": "SST",
           "fluid": "R134a"
         },
         {
@@ -81,7 +76,8 @@ fn probe_based_sst_evap_calibration() {
           "emergent_pressure": true,
           "correlation": "Longo2004",
           "dp_correlation": "SimplifiedChannel",
-          "ua": 2000.0
+          "ua": 2000.0,
+          "z_ua": 1.0
         },
         {
           "type": "BrineSource",
@@ -121,8 +117,7 @@ fn probe_based_sst_evap_calibration() {
         }
       ],
       "edges": [
-        { "from": "exv:outlet",           "to": "evap_sst_probe:inlet" },
-        { "from": "evap_sst_probe:outlet","to": "cond:inlet" },
+        { "from": "comp:outlet",          "to": "cond:inlet" },
         { "from": "cond:outlet",          "to": "exv:inlet" },
         { "from": "exv:outlet",           "to": "evap:inlet" },
         { "from": "evap:outlet",          "to": "evap_sst_probe:inlet" },
@@ -140,22 +135,21 @@ fn probe_based_sst_evap_calibration() {
     "tolerance": 1e-06,
     "timeout_ms": 60000
   },
-  "controls": [
+  "embeddings": [
     {
-      "type": "SaturatedController",
-      "id": "probe_sdt_calib",
-      "measure": {
-        "component": "evap_sst_probe",
-        "output": "saturationTemperature"
-      },
-      "actuator": {
+      "id": "emb_evap_z_ua",
+      "unknown": {
         "component": "evap",
         "factor": "z_ua",
-        "initial": 0.3,
+        "start": 0.3,
         "min": 0.05,
         "max": 2.0
       },
-      "target": 277.55
+      "equation": {
+        "component": "evap_sst_probe",
+        "output": "saturationTemperature",
+        "value": 277.55
+      }
     }
   ]
 }
@@ -163,7 +157,7 @@ fn probe_based_sst_evap_calibration() {
     let result = run_config(json);
     assert!(
         matches!(result.status, SimulationStatus::Converged),
-        "Probe-based SDT calibration must converge: {:?} ({:?})",
+        "Probe-based SST calibration must converge: {:?} ({:?})",
         result.status,
         result.error
     );
@@ -171,21 +165,40 @@ fn probe_based_sst_evap_calibration() {
         .solved_variables
         .iter()
         .find(|v| v.variable == "z_ua" && v.component.as_deref() == Some("evap"))
-        .expect("solved_variables must contain cond/z_ua");
+        .expect("solved_variables must contain evap/z_ua");
     eprintln!("DIAG z_ua résolu = {}", solved.value);
-    eprintln!("DIAG cible SST = 277.55 K (41.85°C)");
+    eprintln!("DIAG cible SST = 277.55 K (4.4°C)");
+
+    let mut sst_c = None;
     if let Some(state) = result.state.as_ref() {
         for e in state.iter() {
-            if e.target.as_deref() == Some("evap") || e.source.as_deref() == Some("evap") {
-                eprintln!("DIAG edge {}→{}  P={}bar  T_sat={}°C  T={}°C",
+            if e.source.as_deref() == Some("evap")
+                || e.target.as_deref() == Some("evap_sst_probe")
+                || e.source.as_deref() == Some("evap_sst_probe")
+            {
+                eprintln!(
+                    "DIAG edge {}→{}  P={}bar  T_sat={}°C  T={}°C",
                     e.source.as_deref().unwrap_or("?"),
                     e.target.as_deref().unwrap_or("?"),
                     e.pressure_bar,
                     e.saturation_temperature_c.unwrap_or(f64::NAN),
-                    e.temperature_c.unwrap_or(f64::NAN));
+                    e.temperature_c.unwrap_or(f64::NAN)
+                );
+                if e.source.as_deref() == Some("evap_sst_probe")
+                    || e.target.as_deref() == Some("evap_sst_probe")
+                {
+                    if let Some(ts) = e.saturation_temperature_c {
+                        sst_c = Some(ts);
                     }
                 }
             }
+        }
+    }
+    let sst_k = sst_c.expect("must read SST from suction probe edge") + 273.15;
+    assert!(
+        (sst_k - 277.55).abs() < 0.5,
+        "SST must hit target 277.55 K within 0.5 K, got {sst_k}"
+    );
     assert!(
         solved.value > 0.05 && solved.value < 2.0,
         "z_ua must solve within bounds, got {}",

crates/components/src/compressor.rs

@@ -1083,6 +1083,23 @@ impl Compressor<Connected> {
     pub fn set_operational_state(&mut self, state: OperationalState) {
         self.operational_state = state;
     }
+
+    /// Live energy-retention factor \(f_w\): fraction of shaft work kept in the
+    /// refrigerant (`1` = adiabatic, `0` = all work lost to ambient).
+    ///
+    /// Reads `state[calib_indices.f_w]` when free; otherwise stored calib.
+    /// Clamped to [0, 1].
+    fn live_f_w(&self, state: Option<&StateSlice>) -> f64 {
+        let raw = if let Some(st) = state {
+            self.calib_indices
+                .f_w
+                .map(|idx| st.get(idx).copied().unwrap_or(self.calib.f_w))
+                .unwrap_or(self.calib.f_w)
+        } else {
+            self.calib.f_w
+        };
+        raw.clamp(0.0, 1.0)
+    }
 }
 
 impl Component for Compressor<Connected> {
@@ -1194,9 +1211,13 @@ impl Component for Compressor<Connected> {
         // ṁ_calc - ṁ_state = 0
         residuals[0] = mass_flow_calc - mass_flow_state;
 
-        // Residual 1: Energy balance
-        // Power_calc - ṁ × (h_discharge - h_suction) / η_mech = 0
+        // Residual 1: Energy balance with retention factor f_w
+        // (fraction of shaft work kept in the refrigerant):
+        //   ṁ·Δh = Ẇ·f_w / η_mech  ⇒  Ẇ·f_w − ṁ·Δh/η_mech = 0
+        // so h_dis ≈ h_suc + f_w·Ẇ/(ṁ·η_mech).
+        // f_w = 1 → adiabatic (default); f_w = 0 → all work lost to ambient.
         let enthalpy_change = h_discharge - h_suction;
+        let f_w = self.live_f_w(Some(state));
 
         // Prevent division by zero
         if self.mechanical_efficiency.abs() < 1e-10 {
@@ -1205,7 +1226,8 @@ impl Component for Compressor<Connected> {
             ));
         }
 
-        residuals[1] = power_calc - mass_flow_state * enthalpy_change / self.mechanical_efficiency;
+        residuals[1] =
+            power_calc * f_w - mass_flow_state * enthalpy_change / self.mechanical_efficiency;
 
         // r2: ṁ_discharge − ṁ_suction = 0  (mass conservation, CM1.3)
         // CM1.4: skip when same_branch_m — ṁ_dis == ṁ_suc (same state index),
@@ -1265,7 +1287,8 @@ impl Component for Compressor<Connected> {
         )?;
         jacobian.add_entry(0, suc_h_idx, dr0_dh_suction);
 
-        // Row 1: Energy residual  r1 = power_calc − ṁ × Δh / η_mech
+        // Row 1: Energy residual  r1 = power·f_w − ṁ·Δh/η_mech
+        let f_w = self.live_f_w(Some(state));
         // ∂r1/∂ṁ_suction = −(h_discharge − h_suction) / η_mech
         let dr1_dm = -(h_discharge - h_suction) / self.mechanical_efficiency;
         jacobian.add_entry(1, suc_m_idx, dr1_dm);
@@ -1280,7 +1303,7 @@ impl Component for Compressor<Connected> {
                     Temperature::from_kelvin(t),
                     Temperature::from_kelvin(t_discharge),
                     None,
-                ))
+                ) * f_w)
             },
             h_suction,
             1.0,
@@ -1296,7 +1319,7 @@ impl Component for Compressor<Connected> {
                     Temperature::from_kelvin(t_suction),
                     Temperature::from_kelvin(t),
                     None,
-                ))
+                ) * f_w)
             },
             h_discharge,
             1.0,
@@ -1326,7 +1349,18 @@ impl Component for Compressor<Connected> {
                 Temperature::from_kelvin(t_discharge_k),
                 None,
             );
-            jacobian.add_entry(1, z_power_idx, p_nominal);
+            // r1 = (z_power·Ẇ_nom)·f_w − …  ⇒  ∂r1/∂z_power = Ẇ_nom·f_w
+            jacobian.add_entry(1, z_power_idx, p_nominal * f_w);
+        }
+
+        if let Some(f_w_idx) = self.calib_indices.f_w {
+            let p_live = self.power_consumption_cooling(
+                Temperature::from_kelvin(t_suction_k),
+                Temperature::from_kelvin(t_discharge_k),
+                Some(state),
+            );
+            // r1 = Ẇ·f_w − …  ⇒  ∂r1/∂f_w = +Ẇ
+            jacobian.add_entry(1, f_w_idx, p_live);
         }
 
         // ∂r0/∂f_etav (AHRI 540 only): ṁ_calc = f_m · f_etav · base with

crates/components/src/heat_exchanger/exchanger.rs

@@ -797,17 +797,30 @@ impl<Model: HeatTransferModel + 'static> HeatExchanger<Model> {
         h_jkg: f64,
     ) -> Result<f64, ComponentError> {
         if !p_pa.is_finite() || p_pa <= 0.0 {
-            return Err(ComponentError::InvalidState(format!(
+            return Err(ComponentError::DomainViolation(DomainViolation {
+                component: Some(self.name.clone()),
+                detail: format!(
                     "{} {} side has invalid pressure: {} Pa",
                     self.name, side, p_pa
-            )));
+                ),
+            }));
         }
         if !h_jkg.is_finite() {
-            return Err(ComponentError::InvalidState(format!(
+            return Err(ComponentError::DomainViolation(DomainViolation {
+                component: Some(self.name.clone()),
+                detail: format!(
                     "{} {} side has invalid enthalpy: {} J/kg",
                     self.name, side, h_jkg
-            )));
+                ),
+            }));
         }
+        // Clamp wild Newton trial enthalpies into a broad physical envelope so
+        // CoolProp is not queried with absurd (P,h) that yield T=inf. Exact
+        // result is preserved for states already inside the clamp.
+        const H_MIN_JKG: f64 = -5.0e5;
+        const H_MAX_JKG: f64 = 3.0e6;
+        let h_query = h_jkg.clamp(H_MIN_JKG, H_MAX_JKG);
+        let p_query = p_pa.clamp(1.0e3, 5.0e7);
         let backend = self.fluid_backend.as_ref().ok_or_else(|| {
             ComponentError::InvalidState(format!(
                 "{} {} side fluid '{}' requires a FluidBackend; no simulation fallback is allowed",
@@ -819,15 +832,19 @@ impl<Model: HeatTransferModel + 'static> HeatExchanger<Model> {
                 FluidsFluidId::new(fluid_id),
                 property,
                 entropyk_fluids::FluidState::PressureEnthalpy(
-                    Pressure::from_pascals(p_pa),
-                    entropyk_core::Enthalpy::from_joules_per_kg(h_jkg),
+                    Pressure::from_pascals(p_query),
+                    entropyk_core::Enthalpy::from_joules_per_kg(h_query),
                 ),
             )
             .map_err(|e| {
-                ComponentError::CalculationFailed(format!(
+                // Off-envelope CoolProp failures during Newton are recoverable.
+                ComponentError::DomainViolation(DomainViolation {
+                    component: Some(self.name.clone()),
+                    detail: format!(
                         "{} failed to evaluate {:?} for {} side fluid '{}': {}",
                         self.name, property, side, fluid_id, e
-                ))
+                    ),
+                })
             })
     }
 

crates/components/src/heat_exchanger/flooded_evaporator.rs

@@ -641,10 +641,22 @@ impl FloodedEvaporator {
             .map_err(|e| ComponentError::CalculationFailed(e.to_string()))
     }
 
+    /// Live UA = UA_nominal × z_ua (reads `state[calib_indices.z_ua]` when free).
+    fn live_ua(&self, state: Option<&StateSlice>) -> f64 {
+        let z = state
+            .and_then(|st| {
+                self.inner
+                    .calib_indices_ref()
+                    .z_ua
+                    .and_then(|idx| st.get(idx).copied())
+            })
+            .unwrap_or_else(|| self.calib().z_ua);
+        self.inner.ua_nominal() * z.max(0.0)
+    }
+
     /// Effectiveness for a phase-changing refrigerant: `C_min = C_sec`, `C_r → 0`,
     /// so `ε = 1 − exp(−UA / C_sec)`.
-    fn effectiveness(&self, c_sec: f64) -> f64 {
-        let ua = self.ua();
+    fn effectiveness(&self, c_sec: f64, ua: f64) -> f64 {
         if c_sec <= 1e-10 || ua <= 0.0 {
             return 0.0;
         }
@@ -659,9 +671,10 @@ impl FloodedEvaporator {
         p_in_pa: f64,
         t_sec_in: f64,
         c_sec: f64,
+        ua: f64,
     ) -> Result<f64, ComponentError> {
         let t_evap = self.evap_temperature(p_in_pa)?;
-        let eps = self.effectiveness(c_sec);
+        let eps = self.effectiveness(c_sec, ua);
         Ok(eps * c_sec * (t_sec_in - t_evap))
     }
 
@@ -677,7 +690,7 @@ impl FloodedEvaporator {
                 "coupled_duty requires rating-mode secondary inlet temperature".into(),
             )
         })?;
-        self.coupled_duty_with(p_in_pa, t_sec_in, c_sec)
+        self.coupled_duty_with(p_in_pa, t_sec_in, c_sec, self.live_ua(None))
     }
 
     /// Rates the evaporator at a fixed refrigerant regime (constant evaporating
@@ -717,7 +730,8 @@ impl FloodedEvaporator {
             ));
         }
         let t_evap = self.evap_temperature(p_in_pa)?;
-        let eps = self.effectiveness(c_sec);
+        let ua = self.live_ua(None);
+        let eps = self.effectiveness(c_sec, ua);
         let q = self.coupled_duty(p_in_pa)?;
         let secondary_outlet_k = if c_sec > 1e-10 {
             t_sec_in - q / c_sec
@@ -1089,7 +1103,8 @@ impl Component for FloodedEvaporator {
                 let h_in = state[inlet_h_idx];
                 let h_out = state[outlet_h_idx];
                 let (t_sec_in, c_sec) = self.resolve_secondary_stream(state)?;
-                let q = self.coupled_duty_with(p_in, t_sec_in, c_sec)?;
+                let ua = self.live_ua(Some(state));
+                let q = self.coupled_duty_with(p_in, t_sec_in, c_sec, ua)?;
 
                 // System mode: C∞ zero-flow gating on both streams (staging / Newton trials).
                 // Rating mode: secondary is a fixed boundary (C_sec > 0). Do NOT multiply Q by
@@ -1188,10 +1203,10 @@ impl Component for FloodedEvaporator {
         let h_in = state[inlet_h_idx];
         let h_out = state[outlet_h_idx];
         let (t_sec_in, c_sec) = self.resolve_secondary_stream(state)?;
-        let eps = self.effectiveness(c_sec);
-        let q = self.coupled_duty_with(p_in, t_sec_in, c_sec)?;
+        let ua = self.live_ua(Some(state));
+        let eps = self.effectiveness(c_sec, ua);
+        let q = self.coupled_duty_with(p_in, t_sec_in, c_sec, ua)?;
         let t_evap = self.evap_temperature(p_in)?;
-        let ua = self.ua();
 
         // System mode exposes secondary edge unknowns; rating mode freezes (T,C).
         let system = self.system_secondary_ready();
@@ -1262,6 +1277,22 @@ impl Component for FloodedEvaporator {
             jacobian.add_entry(row, m_s, -d_qeff_dm_sec);
             jacobian.add_entry(row, h_s, -d_qeff_dh_sec);
         }
+        // Live z_ua column: UA = UA_nom·z_ua, ε = 1−e^(−UA/C), Q = ε·C·ΔT
+        if let Some(z_ua_idx) = self.inner.calib_indices_ref().z_ua {
+            let d_eps_dua = if c_sec > 1e-12 {
+                (-ua / c_sec).exp() / c_sec
+            } else {
+                0.0
+            };
+            let d_q_dua = d_eps_dua * c_sec * (t_sec_in - t_evap);
+            let alpha_r = if system {
+                flow_activity(m_ref, DEFAULT_M_EPS_KG_S)
+            } else {
+                1.0
+            };
+            let d_qeff_dz = alpha_r * alpha_s * d_q_dua * self.inner.ua_nominal();
+            jacobian.add_entry(row, z_ua_idx, -d_qeff_dz);
+        }
         row += 1;
 
         // r2 outlet closure

crates/components/src/isentropic_compressor.rs

@@ -210,7 +210,11 @@ pub struct IsentropicCompressor {
     /// Inverse-control calibration state indices. When `f_m` is `Some(i)`, the
     /// volumetric mass-flow closure is scaled by the control variable at
     /// `state[i]`, turning the compressor into a capacity/mass-flow actuator.
+    /// When `f_w` is `Some(i)`, discharge enthalpy uses the live energy-
+    /// retention factor at `state[i]` (`1` = adiabatic, `0` = all lost).
     calib_indices: CalibIndices,
+    /// Nominal energy-retention factor when not a free unknown. Default 1.
+    f_w: f64,
     /// When `true`, a screw-compressor slide valve modulates the effective swept
     /// volume to hold a target suction saturated temperature (SST). The slide
     /// position `σ ∈ [σ_min, 1]` is a free actuator that scales the displacement
@@ -279,12 +283,19 @@ impl IsentropicCompressor {
             circuit_id: CircuitId::default(),
             operational_state: OperationalState::default(),
             calib_indices: CalibIndices::default(),
+            f_w: 1.0,
             slide_valve: false,
             sst_target_k: None,
             liquid_injection: false,
         }
     }
 
+    /// Sets the nominal energy-retention factor `f_w` (`1` = adiabatic).
+    pub fn with_f_w(mut self, f_w: f64) -> Self {
+        self.f_w = f_w.clamp(0.0, 1.0);
+        self
+    }
+
     /// Attaches a refrigerant identifier for property lookups.
     pub fn with_refrigerant(mut self, refrigerant: &str) -> Self {
         self.refrigerant_id = refrigerant.to_string();
@@ -597,6 +608,17 @@ impl IsentropicCompressor {
     /// solver state when this compressor is used as an actuator, or `1.0` when
     /// no control variable is linked. Non-finite or non-positive values fall
     /// back to `1.0` to keep the closure well-posed during early iterations.
+    fn control_f_w(&self, state: &StateSlice) -> f64 {
+        match self.calib_indices.f_w {
+            Some(idx) => state
+                .get(idx)
+                .copied()
+                .unwrap_or(self.f_w)
+                .clamp(0.0, 1.0),
+            None => self.f_w.clamp(0.0, 1.0),
+        }
+    }
+
     fn control_f_m(&self, state: &StateSlice) -> f64 {
         match self.calib_indices.z_flow {
             Some(i) if i < state.len() => {
@@ -642,6 +664,7 @@ impl IsentropicCompressor {
         p_suc_pa: f64,
         h_suc_jkg: f64,
         p_dis_pa: f64,
+        state: &StateSlice,
     ) -> Result<f64, ComponentError> {
         let s_suc = backend
             .property(
@@ -660,7 +683,11 @@ impl IsentropicCompressor {
                 FluidState::PressureEntropy(Pressure::from_pascals(p_dis_pa), Entropy(s_suc)),
             )
             .map_err(|e| ComponentError::CalculationFailed(format!("H_dis_isen: {}", e)))?;
-        Ok(h_suc_jkg + (h_dis_isen - h_suc_jkg) / self.effective_isentropic_efficiency())
+        // Retention: h_dis = h_suc + f_w·Δh_is/η_is
+        // f_w = 1 → adiabatic; f_w = 0 → all work lost (h_dis → h_suc).
+        let dh = (h_dis_isen - h_suc_jkg) / self.effective_isentropic_efficiency();
+        let f_w = self.control_f_w(state);
+        Ok(h_suc_jkg + f_w * dh)
     }
 }
 
@@ -729,7 +756,7 @@ impl Component for IsentropicCompressor {
                 ));
             }
             let h_dis =
-                self.compute_h_dis_from_state(backend.as_ref(), fluid, p_suc, h_suc, p_dis)?;
+                self.compute_h_dis_from_state(backend.as_ref(), fluid, p_suc, h_suc, p_dis, state)?;
             residuals[0] = state[dis_h] - h_dis;
             if !self.same_branch_m {
                 residuals[1] = match (self.suction_m_idx, self.discharge_m_idx) {
@@ -776,7 +803,7 @@ impl Component for IsentropicCompressor {
                 let m_calc =
                     self.swept_mass_flow(backend.as_ref(), fluid.clone(), p_suc, h_suc, p_dis)?;
                 let h_dis =
-                    self.compute_h_dis_from_state(backend.as_ref(), fluid, p_suc, h_suc, p_dis)?;
+                    self.compute_h_dis_from_state(backend.as_ref(), fluid, p_suc, h_suc, p_dis, state)?;
                 // Inverse-control actuator: scale the swept mass flow by the
                 // linked control variable f_m (1.0 when no control is attached)
                 // and the slide-valve position σ (1.0 when no slide valve).
@@ -824,9 +851,15 @@ impl Component for IsentropicCompressor {
                 }
                 return Ok(());
             }
-            return Err(ComponentError::InvalidState(
-                "IsentropicCompressor displacement closure requires live physical suction and discharge states".to_string(),
-            ));
+            // Soft domain penalty — never abort the whole system residual
+            // evaluation. A hard InvalidState here kills Picard/homotopy recovery
+            // after a singular-J Newton step wanders into P≈0 / h≈0.
+            residuals[0] = 1.0e6;
+            residuals[1] = 1.0e6;
+            if !self.same_branch_m && residuals.len() > 2 {
+                residuals[2] = 1.0e6;
+            }
+            return Ok(());
         }
 
         if let (Some(backend), Some(dis_p), Some(dis_h)) = (
@@ -859,7 +892,7 @@ impl Component for IsentropicCompressor {
                                 p_suc,
                                 h_suc,
                                 p_cond_sat,
-                            )?
+                            state)?
                         } else {
                             return Err(ComponentError::InvalidState(
                             "IsentropicCompressor requires physical live suction pressure/enthalpy"
@@ -931,7 +964,7 @@ impl Component for IsentropicCompressor {
                     let dph = h_suc * 1e-4 + 10.0;
                     let dpd = p_dis * 1e-4 + 100.0;
                     let h = |ps: f64, hs: f64, pd: f64| {
-                        self.compute_h_dis_from_state(backend.as_ref(), fluid.clone(), ps, hs, pd)
+                        self.compute_h_dis_from_state(backend.as_ref(), fluid.clone(), ps, hs, pd, state)
                     };
                     if let (Ok(a), Ok(b)) =
                         (h(p_suc + dpp, h_suc, p_dis), h(p_suc - dpp, h_suc, p_dis))
@@ -1030,7 +1063,7 @@ impl Component for IsentropicCompressor {
                 let inj_ready = self.injection_ready();
                 let hd = |ps: f64, hs: f64, pd: f64| -> Result<f64, ComponentError> {
                     let h =
-                        self.compute_h_dis_from_state(backend.as_ref(), fluid.clone(), ps, hs, pd)?;
+                        self.compute_h_dis_from_state(backend.as_ref(), fluid.clone(), ps, hs, pd, state)?;
                     if inj_ready {
                         let h_liq = self.liquid_enthalpy(pd)?;
                         Ok(h - phi_inj * (h - h_liq))
@@ -1053,6 +1086,22 @@ impl Component for IsentropicCompressor {
                 {
                     jacobian.add_entry(1, dis_p, -(a - b) / (2.0 * dpd));
                 }
+                // ∂r1/∂f_w = −dh  (h_dis = h_suc + f_w·dh ⇒ r = h − h_dis)
+                if let Some(f_w_idx) = self.calib_indices.f_w {
+                    if let Ok(h_full) = self.compute_h_dis_from_state(
+                        backend.as_ref(),
+                        fluid.clone(),
+                        p_suc,
+                        h_suc,
+                        p_dis,
+                        state,
+                    ) {
+                        // Reconstruct dh from h_full at current f_w: h = h_suc + fw·dh
+                        let fw = self.control_f_w(state).max(1e-9);
+                        let dh = (h_full - h_suc) / fw;
+                        jacobian.add_entry(1, f_w_idx, -dh);
+                    }
+                }
                 // ∂r1/∂φ_inj = +(h_dis − h_liq): the injection actuator couples
                 // into the energy balance so a controls[] loop has a plant to act
                 // on (higher injection ⇒ lower discharge enthalpy ⇒ lower DGT).
@@ -1064,7 +1113,7 @@ impl Component for IsentropicCompressor {
                             p_suc,
                             h_suc,
                             p_dis,
-                        );
+                        state);
                         let h_liq = self.liquid_enthalpy(p_dis);
                         if let (Ok(h_dis), Ok(h_liq)) = (h_dis, h_liq) {
                             jacobian.add_entry(1, inj_idx, h_dis - h_liq);
@@ -1123,14 +1172,14 @@ impl Component for IsentropicCompressor {
                             p_suc + dp,
                             h_suc,
                             p_cond_sat,
-                        );
+                        state);
                         let hm = self.compute_h_dis_from_state(
                             backend.as_ref(),
                             fluid.clone(),
                             p_suc - dp,
                             h_suc,
                             p_cond_sat,
-                        );
+                        state);
                         if let (Ok(hp), Ok(hm)) = (hp, hm) {
                             jacobian.add_entry(1, suc_p, -(hp - hm) / (2.0 * dp));
                         }
@@ -1142,14 +1191,14 @@ impl Component for IsentropicCompressor {
                             p_suc,
                             h_suc + dh,
                             p_cond_sat,
-                        );
+                        state);
                         let hm = self.compute_h_dis_from_state(
                             backend.as_ref(),
                             fluid,
                             p_suc,
                             h_suc - dh,
                             p_cond_sat,
-                        );
+                        state);
                         if let (Ok(hp), Ok(hm)) = (hp, hm) {
                             jacobian.add_entry(1, suc_h, -(hp - hm) / (2.0 * dh));
                         }
@@ -1259,7 +1308,7 @@ impl Component for IsentropicCompressor {
                         state[sp],
                         h_suc,
                         state[dp],
-                    )
+                    state)
                     .unwrap_or(h_dis)
                 }
                 _ => h_dis,

crates/core/src/calib.rs

@@ -10,19 +10,25 @@
 //!
 //! | Entropyk field | Legacy `f_*` | BOLT equivalent | Effect |
 //! |---|---|---|---|
-//! | `z_flow` | `f_m` | `Z_flow_suc` | ṁ_suc,eff = z_flow × ṁ_suc,nominal |
+//! | `z_flow` | `f_m` | `Z_flow_suc` | ṁ_suc,eff = z_flow × ṁ_suc,nominal (machine **capacity**) |
 //! | `z_flow_eco` | — | `Z_flow_eco` | ṁ_eco,eff = z_flow_eco × ṁ_eco,nominal |
 //! | `z_dp` | `f_dp` | `Z_dpc`, `Z_dp_ref` | ΔP_eff = z_dp × ΔP_nominal |
 //! | `z_ua` | `f_ua` | `Z_UA`, `Z_Ucd`, `Z_Uev` | UA_eff = z_ua × UA_nominal |
 //! | `z_power` | `f_power` | `Z_power` | Ẇ_eff = z_power × Ẇ_nominal |
 //! | `z_etav` | `f_etav` | — (η_v correction) | η_v,eff = z_etav × η_v,nominal |
+//! | `f_w` | `f_w` | energy retention | \(h_{dis}=h_{suc}+f_w\cdot\dot W/\dot m\) (**DGT**) |
+//!
+//! `f_w` is the fraction of compressor work **retained** in the refrigerant
+//! (not a loss fraction): `f_w = 1` → adiabatic (no shell loss);
+//! `f_w = 0.98` → ~2% lost to ambient; `f_w = 0` → all work lost (Δh → 0).
 //!
 //! ## Recommended calibration order
 //!
-//! 1. **z_flow** — mass flow (compressor power + ṁ measurements)
-//! 2. **z_dp** — pressure drops (inlet/outlet pressures)
-//! 3. **z_ua** — heat transfer (superheat, subcooling, capacity)
-//! 4. **z_power** — compressor power (if z_flow insufficient)
+//! 1. **z_flow** — machine capacity via ṁ (pair with Capacity probe)
+//! 2. **f_w** — compressor energy retention / shell loss (pair with discharge T / DGT)
+//! 3. **z_dp** — pressure drops (pair with P)
+//! 4. **z_ua** — heat transfer (pair with Tsat / Tsh)
+//! 5. **z_power** — compressor power map (if needed)
 
 use serde::{Deserialize, Serialize};
 
@@ -42,11 +48,17 @@ pub const Z_UA: &str = "z_ua";
 pub const Z_POWER: &str = "z_power";
 /// Canonical name for the volumetric-efficiency Z-factor (`z_etav`).
 pub const Z_ETAV: &str = "z_etav";
+/// Canonical name for the compressor energy-retention factor (`f_w`).
+///
+/// Fraction of shaft work delivered to the refrigerant enthalpy rise.
+/// `1.0` = adiabatic; `0.0` = all work lost to ambient.
+pub const F_W: &str = "f_w";
 
 /// Normalizes a user/config factor string to a canonical Z-factor name.
 ///
 /// Accepts legacy `f_*` names, canonical `z_*` names, and common BOLT spellings
-/// (`Z_power`, `Z_flow_suc`, `Z_Ucd`, …).
+/// (`Z_power`, `Z_flow_suc`, `Z_Ucd`, …). Also accepts heat-loss aliases
+/// (`f_w`, `fw`, `f_q`, `z_fw`).
 pub fn normalize_factor_name(factor: &str) -> Option<&'static str> {
     match factor.trim().to_ascii_lowercase().replace('_', "").as_str() {
         "fm" | "zflow" | "zflowsuc" => Some(Z_FLOW),
@@ -55,6 +67,7 @@ pub fn normalize_factor_name(factor: &str) -> Option<&'static str> {
         "fua" | "zua" | "zucd" | "zuev" => Some(Z_UA),
         "fpower" | "zpower" => Some(Z_POWER),
         "fetav" | "zetav" => Some(Z_ETAV),
+        "fw" | "fq" | "zfw" | "heatloss" => Some(F_W),
         _ => None,
     }
 }
@@ -74,6 +87,9 @@ pub fn id_ends_with_calib_suffix(id: &str) -> Option<&'static str> {
         "z_uev",
         "z_dpc",
         "z_dp",
+        "f_w",
+        "f_q",
+        "z_fw",
         "f_m",
         "f_dp",
         "f_ua",
@@ -146,6 +162,22 @@ pub struct Calib {
     /// z_etav: η_v,eff = z_etav × η_v,nominal (compressor displacement correction)
     #[serde(default = "one", rename = "z_etav", alias = "zEtav", alias = "f_etav")]
     pub z_etav: f64,
+    /// Compressor energy-retention factor: fraction of shaft work kept in the
+    /// refrigerant (\(h_{dis}=h_{suc}+f_w\cdot\dot W/\dot m\)).
+    ///
+    /// - `1.0` — adiabatic (nothing lost to ambient) — **default**
+    /// - `0.98` — ~2% shell loss
+    /// - `0.0` — all work lost (no discharge enthalpy rise)
+    #[serde(
+        default = "one",
+        rename = "f_w",
+        alias = "fw",
+        alias = "f_q",
+        alias = "fQ",
+        alias = "z_fw",
+        alias = "heat_loss"
+    )]
+    pub f_w: f64,
     /// Traceability: identifier or hash of the test data used to derive these factors.
     #[serde(default, skip_serializing_if = "Option::is_none")]
     pub calibration_source: Option<String>,
@@ -160,6 +192,7 @@ impl Default for Calib {
             z_ua: 1.0,
             z_power: 1.0,
             z_etav: 1.0,
+            f_w: 1.0,
             calibration_source: None,
         }
     }
@@ -183,6 +216,8 @@ pub struct CalibIndices {
     pub z_power: Option<usize>,
     /// State index for z_etav multiplier
     pub z_etav: Option<usize>,
+    /// State index for compressor energy-retention factor `f_w`
+    pub f_w: Option<usize>,
     /// State index for a *physical actuator* free variable (dimensioned, not a
     /// multiplier). Interpreted per component: EXV/orifice opening [0..1], fan
     /// speed ratio, screw slide position, injection-valve opening, condenser
@@ -201,18 +236,25 @@ pub struct CalibValidationError {
 
 impl std::fmt::Display for CalibValidationError {
     fn fmt(&self, f: &mut std::fmt::Formatter<'_>) -> std::fmt::Result {
+        let range = if self.factor == F_W {
+            "[0.0, 1.0]"
+        } else {
+            "[0.2, 3.0]"
+        };
         write!(
             f,
-            "calib {} = {} is outside allowed range [0.5, 2.0]",
-            self.factor, self.value
+            "calib {} = {} is outside allowed range {}",
+            self.factor, self.value, range
         )
     }
 }
 
 impl std::error::Error for CalibValidationError {}
 
-const MIN_Z: f64 = 0.5;
-const MAX_Z: f64 = 2.0;
+const MIN_Z: f64 = 0.2;
+const MAX_Z: f64 = 3.0;
+const MIN_F_W: f64 = 0.0;
+const MAX_F_W: f64 = 1.0;
 
 impl Calib {
     /// Updates a single factor by name (accepts canonical `z_*`, legacy `f_*`, BOLT `Z_*`).
@@ -242,14 +284,18 @@ impl Calib {
                 self.z_etav = value;
                 true
             }
+            Some(F_W) => {
+                self.f_w = value;
+                true
+            }
             _ => false,
         }
     }
 
-    /// Validates that all factors lie in [0.5, 2.0]. Returns `Ok(())` or the first invalid factor.
+    /// Validates multiplicative Z-factors in [0.2, 3.0] and `f_w` in [0, 1].
     pub fn validate(&self) -> Result<(), CalibValidationError> {
-        let check = |name: &'static str, value: f64| {
-            if !(MIN_Z..=MAX_Z).contains(&value) {
+        let check = |name: &'static str, value: f64, min: f64, max: f64| {
+            if !(min..=max).contains(&value) {
                 Err(CalibValidationError {
                     factor: name,
                     value,
@@ -258,12 +304,13 @@ impl Calib {
                 Ok(())
             }
         };
-        check(Z_FLOW, self.z_flow)?;
-        check(Z_FLOW_ECO, self.z_flow_eco)?;
-        check(Z_DP, self.z_dp)?;
-        check(Z_UA, self.z_ua)?;
-        check(Z_POWER, self.z_power)?;
-        check(Z_ETAV, self.z_etav)?;
+        check(Z_FLOW, self.z_flow, MIN_Z, MAX_Z)?;
+        check(Z_FLOW_ECO, self.z_flow_eco, MIN_Z, MAX_Z)?;
+        check(Z_DP, self.z_dp, MIN_Z, MAX_Z)?;
+        check(Z_UA, self.z_ua, MIN_Z, MAX_Z)?;
+        check(Z_POWER, self.z_power, MIN_Z, MAX_Z)?;
+        check(Z_ETAV, self.z_etav, MIN_Z, MAX_Z)?;
+        check(F_W, self.f_w, MIN_F_W, MAX_F_W)?;
         Ok(())
     }
 }
@@ -281,6 +328,7 @@ mod tests {
         assert_eq!(c.z_ua, 1.0);
         assert_eq!(c.z_power, 1.0);
         assert_eq!(c.z_etav, 1.0);
+        assert_eq!(c.f_w, 1.0); // retention: 1 = adiabatic
         assert!(c.validate().is_ok());
     }
 
@@ -293,23 +341,31 @@ mod tests {
             z_ua: 2.0,
             z_power: 1.0,
             z_etav: 1.0,
+            f_w: 0.98, // ~2% shell loss
             calibration_source: None,
         };
         assert!(ok.validate().is_ok());
 
         let bad_m = Calib {
-            z_flow: 0.4,
+            z_flow: 0.1,
             ..Default::default()
         };
         let err = bad_m.validate().unwrap_err();
         assert_eq!(err.factor, Z_FLOW);
 
         let bad_high = Calib {
-            z_ua: 2.1,
+            z_ua: 3.1,
             ..Default::default()
         };
         let err2 = bad_high.validate().unwrap_err();
         assert_eq!(err2.factor, Z_UA);
+
+        let bad_fw = Calib {
+            f_w: 1.1,
+            ..Default::default()
+        };
+        let err3 = bad_fw.validate().unwrap_err();
+        assert_eq!(err3.factor, F_W);
     }
 
     #[test]
@@ -321,6 +377,7 @@ mod tests {
             z_ua: 1.0,
             z_power: 1.05,
             z_etav: 1.0,
+            f_w: 0.98,
             calibration_source: None,
         };
         let json = serde_json::to_string(&c).unwrap();
@@ -361,6 +418,8 @@ mod tests {
         assert_eq!(normalize_factor_name("Z_flow_eco"), Some(Z_FLOW_ECO));
         assert_eq!(normalize_factor_name("Z_power"), Some(Z_POWER));
         assert_eq!(normalize_factor_name("Z_Ucd"), Some(Z_UA));
+        assert_eq!(normalize_factor_name("f_w"), Some(F_W));
+        assert_eq!(normalize_factor_name("f_q"), Some(F_W));
         assert_eq!(normalize_factor_name("unknown"), None);
     }
 

crates/core/src/lib.rs

@@ -65,7 +65,7 @@ pub use types::{
 
 // Re-export calibration types
 pub use calib::{
-    id_ends_with_calib_suffix, normalize_factor_name, Calib, CalibIndices, CalibValidationError,
+    id_ends_with_calib_suffix, normalize_factor_name, Calib, CalibIndices, CalibValidationError, F_W,
     Z_DP, Z_ETAV, Z_FLOW, Z_FLOW_ECO, Z_POWER, Z_UA,
 };
 

crates/entropyk/src/result.rs

@@ -526,19 +526,18 @@ pub fn extract_solved_variables(system: &System, state: &[f64]) -> Vec<SolvedVar
         }
     }
 
-    // Calibration factors (z_ua, z_dp, z_flow, z_flow_eco, z_power, z_etav)
-    // promoted to free unknowns via control loops. Each `Some(idx)` slot means
-    // the solver computed a value for that factor at `state[idx]`. The generic
-    // `actuator` slot (physical opening / fan speed) is already covered by the
-    // bounded-variable path above, so we only surface the six named Z-factors.
+    // Calibration factors promoted to free unknowns via control loops.
+    // Each `Some(idx)` slot means the solver computed a value at `state[idx]`.
+    // The generic `actuator` slot is already covered by the bounded-variable path.
     for (name, indices) in system.calib_indices_by_name() {
-        for (factor, slot) in [
-            ("z_flow", indices.z_flow),
-            ("z_flow_eco", indices.z_flow_eco),
-            ("z_dp", indices.z_dp),
-            ("z_ua", indices.z_ua),
-            ("z_power", indices.z_power),
-            ("z_etav", indices.z_etav),
+        for (factor, slot, min, max) in [
+            ("z_flow", indices.z_flow, 0.5, 2.0),
+            ("z_flow_eco", indices.z_flow_eco, 0.5, 2.0),
+            ("z_dp", indices.z_dp, 0.5, 2.0),
+            ("z_ua", indices.z_ua, 0.5, 2.0),
+            ("z_power", indices.z_power, 0.5, 2.0),
+            ("z_etav", indices.z_etav, 0.5, 2.0),
+            ("f_w", indices.f_w, 0.0, 1.0),
         ] {
             if let Some(idx) = slot {
                 if idx < state.len() {
@@ -552,10 +551,8 @@ pub fn extract_solved_variables(system: &System, state: &[f64]) -> Vec<SolvedVar
                         component: Some(name.clone()),
                         variable: factor.to_string(),
                         value: state[idx],
-                        // Calibration factors are bounded to [0.5, 2.0]
-                        // (see entropyk_core::CalibValidationError).
-                        min: 0.5,
-                        max: 2.0,
+                        min,
+                        max,
                     });
                 }
             }

crates/solver/src/system.rs

@@ -621,6 +621,7 @@ impl System {
                             entropyk_core::Z_UA => indices.z_ua = Some(state_idx),
                             entropyk_core::Z_POWER => indices.z_power = Some(state_idx),
                             entropyk_core::Z_ETAV => indices.z_etav = Some(state_idx),
+                            entropyk_core::F_W => indices.f_w = Some(state_idx),
                             _ => {}
                         }
                     }
@@ -645,6 +646,7 @@ impl System {
                             entropyk_core::Z_UA => indices.z_ua = Some(state_idx),
                             entropyk_core::Z_POWER => indices.z_power = Some(state_idx),
                             entropyk_core::Z_ETAV => indices.z_etav = Some(state_idx),
+                            entropyk_core::F_W => indices.f_w = Some(state_idx),
                             _ => {}
                         }
                     } else if id_str.ends_with("injection") || id_str.ends_with("actuator") {