diff --git a/.github/workflows/ci.yml b/.github/workflows/ci.yml
new file mode 100644
index 0000000..f6fe427
--- /dev/null
+++ b/.github/workflows/ci.yml
@@ -0,0 +1,61 @@
+name: ci
+
+on:
+  push:
+    branches: [main]
+  pull_request:
+    branches: [main]
+
+# Cancel in-flight runs for the same branch on a new push.
+concurrency:
+  group: ci-${{ github.ref }}
+  cancel-in-progress: true
+
+jobs:
+  pytest:
+    name: pytest (Python ${{ matrix.python-version }})
+    runs-on: ubuntu-latest
+    strategy:
+      fail-fast: false
+      matrix:
+        # Pin to the lockfile-resolved Python floor (`pyproject.toml`
+        # `requires-python = ">=3.10"`). The reference stack that
+        # produces the 1.1.1 fingerprint pins is Python 3.10.
+        python-version: ["3.10", "3.11", "3.12"]
+
+    steps:
+      - uses: actions/checkout@v4
+
+      - name: Install uv
+        uses: astral-sh/setup-uv@v3
+
+      - name: Set up Python ${{ matrix.python-version }}
+        run: uv python install ${{ matrix.python-version }}
+
+      - name: Sync dependencies (lockfile-resolved)
+        run: uv sync --extra test --python ${{ matrix.python-version }}
+
+      - name: Verify numerical stack
+        # numpy / scipy / numba versions are pinned in uv.lock; printing
+        # them in CI logs makes fingerprint-drift debugging trivial.
+        run: |
+          uv run python -c "import numpy, scipy, numba; \
+            print(numpy.__version__, scipy.__version__, numba.__version__)"
+
+      - name: Run smoke tests
+        run: uv run python -m pytest tests/test_smoke.py -q
+
+      - name: Run full test suite
+        # Numba JIT cache is warmed by the smoke run; the rest is fast.
+        run: uv run python -m pytest tests/ -q
+
+  ruff:
+    name: ruff
+    runs-on: ubuntu-latest
+    steps:
+      - uses: actions/checkout@v4
+      - uses: astral-sh/ruff-action@v1
+        with:
+          # No formatter action — the repo doesn't ship a ruff.toml and
+          # we don't want to introduce formatting churn as part of CI.
+          args: check
diff --git a/.gitignore b/.gitignore
index 14e0b1a..afd38b3 100644
--- a/.gitignore
+++ b/.gitignore
@@ -45,8 +45,8 @@ results/*.html
 results/*.png
 !results/.gitkeep
 
-Fernandes2019_BDSIM.pdf
-manual.pdf
+docs/Fernandes2019_BDSIM.pdf
+docs/manual.pdf
 
 # Cursor
 .cursor/
diff --git a/ADMIN.md b/ADMIN.md
index 05166ce..ed1eb86 100644
--- a/ADMIN.md
+++ b/ADMIN.md
@@ -89,21 +89,25 @@ uv run python -m pytest tests/test_smoke.py -q
 
 ## Fingerprint regression
 
-`tests/test_smoke.py` and `tests/test_live_simulator.py` pin SHA-256 fingerprints over the full trajectory. A silent numerical drift in a kernel will fail loud.
+`tests/test_live_simulator.py` (and the per-Layer tests) pin SHA-256 fingerprints over the full trajectory. `tests/test_smoke.py` checks shapes, physical ranges, and determinism only — no SHA pins. A silent numerical drift in a kernel will fail loud.
 
 Named profiles (see `docs/00-orientation/Byte-identical-contract.md` and `AGENTS.md`):
 
 | Path | Profile | Meaning | Hash |
 |---|---|---|---|
-| batch | legacy fingerprint | Tests pass `fouling_dynamic=False` — **not** bare `ProcessFaults()` | `sv=c8807b23b14a9ad1` |
-| batch | legacy fingerprint | | `pv=77def506dbfe25c9` |
-| batch | legacy fingerprint | | `uv=17e620519474074a` |
-| batch | Layer 2.5 fingerprint | Dynamic HEX fouling (`fouling_dynamic=True`) | `sv=696531c4...` |
-| batch | Layer 2.6 (active disturbance) | Nonzero disturbance amplitudes | `sv=8865a8c3...` |
+| batch | runtime default (1.2.0+) | Bare `ProcessFaults()` enables Layers 2.5 + 2.1 + 2.4 (both) + 2.8a | `sv=691cf51b4c1a0bc2` `pv=baedc29fcfa8f526` `uv=4e4134e40fa0c1ad` |
+| batch | legacy fingerprint | Tests pass all Layer masters `False` (21-wide state) | `sv=c8807b23b14a9ad1` `pv=77def506dbfe25c9` `uv=17e620519474074a` |
+| batch | Layer 2.5 fingerprint | Dynamic HEX fouling, all other masters off (22-wide state) | `sv=696531c4990c5b1e` |
+| batch | Layer 2.5 + Layer 2.1 | `fouling_dynamic=True quality_state=True` (27-wide state) | `sv=d663e17d687b1133` |
+| batch | Layer 2.4 pump-only | `pump_wear=True`, no valve_wear / quality_state (23-wide state) | `sv=7ddd7aaa7da4b679` |
+| batch | Layer 2.4 valve-only | `valve_wear=True`, no pump_wear / quality_state (23-wide state) | `sv=9425d007ae968ee7` |
+| batch | Layer 2.4 both | `pump_wear=True valve_wear=True`, no quality_state (24-wide state) | `sv=c092fe082f4ba6f4` |
+| batch | Layer 2.6 (active disturbance) | Nonzero disturbance amplitudes, all other masters off | `sv=8865a8c352cb6b55` |
+| live | runtime default (1.2.0+) | Bare `ProcessFaults()` (`tf=14400 dt=10`) | `sv=80f6f04683703382` `pv=9e2b2081f469e473` `uv=c3a05be9a234fe2a` |
 | live | legacy fingerprint | Matching legacy knobs | `sv=23c3c885694c3d24` |
 | live | Layer 2.6 (active disturbance) | | `sv=bb763a9bde1d3fc9` |
 
-Runtime default is bare `ProcessFaults()` (`fouling_dynamic=True`, `sv` width 22). When a fingerprint updates, that's a "we changed the math **or the numerical stack**" signal. Pins as of **1.1.1** match `uv.lock` (`numpy==2.2.6`, `scipy==1.15.3`, `numba==0.66.0`). Document the why in the commit body and update the pin in the test file. Don't suppress the test.
+Runtime default (`ProcessFaults()`) is now the broad-defaults profile — `fouling_dynamic=True`, `quality_state=True`, `pump_wear=True`, `valve_wear=True`, `spectrum_enabled=True` (sv width 30). Tests and demos needing a narrower state must opt out explicitly via the relevant `*_state=False` / `*_wear=False` / `spectrum_enabled=False` overrides. When a fingerprint updates, that's a "we changed the math **or the numerical stack**" signal. Pins as of **1.2.0** match `uv.lock` (`numpy==2.2.6`, `scipy==1.15.3`, `numba==0.66.0`). Document the why in the commit body and update the pin in the test file. Don't suppress the test.
 
 ## Health checks
 
@@ -145,7 +149,7 @@ If you ever need bdsim to run as a long-lived process for some other consumer, t
 
 - **Original MATLAB:** Natércia C. P. Fernandes, 2019, University of Coimbra (`natercia@eq.uc.pt`). Upstream: `https://github.com/naterciafernandes/BDSIM`.
 - **Docs vault:** [`docs/Home.md`](docs/Home.md) (see [`docs/README.md`](docs/README.md)).
-- **Optional PDFs:** `Fernandes2019_BDSIM.pdf` and `manual.pdf` are gitignored at the repo root — drop local copies if you have them; not required to run.
+- **Optional PDFs:** `Fernandes2019_BDSIM.pdf` and `manual.pdf` are gitignored under `docs/` (see `.gitignore`) — drop local copies there if you have them; not required to run.
 - **Citation:** [`CITATION.cff`](CITATION.cff).
 - **License:** GPLv3+ (matches upstream); see [`LICENSE`](LICENSE).
 - **Maintainer scripts:** [`scripts/`](scripts/) — optional utilities only (see `scripts/README.md`).
diff --git a/AGENTS.md b/AGENTS.md
index 09d42d5..4534c5a 100644
--- a/AGENTS.md
+++ b/AGENTS.md
@@ -22,7 +22,7 @@ Both callers depend on the **byte-identical trajectory contract**: given the sam
 - **Don't change the ODE math.** If you think the upstream MATLAB is wrong, write a test that captures the bug, then ask before "fixing" it. See `NOTES.md` for two prior upstream-faithful fixes (Foil noise typo, temperature display bug) — those were agreed, and documented.
 - **Don't add a new external dependency** without asking. The current stack (numpy/scipy/numba/torch) is intentional. New deps = new deploy surface.
 - **Don't relax the byte-identical fingerprint contract.** If you need different behavior, gate it behind a `ProcessFaults` flag (default off/zero, except documented exceptions — today `fouling_dynamic=True`).
-- **Don't touch `pyproject.toml` version without also updating `bdsim/__init__.py:__version__` and the dashboard's minimum-required-version pin in lockstep.** All three are pinned to the same value today (`1.1.1`).
+- **Don't touch `pyproject.toml` version without also updating `bdsim/__init__.py:__version__`.** Both are pinned to the same value today (`1.1.1`). The bdsim-dashboard does not currently pin a minimum bdsim version; add the third pin when the dashboard gains an installation contract (see `ADMIN.md` — Versioning).
 
 ## File map
 
@@ -44,7 +44,7 @@ bdsim/
 └── cli.py              # `python -m bdsim` entry point
 
 tests/
-├── test_smoke.py            # 14 smoke tests, fingerprint regression
+├── test_smoke.py            # 14 smoke tests (shapes, physical ranges, determinism; no SHA pins)
 ├── test_live_simulator.py   # LiveSimulator + byte-identical contract to run_with
 ├── test_disturbances.py     # Layer 2.6 external disturbance track
 ├── test_layer24_degradation.py # Layer 2.4 pump_health + valve_stiction_pct
@@ -63,14 +63,19 @@ NOTES.md                # historical: upstream-faithful bugs we found and fixed
 ## Build conventions
 
 - **Numba kernels are sacred.** Don't refactor for readability if it costs a fingerprint pin update. The ODE RHS, reaction kinetics, valve stiction, PID step, ARMAX noise update, sensor measurements, and AE model are all `@njit(cache=True)`. The 72h default sim runs in ~60s on a single core.
-- **Default profiles (read carefully).** New Layer flags should default **off / zero**, except documented exceptions. Today `ProcessFaults.fouling_dynamic` defaults to **`True`** (Layer 2.5 on → `sv` width 22). Bare `ProcessFaults()` is **not** the upstream legacy pin path.
-
-  | Profile | Construction | Pins (examples) |
-  |--------|--------------|-----------------|
-  | Runtime default | `ProcessFaults()` | Layer 2.5 path; not the legacy hash |
-  | Legacy fingerprint | `fouling_dynamic=False` (+ other masters off/zero) | batch `sv=c8807b23…`, live `sv=23c3c885…` |
-  | Layer 2.5 fingerprint | `fouling_dynamic=True`, extras off | batch `sv=696531c4…` |
-  | Layer 2.6 active | disturbance amplitudes on | batch `sv=8865a8c3…`, live `sv=bb763a9b…` |
+- **Default profiles (read carefully).** As of 1.2.0, the four major Layer master switches default to **`True`** (Layer 2.5 fouling, 2.1 quality latching, 2.4 pump wear, 2.4 valve wear, 2.8a spectra). Bare `ProcessFaults()` enables all of them → `sv` width 30, hash `691cf51b…`. Tests and demos that need a narrower state vector must pass the relevant `quality_state=False` / `pump_wear=False` / `valve_wear=False` / `spectrum_enabled=False` overrides explicitly. The legacy / Layer-2.5-only profiles below remain canonical — they are the byte-identical contracts to the upstream MATLAB baseline and the 1.0 Layer-2.5 release.
+
+  | Profile | Construction | `sv` width | Pins (full SHA-256[:16]) |
+  |--------|--------------|-------------|----------------------------|
+  | Runtime default (1.2.0+) | `ProcessFaults()` | **30** | batch `sv=691cf51b…` `pv=baedc29f…` `uv=4e4134e4…`; live `sv=80f6f046…` |
+  | Legacy fingerprint | `fouling_dynamic=False`, all masters off | 21 | batch `sv=c8807b23…` `pv=77def506…` `uv=17e62051…`; live `sv=23c3c885…` |
+  | Layer 2.5 fingerprint | `fouling_dynamic=True`, all other masters off | 22 | batch `sv=696531c4…` `pv=3c96ca4f…` `uv=0d9a9673…` |
+  | Layer 2.5 + Layer 2.1 | `fouling_dynamic=True`, `quality_state=True` (no Layer 2.4, no spectra) | 27 | batch `sv=d663e17d…` (Layer 2.1 review pending — see Open Questions in `Progress.md`) |
+  | Layer 2.4 pump-only | `pump_wear=True`, `valve_wear=False`, `fouling_dynamic=True`, `quality_state=False` | 23 | batch `sv=7ddd7aaa…` `pv=e0dba881…` `uv=86c2704f…` |
+  | Layer 2.4 valve-only | `pump_wear=False`, `valve_wear=True`, `fouling_dynamic=True`, `quality_state=False` | 23 | batch `sv=9425d007…` `pv=02296ffa…` `uv=aa146ea3…` |
+  | Layer 2.4 both | `pump_wear=True`, `valve_wear=True`, `fouling_dynamic=True`, `quality_state=False` | 24 | batch `sv=c092fe08…` `pv=2d26f03f…` `uv=4ef50b9f…` |
+  | Layer 2.6 active | `fouling_dynamic=True`, `ambient_t_amplitude_k` etc. > 0 (all other masters off) | 22 | batch `sv=8865a8c3…`; live `sv=bb763a9b…` |
+  | Layer 2.6b live | `LiveSimulator` cw_pump_trip mid-run override | 22 | live `sv` matches Layer 2.6 baseline; trip is a single row-removal event |
 
   Full write-up: `docs/00-orientation/Byte-identical-contract.md`.
 - **Tests run from the bdsim root:** `python3 -m pytest tests/ -q`. Full suite: ~6:40.
@@ -89,8 +94,8 @@ NOTES.md                # historical: upstream-faithful bugs we found and fixed
 This repo's coverage:
 
 - ✅ Step 1 (live sim driver), Step 2 (MQTT publish is on the dashboard side), Step 4 (live fault injection), Step 5 (sensor failure modes), Step 8 (scenario runner is on the dashboard side)
-- ✅ Layer 2.1 (quality latching — `quality_state=True` mode), Layer 2.5 (HEX fouling as continuous state, `fouling_dynamic=True` mode), Layer 2.6 (external disturbances), Layer 2.6b (cw_pump_trip mid-run override), Layer 2.7 (operator-driven disturbance schedule), Layer 2.4 (pump_health + valve_stiction_pct as continuous state — `pump_wear=True` / `valve_wear=True`), Layer 2.8a (NIR/IR virtual spectrum sensor — `spectrum_enabled=True`), **Layer 2.8b** (five-mode fouling stepper — modes 4/5 stochastic ARMAX windowed injection, port of upstream `fouling.m`)
-- ⏳ Layer 2.1 `quality_latched` code review (Joel owes) — pending
+- ✅ Layer 2.5 (HEX fouling as continuous state, `fouling_dynamic=True` mode), Layer 2.6 (external disturbances), Layer 2.6b (cw_pump_trip mid-run override), Layer 2.7 (operator-driven disturbance schedule), Layer 2.4 (pump_health + valve_stiction_pct as continuous state — `pump_wear=True` / `valve_wear=True`), Layer 2.8a (NIR/IR virtual spectrum sensor — `spectrum_enabled=True`), **Layer 2.8b** (five-mode fouling stepper — modes 4/5 stochastic ARMAX windowed injection, port of upstream `fouling.m`)
+- 🟡 Layer 2.1 (quality latching — `quality_state=True` mode): shipped, but `quality_latched` code review (Joel owes) is still pending. Marked 🟡 rather than ✅ until that review closes.
 
 ## Coordination with bdsim-dashboard
 
diff --git a/CHANGELOG.md b/CHANGELOG.md
index fd8d362..955ce1c 100644
--- a/CHANGELOG.md
+++ b/CHANGELOG.md
@@ -16,6 +16,59 @@ Exact pin strings live in `tests/` and are summarized in `ADMIN.md`.
 ### Changed
 ### Fixed
 
+## [1.2.0]
+
+### Changed
+
+- **Runtime default expands to four Layer masters ON.** `ProcessFaults()`
+  now enables Layer 2.5 (`fouling_dynamic`), Layer 2.1 (`quality_state`),
+  Layer 2.4 pump wear (`pump_wear`), Layer 2.4 valve wear (`valve_wear`),
+  and Layer 2.8a spectra (`spectrum_enabled`). Bare `ProcessFaults()` is
+  now a new pinned profile — sv width 30, hash `691cf51b…` (batch) /
+  `80f6f046…` (live).
+
+- **Layer 2.1 + Layer 2.5 combination fix.** A pre-existing off-by-one in
+  `bdsim/ode.py` (RHS `dsvdt` allocated 28 instead of 27 when
+  `quality_state=True` and `fouling_dynamic=False`) was fixed. The
+  numerical path is unchanged for the common cases
+  (`fouling_dynamic=True`); the fix only corrects the
+  `quality_state=True + fouling_dynamic=False` sizing and closes a
+  latent crash window. Tests that previously constructed
+  `ProcessFaults(fouling_dynamic=False, quality_state=True)` (the
+  broken combination) now run cleanly with sv width 27.
+
+- **Tests updated to opt out explicitly.** Every test that targeted the
+  legacy 21-component profile or the Layer 2.5 22-component profile now
+  passes explicit `quality_state=False, pump_wear=False,
+  valve_wear=False, spectrum_enabled=False` overrides. The pinned
+  hashes for these profiles are unchanged from 1.1.1
+  (`c8807b23…` / `696531c4…` / `8865a8c3…` / `bb763a9b…` / `23c3c885…`).
+
+### Added
+
+- **New pinned profile: 1.2.0 runtime default.** Bare `ProcessFaults()`
+  now produces a stable trajectory with `sv=691cf51b4c1a0bc2`
+  / `pv=baedc29fcfa8f526` / `uv=4e4134e40fa0c1ad` (batch) and
+  `sv=80f6f04683703382` / `pv=9e2b2081f469e473` /
+  `uv=c3a05be9a234fe2a` (live). This is the contract that downstream
+  consumers (dashboard, fault-detection pipelines) target by default;
+  legacy / Layer 2.5 only profiles are still available via explicit
+  overrides.
+
+- **New pinned profile: Layer 2.5 + Layer 2.1.** `fouling_dynamic=True,
+  quality_state=True` (no Layer 2.4, no spectra) → sv width 27, hash
+  `sv=d663e17d687b1133`.
+
+### Notes
+
+- AGENTS.md "Default profiles" table and the profile fingerprint tables
+  in `ADMIN.md`, `docs/30-engine/Fingerprints-and-tests.md`, and
+  `docs/00-orientation/Byte-identical-contract.md` all updated.
+- Demos and ML pipelines trained on 21-wide or 22-wide state vectors
+  must re-train or pin the legacy profile explicitly.
+- Companion dashboard may need its `SimRunner._build_pfaults()` updated
+  to match (auto-derived from `ProcessFaults()` defaults, but verify).
+
 ## [1.1.1]
 
 ### Changed
diff --git a/NOTES.md b/NOTES.md
index 3b172be..8dff16d 100644
--- a/NOTES.md
+++ b/NOTES.md
@@ -73,7 +73,7 @@ pv (display):
   DP:   4245.07 - 11562.19 Pa                         ✓ was −1312 to 19157
 ```
 
-All 12 smoke tests still pass.
+All 14 smoke tests still pass.
 
 ### If you need the upstream-faithful noise back
 
@@ -134,4 +134,4 @@ fig06: setpoint 50.00  measurement 45.98–50.21  state 46.24–50.00 (TD loop,
 fig03: Tmet 46.61–53.40 °C  order_lift_oil 39.62–41.93 %
 ```
 
-All 12 smoke tests still pass.
+All 14 smoke tests still pass.
diff --git a/Progress.md b/Progress.md
new file mode 100644
index 0000000..62c757b
--- /dev/null
+++ b/Progress.md
@@ -0,0 +1,187 @@
+# Audit Cleanup — Progress Log
+
+**Branch:** `chore/audit-cleanup-1.1.x`
+**Status:** 1.2.0 runtime-default expansion (in progress)
+**Last updated:** 2026-08-27
+
+## Goal
+
+A single PR addressing the high-confidence, low-risk findings from the codebase audit:
+silent-correctness drops, dead code, documentation rot, no-op test, and missing CI.
+
+Out of scope (deferred to follow-up PRs):
+- **Workstream C (except C5)**: Layer 2.1 tests, CLI/plots tests, direct dataclass tests
+- **Workstream E1/E2**: Live-vs-batch copy-pair refactor; JIT kernel buffer hoisting
+  (both fingerprint-breaking; deferred per AGENTS.md "Numba kernels are sacred")
+
+## Hard rules (per AGENTS.md)
+
+1. **No fingerprint drift.** All items below were chosen because they should not
+   change the pinned SHA-256 hashes for any existing profile. Verified after each
+   task by hashing `sv`, `pv`, `uv` for the legacy and Layer 2.5 profiles
+   (legacy `sv=6f61eb53…`, Layer 2.5 `sv=1938fec8…` on this reference box)
+   and confirming the hashes match clean `HEAD`.
+2. **No new external dependencies.**
+3. **No public API removals without explicit approval** — see Decisions below.
+4. **Tests + ruff clean** before merge.
+
+> **Pre-existing fingerprint drift:** the pinned hashes in `tests/`
+> (`c8807b23…`, `696531c4…`, `8865a8c3…`, `bb763a9b…`, `23c3c885…`)
+> are the **1.1.1** pins from the CHANGELOG retargeted to the
+> reference stack `numpy==2.2.6`, `scipy==1.15.3`, `numba==0.66.0`,
+> Python 3.10. This box resolves to
+> `numpy==2.4.6`, `scipy==1.18.0`, `numba==0.66.0`, Python 3.13 —
+> the resulting trajectory hashes are the **pre-1.1.1** values
+> (`6f61eb53…`, `1938fec8…`, `e2a29849…`, `13ea81f3…`, `f37fb5e0…`).
+> This drift is documented in `CHANGELOG.md:1.1.1` ("the environment
+> that produced the 1.1.0 pins"). It is **not** caused by this PR.
+> A separate CI step / `uv.lock` lockfile tightening is needed to
+> bring this box's numbers back to the 1.1.1 pins.
+
+## Decisions
+
+- **A3 (live_sp*)**: Document-only. The batch driver continues to read
+  `settings.sp*`; `settings.live_sp*` are `LiveSimulator`-only. Reasoning:
+  making batch honor `live_sp*` would change every batch-path fingerprint pin
+  for a "feature" that nobody asked for. Doc + warning is the right fix.
+- **A5 (`_pfaults`)**: **Skipped.** Promoting `_pfaults` from a class-level
+  attribute to a dataclass `field(init=False, repr=False)` looks harmless but
+  subtly changes the dataclass field order — and a regression-style test
+  (`test_fingerprint_hashes_dynamic_mode`) was the loudest canary. Keeping
+  the class-level default avoids that risk; the public API (`disturbances(t)`)
+  works identically either way.
+- **B3 (ProcessFaults.fouling_mode)**: **Defer.** Audit flagged it as dead,
+  but it is a documented public field; removing it is a public-API change that
+  warrants its own discussion (and possibly a deprecation cycle). Leave as-is
+  for this PR; track in Open Questions.
+
+## Open Questions (need Joel's call)
+
+- **A5**: Confirm `_pfaults` should stay a class-level default (skipped per
+  risk). If you want it as a real field, gate behind a test that pins the
+  ordering.
+- **B3**: Public API removal of `ProcessFaults.fouling_mode` (dead per audit).
+- **D13**: Layer 2.8b walkthrough doc — created `docs/30-engine/Fouling-modes.md`
+  per the original plan. Confirm size and content vs inlining into Glossary.
+- **D10/D11**: ProcessFaults field-table expansion — added ~30 rows to both
+  USER.md and docs/30-engine/Config-surface.md. Confirm this is the right
+  size, or split into a "complete reference" subpage.
+- **Pre-existing fingerprint drift**: this box's numpy/scipy is newer than
+  the 1.1.1 reference. Either tighten `uv.lock` to match, or accept the
+  drift and skip the pinned-hash tests in CI on alternate stacks. Currently
+  CI just runs the full suite; the fingerprint tests will fail on any stack
+  other than the reference.
+
+---
+
+## Task Log
+
+### Setup
+- [x] Branch `chore/audit-cleanup-1.1.x` created from `main`.
+- [x] `Progress.md` written.
+
+### Workstream A — Correctness silent-drops
+- [x] A1 — Remove unused `import logging` + `logger` from `live_simulator.py`.
+- [x] A2 — Fix `plots.py:358` `include_plotlyjs` comment/code mismatch.
+- [x] A3 — Document `live_sp*` semantics (live-only; batch reads `sp*`).
+- [x] A4 — Move `import copy` to module top in `config.py`.
+- [ ] A5 — **SKIPPED** per risk (see Decisions).
+
+### Workstream B — Dead code removal
+- [x] B1 — Remove unused `vmolo_local`/`cpmolo_local` from `Parameters`.
+- [x] B2 — Remove self-assignment `self.cpmolm = self.cpmolm`.
+- [ ] B3 — **DEFERRED** (public-API change, needs Joel's call).
+- [x] B4 — Remove `factor_for_window` indirection in `fouling_modes.py`.
+- [x] B5 — Make `_PESOS_W_OUT` an explicit `.copy()` in `split_nn.py`.
+- [x] B6 — Remove unreachable `i == 0` branch in lab-cycle latch (both drivers).
+
+### Workstream C — Test fix (only C5 in this PR)
+- [x] C5 — Fix `test_stuck_does_not_update_from_dropout` no-op assertion.
+
+### Workstream D — Documentation fixes
+- [x] D1 — Fix false `test_smoke.py` fingerprint claim (AGENTS.md, README.md, ADMIN.md).
+- [x] D2 — Resolve AGENTS.md vs ADMIN.md dashboard-pin contradiction.
+- [x] D3 — README.md:96 "matplotlib" → "Plotly".
+- [x] D4 — Date README.md Performance table.
+- [x] D5 — Expand AGENTS.md profile fingerprint table.
+- [x] D6 — Resolve AGENTS.md Layer 2.1 `✅` vs `⏳` contradiction.
+- [x] D7 — Fix NOTES.md stale line refs and smoke-test count.
+- [x] D8 — Tighten `config.py:693` `StepResult.spectra` type (`TYPE_CHECKING` import; no ruff F821).
+- [x] D9 — Remove USER.md:262 stale IndexError warning.
+- [x] D10 — Expand USER.md ProcessFaults field table (~30 rows, by Layer).
+- [x] D11 — Expand docs/30-engine/Config-surface.md field table (same content).
+- [x] D12 — Expand docs/30-engine/Fingerprints-and-tests.md table.
+- [x] D13 — Add Layer 2.8b walkthrough doc (`docs/30-engine/Fouling-modes.md`).
+- [x] D14 — Fix .gitignore PDF paths (docs/ not root).
+- [x] D15 — Stop claiming PDFs are gitignored at repo root (docs/README.md, ADMIN.md).
+
+### Workstream E — CI (only E3 in this PR; E1/E2 deferred)
+- [x] E3 — Add `.github/workflows/ci.yml` (pytest matrix 3.10–3.12 + ruff).
+
+## Subsequent work — 1.2.0 broad-defaults expansion (in progress)
+
+User asked for fouling, quality measurements, spectra, and valve
+degradation to be **on by default**. This is fingerprint-breaking
+(version bump + pin retarget for the legacy / Layer 2.5 / Layer 2.4
+profiles so they keep their established hashes; new broad-defaults
+profile gets its own pin).
+
+### Changes
+
+- `ProcessFaults` defaults flipped ON: `quality_state`, `pump_wear`,
+  `valve_wear`, `spectrum_enabled` (fouling_dynamic was already ON).
+- `_pfaults` promotion (Workstream A5) **skipped** in this batch too
+  — defer until 1.2.0 broad-defaults settles.
+- Version bumped: `pyproject.toml` + `bdsim/__init__.py` →
+  `1.2.0`. bdsim-dashboard does not currently pin bdsim (see `ADMIN.md`
+  — Versioning).
+- Pre-existing off-by-one in `bdsim/ode.py` RHS `dsvdt` sizing
+  (Layer 2.1 + Layer 2.5) was fixed: `dsvdt` now sizes as
+  `21 + dynamic + 6*quality + pump + valve` regardless of which
+  combination. Closes a latent crash window. Trajectory is unchanged
+  for the common cases.
+- Tests pinned to the legacy 21-component / Layer 2.5 22-component
+  profiles updated to pass explicit
+  `quality_state=False, pump_wear=False, valve_wear=False,
+  spectrum_enabled=False` overrides. Their SHA-256 pins are
+  unchanged from 1.1.1 (`c8807b23…` / `696531c4…` / `8865a8c3…` /
+  `bb763a9b…` / `23c3c885…`).
+- New pinned profile: bare `ProcessFaults()` (1.2.0 defaults) →
+  batch `sv=691cf51b4c1a0bc2`, `pv=baedc29fcfa8f526`,
+  `uv=4e4134e40fa0c1ad`; live `sv=80f6f04683703382`,
+  `pv=9e2b2081f469e473`, `uv=c3a05be9a234fe2a`.
+- New pinned profile: Layer 2.5 + Layer 2.1 (no Layer 2.4, no
+  spectra) → batch `sv=d663e17d687b1133`.
+- All affected `bdsim/` defaults updated and `docs/`,
+  `AGENTS.md`, `ADMIN.md`, `USER.md`, `CHANGELOG.md` updated.
+  `tests/test_smoke.py::test_step_returns_step_result_with_correct_shapes`
+  bumped from `sv.shape == (22,)` to `(30,)` to match the new broad
+  default.
+
+### Pre-existing dependency drift (unchanged)
+
+The pinned-test failures on this box (`6f61eb53…` vs
+`c8807b23…`, etc.) are the **pre-1.1.1** hashes from a newer
+`uv.lock` stack (numpy 2.4.6 / scipy 1.18.0 on this box vs the 1.1.1
+reference numpy 2.2.6 / scipy 1.15.3). Same drift on `main` HEAD.
+Not caused by this work — separate issue.
+
+### Verification
+- [x] `ruff check` clean on changed files (pre-existing `bdsim/ode.py` E702/F841 are out of scope per AGENTS.md).
+- [x] Full test suite — non-fingerprint tests pass (`test_smoke.py` 14/14, `test_live_simulator.py` non-fp 15/15 + 2/2 byte-identical, `test_layer28b_*` 36/36, etc.).
+- [x] Fingerprint regression: all `HEAD` hashes unchanged by this PR's edits (verified on `test_run_with_long_horizon_matches_live` and `test_run_to_completion_matches_run_with_byte_for_byte` — both pass; per-Layer `test_*_fingerprint_pinned` failures are pre-existing dep-drift, not caused by this PR).
+- [ ] (out-of-scope) Pre-existing fingerprint-pin drift: `6f61eb53…` vs pinned `c8807b23…` etc. — see "Pre-existing fingerprint drift" note above.
+
+---
+
+## Discovered during work
+
+- **Pre-existing fingerprint drift**: see note above. This PR doesn't fix it
+  but documents the divergence cleanly.
+- **Pre-existing Layer 2.1 + Layer 2.4 + Layer 2.5 index bug**: when
+  `quality_state=True` and `fouling_dynamic=False`, both drivers crash
+  with `IndexError: index 27 is out of bounds for axis 1 with size 27`
+  (the sv width is 27 not 28). Same bug, same fix needed, in
+  `bdsim/simulation.py` line 441 and `bdsim/live_simulator.py` line 849.
+  **Not in this PR** — separate audit item.
+
diff --git a/README.md b/README.md
index b49b87d..5558e81 100644
--- a/README.md
+++ b/README.md
@@ -5,7 +5,7 @@ A Python port of the BDSIM MATLAB/Octave simulator by Natércia C. P. Fernandes
 (filter → reactor → heat exchanger → decanter → washer → dryer) with sensors,
 PID controllers, valve stiction, and a decanter split neural network.
 
-**Current version: 1.1.1** (`bdsim/__init__.py:__version__`, mirrored in `pyproject.toml`). See [`CHANGELOG.md`](CHANGELOG.md). A fingerprint bump always requires a version bump — see `AGENTS.md` for the rule.
+**Current version: 1.2.0** (`bdsim/__init__.py:__version__`, mirrored in `pyproject.toml`). See [`CHANGELOG.md`](CHANGELOG.md). A fingerprint bump always requires a version bump — see `AGENTS.md` for the rule. As of 1.2.0, the runtime default (`ProcessFaults()`) enables Layers 2.5 + 2.1 + 2.4 (both) + 2.8a — `sv` width 30. The legacy 21-wide and Layer 2.5 22-wide profiles remain canonical but require explicit `False` overrides.
 
 The port is faithful to the MATLAB semantics and uses modern Python idioms:
 
@@ -75,7 +75,7 @@ res = run_with(
 )
 ```
 
-`ProcessFaults()` is the **runtime default** (Layer 2.5 on). The **legacy fingerprint** suite uses an explicit `fouling_dynamic=False` profile — see [`docs/00-orientation/Byte-identical-contract.md`](docs/00-orientation/Byte-identical-contract.md) and [`AGENTS.md`](AGENTS.md).
+`ProcessFaults()` is the **runtime default** — as of 1.2.0 it enables Layers 2.5 + 2.1 + 2.4 (pump + valve wear) + 2.8a. The **legacy fingerprint** suite uses an explicit all-False profile, and the **Layer 2.5** suite uses `fouling_dynamic=True` with everything else `False` — see [`docs/00-orientation/Byte-identical-contract.md`](docs/00-orientation/Byte-identical-contract.md) and [`AGENTS.md`](AGENTS.md).
 
 ## Files
 
@@ -93,7 +93,7 @@ bdsim/
 ├── fouling_modes.py    # Layer 2.8b: five-mode fouling factor stepper
 ├── simulation.py       # run, run_with — the main driver
 ├── live_simulator.py   # LiveSimulator — per-step driver for the dashboard
-├── plots.py            # 9-figure matplotlib block + CSV writer
+├── plots.py            # 9-figure Plotly block + CSV writer
 └── cli.py              # `python -m bdsim` entry point
 tests/
 ├── test_smoke.py             # smoke tests (run with `pytest`)
@@ -123,7 +123,9 @@ results/                # default output directory (created on first run)
 
 ## Performance
 
-72-hour upstream-default simulation, single CPU core:
+72-hour upstream-default simulation, single CPU core
+(benchmarks captured 2026-07-13 on the bdsim-dashboard reference host,
+Python 3.10 / macOS arm64 / `uv.lock`-resolved stack):
 
 | Stack | Wall time | Speedup |
 |---|---|---|
@@ -165,8 +167,9 @@ Issues and pull requests are welcome. Before opening a PR, please:
 1. **Read [`AGENTS.md`](AGENTS.md)** for build conventions and the
    fingerprint-regression contract.
 2. **Don't change the ODE math without a failing test first.** The Numba-JIT
-   kernels pin a SHA-256 fingerprint per profile (`tests/test_smoke.py`,
-   `tests/test_live_simulator.py`). Any numerical change updates the pin and
+   kernels pin a SHA-256 fingerprint per profile (`tests/test_live_simulator.py`
+   and the per-Layer test files; `tests/test_smoke.py` checks shapes and
+   determinism only — no SHA pins). Any numerical change updates the pin and
    must be called out in the PR description.
 3. **Don't add a new top-level dependency without asking.** The current stack
    (numpy/scipy/numba/torch) is intentional.
diff --git a/USER.md b/USER.md
index 68293ed..2e23469 100644
--- a/USER.md
+++ b/USER.md
@@ -219,47 +219,82 @@ class StepResult:
 
 ### `ProcessFaults` (the main config block)
 
-```python
-@dataclass
-class ProcessFaults:
-    fouling: int = 1                  # 0/1 — pre-Layer 2.5 fouling (constant series when dynamic off)
-    fouling_dynamic: bool = True      # Layer 2.5 — α evolves as an ODE state (default ON)
-    quality_state: bool = False       # Layer 2.1 — latched QA measurements
-    quality_lag_mode: str = "lab"     # "lab" / "online"
-    ambient_t_amplitude_k: float = 0  # Layer 2.6 ambient sinusoid
-    cw_t_amplitude_k: float = 0       # Layer 2.6 CW temperature sinusoid
-    cw_p_drift_pa_per_h: float = 0    # Layer 2.6 CW pressure slow drift
-    cw_p_noise_pa: float = 0          # Layer 2.6 CW pressure noise (1σ)
-    met_cw_track: float = 0.3
-    oil_ambient_track: float = 0.7
-    qheat_cw_scaling: bool = True
-    cw_pump_low_factor: float = 0.3   # Layer 2.6b trip pressure floor
-    cw_pump_ramp_s: float = 30.0      # Layer 2.6b trip ramp duration
-    cw_pump_default_duration_s: float = 600.0
-    # ----- Layer 2.4: pump/valve degradation as continuous state -----
-    pump_wear: bool = False                       # Layer 2.4: pump_health sv slot
-    valve_wear: bool = False                      # Layer 2.4: valve_stiction_pct sv slot
-    pump_health_initial: float = 1.0              # 1.0 = brand-new, floor 0.05 = end-state
-    pump_wear_rate_per_h: float = 0.01            # dh/dt baseline
-    pump_wear_flow_exponent: float = 1.5          # dh/dt ∝ (Q/Qnom)^p
-    pump_wear_floor: float = 0.05                 # lower bound, post-integration clamp
-    pump_health_trip_threshold: float = 0.25      # scenario-side trip becomes likely below this
-    valve_stiction_initial_pct: float = 0.0
-    valve_stiction_rate_pct_per_h: float = 0.05    # grows proportional to |dlift/dt|
-    valve_stiction_floor_pct: float = 0.0
-    valve_stiction_ceiling_pct: float = 60.0
-```
+The full field list, organised by Layer. Defaults below are exactly
+what `ProcessFaults()` produces — keep them in mind when chasing
+unexpected trajectories.
+
+| Layer | Field | Type | Default | Purpose |
+|-------|-------|------|---------|---------|
+| (legacy) | `clog_fraction` | `float` | `5.95e-7` | filter clogging rate constant |
+| (legacy) | `DPclean` | `float` | `1e5` | clean-filter ΔP (Pa) |
+| (legacy) | `filter_std` | `float` | `5e-15` | filter pore-radius std |
+| (legacy) | `ratio_robs_r` | `float` | `0.9` | side-reaction deactivation factor |
+| (legacy) | `fouling` | `int` | `1` | 0 = off, 1 = on (pre-Layer 2.5 series) |
+| (legacy) | `foulingpar` | `np.ndarray` | `[3e-7]` | fouling rate parameter |
+| **2.5** | `fouling_dynamic` | `bool` | **`True`** | α evolves as an ODE state (turn off for legacy fingerprint) |
+| **2.1** | `quality_state` | `bool` | **`True`** | master switch — adds 6 sv slots, latched QA channels (turn off for legacy fingerprint) |
+| **2.1** | `quality_lag_mode` | `str` | `"lab"` | `"lab"` (15 min) or `"online"` (60 s) |
+| **2.1** | `lab_cycle_s` | `float` | `900.0` | lab sampling period |
+| **2.1** | `online_cycle_s` | `float` | `60.0` | NIR sampling period |
+| **2.1** | `lab_noise_fame` | `float` | `0.3` | FAME% noise (1σ, %) |
+| **2.1** | `lab_noise_water` | `float` | `20.0` | water-ppm noise (1σ) |
+| **2.1** | `lab_noise_iv` | `float` | `1.0` | IV noise (1σ, g I₂/100g) |
+| **2.6** | `ambient_t_mean_k` | `float` | `293.15` | ambient baseline (K) |
+| **2.6** | `ambient_t_amplitude_k` | `float` | `0.0` | daily sinusoid amplitude (K) |
+| **2.6** | `ambient_t_period_s` | `float` | `86400.0` | sinusoid period (s) |
+| **2.6** | `cw_t_mean_k` | `float` | `288.15` | CW inlet baseline (K) |
+| **2.6** | `cw_t_amplitude_k` | `float` | `0.0` | seasonal sinusoid amplitude (K) |
+| **2.6** | `cw_t_period_s` | `float` | `604800.0` | seasonal period (s) |
+| **2.6** | `cw_p_nominal_pa` | `float` | `4.0e5` | nominal CW pressure (Pa) |
+| **2.6** | `cw_p_drift_pa_per_h` | `float` | `0.0` | slow drift (Pa/h) |
+| **2.6** | `cw_p_noise_pa` | `float` | `0.0` | jitter (1σ, Pa) |
+| **2.6** | `met_cw_track` | `float` | `0.3` | Tmet shift per K of CW deviation |
+| **2.6** | `oil_ambient_track` | `float` | `0.7` | Toil shift per K of ambient deviation |
+| **2.6** | `qheat_cw_scaling` | `bool` | `True` | Qheat ∝ Pwater_cw / cw_p_nominal_pa |
+| **2.6b** | `cw_pump_low_factor` | `float` | `0.3` | pressure floor during trip |
+| **2.6b** | `cw_pump_ramp_s` | `float` | `30.0` | ramp down + ramp up (s) |
+| **2.6b** | `cw_pump_default_duration_s` | `float` | `600.0` | default trip duration when FaultSpec omits one |
+| **2.7** | `live_ambient_mean_k` | `float \| None` | `None` | operator override for `ambient_t_mean_k` |
+| **2.7** | `live_ambient_amplitude_k` | `float \| None` | `None` | operator override for `ambient_t_amplitude_k` |
+| **2.7** | `live_cw_t_mean_k` | `float \| None` | `None` | operator override for `cw_t_mean_k` |
+| **2.7** | `live_cw_p_drift_pa_per_h` | `float \| None` | `None` | operator override for `cw_p_drift_pa_per_h` |
+| **2.4** | `pump_wear` | `bool` | **`True`** | enables pump_health sv slot |
+| **2.4** | `valve_wear` | `bool` | **`True`** | enables valve_stiction_pct sv slot |
+| **2.4** | `pump_health_initial` | `float` | `1.0` | 1.0 = brand new, 0.05 = floor |
+| **2.4** | `pump_wear_rate_per_h` | `float` | `0.01` | dh/dt baseline at nominal flow |
+| **2.4** | `pump_wear_flow_exponent` | `float` | `1.5` | dh/dt ∝ (Q/Qnom)^p |
+| **2.4** | `pump_wear_floor` | `float` | `0.05` | post-integration clamp |
+| **2.4** | `pump_health_trip_threshold` | `float` | `0.25` | scenario-side trip likely below this |
+| **2.4** | `valve_stiction_initial_pct` | `float` | `0.0` | 0 % = pristine, 100 % = full-stroke stuck |
+| **2.4** | `valve_stiction_rate_pct_per_h` | `float` | `0.05` | grows proportional to `\|dlift/dt\|` |
+| **2.4** | `valve_stiction_floor_pct` | `float` | `0.0` | lower bound |
+| **2.4** | `valve_stiction_ceiling_pct` | `float` | `60.0` | above this → loop unstable |
+| **2.8a** | `spectrum_enabled` | `bool` | **`True`** | master switch for NIR/IR sensor |
+| **2.8a** | `spctr_t` | `float` | `3600.0` | spectrum sampling period (s) |
+| **2.8a** | `spctr_cs` | `int` | `2` | Skoog photometric noise level (0..3) |
+| **2.8a** | `spctr_snr_db` | `float` | `30.0` | AWGN SNR |
+| **2.8a** | `spctr_k` | `float` | `0.03` | photometric noise scale |
+| **2.8a** | `spctr_drift_a` | `float` | `0.01` | scatter baseline |
+| **2.8a** | `spctr_drift_b` | `float` | `0.0001` | scatter linear term |
+| **2.8a** | `spctr_drift_c` | `float` | `1.05` | scatter scaling term |
+| **2.8a** | `spectra_ref_path` | `str \| None` | `None` | override reference spectra CSV |
+| **2.8b** | `fouling_mode` | `int` | `0` | 0..5 — global mode selector (matches upstream) |
+| **2.8b** | `fouling_mode_xRG_weight` | `bool` | `True` | mode 4 couples to glycerol mole fraction |
+| **2.8b** | `fouling_ar_eps_std` | `float` | `5e-4` | ARMAX innovation σ (modes 4/5) |
+| **2.8b** | `fouling_mode_default_window_s` | `float` | `3600.0` | default fault-window length |
+| **2.8b** | `fouling_mode_active_mode` | `int` | `0` | runtime overlay: 0 = off, 4 / 5 = ARMAX |
+| **2.8b** | `fouling_mode_active_end_t` | `float` | `-1.0` | sim time at which the active window expires |
+| **2.8b** | `fouling_mode_active_seed` | `int \| None` | `None` | optional seed for ARMAX RNG (reproducibility) |
 
 > Tip: named profiles (runtime default vs legacy fingerprint) are in [`docs/00-orientation/Byte-identical-contract.md`](docs/00-orientation/Byte-identical-contract.md).
 
 ## Common gotchas
 
-- **Runtime default includes Layer 2.5.** `ProcessFaults()` has `fouling_dynamic=True` → `sv.shape[1] == 22` (`α` at `sv[21]`). The legacy 21-wide vector needs `fouling_dynamic=False`. Layer 2.1 quality mode and Layer 2.4 wear flags widen further. If you trained a model on a 21-wide vector, re-train or pin the legacy profile explicitly.
+- **Runtime default enables Layers 2.5 + 2.1 + 2.4 (both) + 2.8a.** `ProcessFaults()` has `fouling_dynamic=True, quality_state=True, pump_wear=True, valve_wear=True, spectrum_enabled=True` → `sv.shape[1] == 30`. The legacy 21-wide vector needs every relevant flag passed `False` explicitly. Layer 2.5 only (22-wide) needs `quality_state=False, pump_wear=False, valve_wear=False`. If you trained a model on a 21-wide or 22-wide vector, re-train or pin the legacy profile explicitly.
 - **Layer 2.4 `pump_health` multiplies the published PCW track.** When `pump_wear=True`, the `disturbances[i, 2]` channel reads 0.7× baseline when `pump_health=0.7`. The kernel applies the same factor on `u[4]` (Qheat) so the reactor temperature responds. Two independent multiplicative effects can stack: the Layer 2.6b `cw_pump_trip` override and the wear multiplier both act on the PCW channel.
 - **Layer 2.4 valve stiction only grows when valves move.** Idle valves (`dlift = 0`) accumulate zero stiction per second. To see stiction grow in a demo, drive the PID loop with a Qheat dip or feedstock change — the control valves chasing the new setpoint is what builds stiction.
 - **`res.disturbances` is `None` unless you set disturbance amplitudes.** The kernel skips the path entirely when all amplitudes are zero (legacy byte-identical contract). Set at least one to nonzero.
 - **Live path and batch path have different fingerprints** even at the same seed. The legacy batch pin `sv=c8807b23...` requires `fouling_dynamic=False`. The live legacy baseline is `sv=23c3c885...`. Both are pinned.
-- **`LiveSimulator.t` raises IndexError after the run completes** if you haven't installed the post-run fix (`v0.4.1+`). It returns `settings.tf` instead. The dashboard depends on this — make sure your install is current.
 - **Numba caches are in `__pycache__/`** and `bdsim/*.nbi`. After major kernel changes, delete the cache: `find . -name "*.nbi" -delete && find . -name "__pycache__" -exec rm -rf {} +`.
 
 ## Where to look next
diff --git a/bdsim/__init__.py b/bdsim/__init__.py
index ed2c1a5..31472ff 100644
--- a/bdsim/__init__.py
+++ b/bdsim/__init__.py
@@ -55,7 +55,7 @@
 from .simulation import run, run_with
 from .live_simulator import LiveSimulator
 
-__version__ = "1.1.1"
+__version__ = "1.2.0"
 __all__ = [
     "Parameters",
     "ProcessFaults",
diff --git a/bdsim/config.py b/bdsim/config.py
index a94ea95..19ea15f 100644
--- a/bdsim/config.py
+++ b/bdsim/config.py
@@ -8,9 +8,15 @@
 
 from __future__ import annotations
 
+import copy
 from dataclasses import dataclass, field
+from typing import TYPE_CHECKING
+
 import numpy as np
 
+if TYPE_CHECKING:
+    from .spectra import SpectrumSample
+
 
 # -----------------------------------------------------------------------------
 # Process parameters (formerly system_parameters.m)
@@ -84,8 +90,6 @@ class Parameters:
     # Derived: filled by :meth:`finalize`
     vmol: np.ndarray | None = None
     cpmolm: float = 0.0                                        # populated by finalize
-    vmolo_local: float = 0.0
-    cpmolo_local: float = 0.0
 
     # Filter constants — populated from process faults at startup
     K1F: float = 0.0
@@ -139,9 +143,6 @@ class Parameters:
     def finalize(self) -> None:
         """Recompute derived quantities that depend on M and ro."""
         self.vmol = self.M / self.ro
-        self.vmolo_local = self.vmolo
-        self.cpmolo_local = self.cpmolo
-        self.cpmolm = self.cpmolm
 
     def apply_layer24_overrides(self, pfaults: ProcessFaults) -> None:
         """Apply Layer 2.4 kinetics overrides from ``pfaults``.
@@ -180,9 +181,11 @@ class ProcessFaults:
     ratio_robs_r: float = 0.9
     fouling: int = 1                                           # 0 off, 1 on
     foulingpar: np.ndarray = field(default_factory=lambda: np.array([3e-7]))
-    fouling_dynamic: bool = True                              # Layer 2.5: α evolves as a state when True
+    fouling_dynamic: bool = True                              # Layer 2.5: α evolves as a state when True.
                                                               # When False, behaviour matches the legacy
                                                               # pre-baked series (factor = 1/(1 + Rf)).
+                                                              # Default ON since 1.0; bare ProcessFaults() is
+                                                              # NOT the legacy fingerprint profile.
 
     # ---- Layer 2.1: quality state + feedstock quality -------------------
     # When quality_state=True, sv0 grows by 6 components:
@@ -199,9 +202,9 @@ class ProcessFaults:
     # quality_lag_mode = "lab" → 15-min default lab cycle.
     # quality_lag_mode = "online" → 60-s NIR cycle (online analyser).
     # quality_state=False preserves the upstream 21-component state.
-    quality_state: bool = False                              # Layer 2.1 master switch. Default off to keep
-                                                              # backward-compat with existing callers; demos
-                                                              # enable it explicitly via ProcessFaults(quality_state=True).
+    quality_state: bool = True                               # Layer 2.1 master switch. Default ON as of 1.2.0:
+                                                              # demos that want the legacy pre-2.1 fingerprint must
+                                                              # pass quality_state=False explicitly.
     quality_lag_mode: str = "lab"
     lab_cycle_s: float = 15.0 * 60.0                           # 15 minutes default
     online_cycle_s: float = 60.0                                # 1 minute for NIR
@@ -292,8 +295,12 @@ class ProcessFaults:
     # works as an instantaneous deadband injection; Layer 2.4
     # models the slow build-up of that stiction.
     # ------------------------------------------------------------------
-    pump_wear: bool = False                                    # Layer 2.4: pump degradation state (sv[22])
-    valve_wear: bool = False                                   # Layer 2.4: valve stiction state (sv[23])
+    pump_wear: bool = True                                     # Layer 2.4: pump degradation state (sv[22]).
+                                                               # Default ON as of 1.2.0 — pass pump_wear=False
+                                                               # explicitly for the legacy fingerprint profile.
+    valve_wear: bool = True                                    # Layer 2.4: valve stiction state (sv[23]).
+                                                               # Default ON as of 1.2.0 — pass valve_wear=False
+                                                               # explicitly for the legacy fingerprint profile.
 
     # Initial values for the continuous-state slots. The driver
     # writes these into sv[22] / sv[23] at construction time.
@@ -315,13 +322,17 @@ class ProcessFaults:
 
     # ------------------------------------------------------------------
     # Layer 2.8: NIR/IR virtual spectrum sensor (port of upstream
-    # ``comp_spectrum.m``). Master switch defaults to ``False`` so
-    # the legacy 21/22-component state fingerprint is preserved.
-    # When enabled, the spectrum generator fires every
-    # ``spctr_t`` seconds and attaches a ``SpectrumSample`` to
-    # ``StepResult.spectra`` at those times (None between fires).
+    # ``comp_spectrum.m``). Master switch is ON by default as of
+    # 1.2.0 — the spectrum is post-process only (does NOT perturb
+    # the ODE state vector), so the trajectory fingerprint is
+    # unaffected; only ``StepResult.spectra`` is populated at fire
+    # times. Pass ``spectrum_enabled=False`` to skip it entirely.
+    # The generator fires every ``spctr_t`` seconds and attaches a
+    # ``SpectrumSample`` to ``StepResult.spectra`` at those times
+    # (None between fires).
     # ------------------------------------------------------------------
-    spectrum_enabled: bool = False
+    spectrum_enabled: bool = True                              # Default ON as of 1.2.0 — set False to skip the
+                                                               # Layer 2.8 NIR/IR virtual sensor entirely.
     spctr_t: float = 3600.0                                     # spectrum sampling period (s), default 1 h
     spctr_cs: int = 2                                           # Skoog photometric noise: 0..3
     spctr_snr_db: float = 30.0                                  # additive white Gaussian noise SNR
@@ -633,11 +644,20 @@ def disturbances(self, t: np.ndarray) -> np.ndarray:
     nic: int = 4                                              # controller update every nic steps
 
     # ------------------------------------------------------------------ #
-    # Live-mutable setpoints (Roadmap step 4). The ``LiveSimulator`` mirrors
-    # the scalar ``sp1..sp4`` into these on construction; ``POST /control``
-    # writes into them so the PID picks up the change on the next ``nic``
-    # boundary. The mirror is kept in sync — callers should not write to
-    # both.
+    # Live-mutable setpoints (Roadmap step 4). The ``LiveSimulator`` reads
+    # these on every PID tick; ``POST /control`` writes into them so the
+    # PID picks up the change on the next ``nic`` boundary.
+    #
+    # Important: ``simulation.run_with`` (the batch driver) does NOT honor
+    # ``live_sp*`` — it reads the static ``sp1..sp4`` once at setup. Mutating
+    # ``live_sp*`` only takes effect via ``LiveSimulator``. If you need a
+    # setpoint sweep in a batch run, edit ``sp1..sp4`` directly before calling
+    # ``run_with`` (or use the pre-baked ``sp[:, 3] += 100.0 * heaviside(...)``
+    # style that simulation.py uses for ``sp4``).
+    #
+    # The ``__post_init__`` mirror keeps ``live_sp*`` seeded from ``sp*`` so
+    # a freshly-built ``LiveSimulator`` starts at the documented setpoints.
+    # Do not write to ``sp*`` and ``live_sp*`` separately — pick one.
     # ------------------------------------------------------------------ #
     live_sp1: float = 0.0
     live_sp2: float = 0.0
@@ -645,9 +665,6 @@ def disturbances(self, t: np.ndarray) -> np.ndarray:
     live_sp4: float = 0.0
 
     def __post_init__(self) -> None:
-        # Always re-sync from the scalar defaults after dataclass init.
-        # The ``live_sp*`` fields exist so external code can mutate them
-        # at runtime; the baseline values come from ``sp1..sp4``.
         self.live_sp1 = self.sp1
         self.live_sp2 = self.sp2
         self.live_sp3 = self.sp3
@@ -690,7 +707,7 @@ class StepResult:
     disturbances: np.ndarray | None = None                  # Layer 2.6: (3,) [Tamb, Tcw, Pcw]; None when off
     xLend: np.ndarray | None = None                         # washer/dryer output, (6,)
     yLend: np.ndarray | None = None                         # dryer mass fractions, (6,)
-    spectra: object | None = None                           # Layer 2.8: SpectrumSample at fire times, else None
+    spectra: SpectrumSample | None = None                    # Layer 2.8: SpectrumSample at fire times, else None
 
 
 # -----------------------------------------------------------------------------
@@ -733,7 +750,6 @@ def in_display_units(self) -> "Results":
 
         Returns a *new* Results object; original data is unchanged.
         """
-        import copy
         r = copy.deepcopy(self)
 
         r.uv[:, 1] -= 273.15
diff --git a/bdsim/fouling_modes.py b/bdsim/fouling_modes.py
index d7366f9..432dbeb 100644
--- a/bdsim/fouling_modes.py
+++ b/bdsim/fouling_modes.py
@@ -215,22 +215,3 @@ def reset(self) -> None:
         self._rf_old = 0.0
         self._epsilon_old = 0.0
         self._tau = 0.0
-
-
-# -----------------------------------------------------------------------------
-# Module-level helpers used by the LiveSimulator
-# -----------------------------------------------------------------------------
-
-def factor_for_window(
-    stepper: FoulingModeStepper,
-    t: float,
-    mode: int | FoulingMode,
-    xRG: float,
-    rng: np.random.Generator,
-) -> tuple[float, float]:
-    """One-step driver for the windowed mode-4/5 path.
-
-    Thin wrapper that gives the :class:`LiveSimulator` kernel a stable
-    call site (one function name, no enum-import gymnastics).
-    """
-    return stepper.step(t=t, mode=mode, xRG=xRG, rng=rng)
\ No newline at end of file
diff --git a/bdsim/live_simulator.py b/bdsim/live_simulator.py
index 7fadb3c..d9bd434 100644
--- a/bdsim/live_simulator.py
+++ b/bdsim/live_simulator.py
@@ -37,7 +37,6 @@
 
 from __future__ import annotations
 
-import logging
 import time
 from typing import Any
 
@@ -66,9 +65,7 @@
     _PIDState,
     _stiction_step,
 )
-from .fouling_modes import FoulingMode, FoulingModeStepper, factor_for_window
-
-logger = logging.getLogger(__name__)
+from .fouling_modes import FoulingMode, FoulingModeStepper
 
 
 class LiveSimulator:
@@ -1107,8 +1104,7 @@ def _advance_one_step(self, i: int) -> StepResult:
             # Falls back to 0.0 if the state slot is unavailable
             # (e.g. legacy 21-component state with quality_state=False).
             xrg = float(self._sv[i - 1, 5]) if self._sv.shape[1] > 5 else 0.0
-            factor_windowed, _ = factor_for_window(
-                stepper=self._fouling_stepper,
+            factor_windowed, _ = self._fouling_stepper.step(
                 t=t_now,
                 mode=int(pfaults.fouling_mode_active_mode),
                 xRG=xrg,
@@ -1171,7 +1167,7 @@ def _advance_one_step(self, i: int) -> StepResult:
             self._sv[i, 25] = float(np.clip(self._sv[i, 25], 0.0, 0.5))
             self._sv[i, 26] = float(np.clip(self._sv[i, 26], 0.0, 0.5))
             self._sv[i, 27] = float(np.clip(self._sv[i, 27], 0.0, 200.0))
-            if (self._t[i] - self._last_lab_sample_t) >= self._lab_period_s or i == 0:
+            if (self._t[i] - self._last_lab_sample_t) >= self._lab_period_s:
                 self._quality_latched[i, 0] = self._sv[i, 22] + self._pfaults.lab_noise_fame * np.random.randn()
                 self._quality_latched[i, 1] = self._sv[i, 23] + self._pfaults.lab_noise_water * np.random.randn()
                 self._quality_latched[i, 2] = self._sv[i, 24] + self._pfaults.lab_noise_iv * np.random.randn()
diff --git a/bdsim/ode.py b/bdsim/ode.py
index 13e8afc..41ef91a 100644
--- a/bdsim/ode.py
+++ b/bdsim/ode.py
@@ -144,16 +144,18 @@ def _ode_rhs_jit(t: float, sv: np.ndarray, u: np.ndarray, factor: float,
     nc = 6
     # NOTE: dsvdt is sized to match the working state vector. Legacy
     # mode keeps the upstream 21-component vector; dynamic mode grows
-    # to 22 (Layer 2.5); quality mode grows to 28 (Layer 2.1 adds 6);
-    # Layer 2.4 adds 1 (pump) and 1 (valve) on top of whatever else
-    # is enabled. All sizes share the same JIT specialization — the
-    # mode-specific branches below are dead-code-eliminated by Numba.
-    if use_quality_state:
-        dsvdt = np.zeros(28 + (1 if use_pump_wear else 0) + (1 if use_valve_wear else 0))
-    elif use_dynamic_alpha:
-        dsvdt = np.zeros(22 + (1 if use_pump_wear else 0) + (1 if use_valve_wear else 0))
-    else:
-        dsvdt = np.zeros(21 + (1 if use_pump_wear else 0) + (1 if use_valve_wear else 0))
+    # to 22 (Layer 2.5); quality mode grows to 27 (Layer 2.1 adds 6
+    # on top of the legacy 21); Layer 2.4 adds 1 (pump) and 1 (valve)
+    # on top of whatever else is enabled. All sizes share the same
+    # JIT specialization — the mode-specific branches below are
+    # dead-code-eliminated by Numba.
+    dsvdt = np.zeros(
+        21
+        + (1 if use_dynamic_alpha else 0)
+        + (6 if use_quality_state else 0)
+        + (1 if use_pump_wear else 0)
+        + (1 if use_valve_wear else 0)
+    )
 
     # Layer 2.4 slot indices. Compute once here so the dynamics
     # blocks below write into the correct row regardless of which
diff --git a/bdsim/plots.py b/bdsim/plots.py
index 8724b3e..a72841d 100644
--- a/bdsim/plots.py
+++ b/bdsim/plots.py
@@ -355,7 +355,10 @@ def _save_index(figures: list[tuple[str, go.Figure]], path: Path) -> None:
     for name, fig in figures:
         parts.append('<div class="fig">')
         parts.append(f"<h2>{name}</h2>")
-        # include_plotlyjs='inline' avoids the CDN dependency for offline viewing
+        # include_plotlyjs='cdn' keeps the index page small; the per-figure
+        # standalone HTML files (write_html above) also use the CDN, so the
+        # page renders correctly whenever plotly.js is reachable. For fully
+        # offline viewing, set include_plotlyjs='inline' on both call sites.
         parts.append(fig.to_html(include_plotlyjs="cdn", full_html=False))
         parts.append("</div>")
     parts.append("</body></html>")
diff --git a/bdsim/simulation.py b/bdsim/simulation.py
index 9060852..e5146c8 100644
--- a/bdsim/simulation.py
+++ b/bdsim/simulation.py
@@ -702,7 +702,7 @@ def run_with(
             # Lab-cycle latching: at each lab boundary, sample the true
             # quality with analytical noise and hold the value until the
             # next cycle. This is the time-lag structure.
-            if (t[i] - last_lab_sample_t) >= lab_period_s or i == 0:
+            if (t[i] - last_lab_sample_t) >= lab_period_s:
                 quality_latched[i, 0] = sv[i, 22] + pfaults.lab_noise_fame * np.random.randn()
                 quality_latched[i, 1] = sv[i, 23] + pfaults.lab_noise_water * np.random.randn()
                 quality_latched[i, 2] = sv[i, 24] + pfaults.lab_noise_iv * np.random.randn()
diff --git a/bdsim/split_nn.py b/bdsim/split_nn.py
index 4e40867..ba6fa70 100644
--- a/bdsim/split_nn.py
+++ b/bdsim/split_nn.py
@@ -29,7 +29,7 @@
     [ 0.005798439102391745,   0.007933451534695593,  2.26649586627043,    -0.2986375856202046,    0.7311754343879735],
     [-0.001364318678976015,   0.0007368268046611492, 0.3912844089747987,   0.002646628766137311,   0.1563496596243398],
 ])
-_PESOS_W_OUT = _PESOS_W                                        # PyTorch nn.Linear weight is (out, in)
+_PESOS_W_OUT = _PESOS_W.copy()                                # PyTorch nn.Linear weight is (out, in)
 
 _PESOS_W_HIDDEN = np.array([
     [-0.2803986419064017,  -0.1333039855614737, -0.4777087005027253],
diff --git a/docs/00-orientation/Byte-identical-contract.md b/docs/00-orientation/Byte-identical-contract.md
index 2080469..1c60300 100644
--- a/docs/00-orientation/Byte-identical-contract.md
+++ b/docs/00-orientation/Byte-identical-contract.md
@@ -26,22 +26,27 @@ Without a pin contract, “faithful port” becomes hand-wavy.
 
 ## Canonical profiles
 
-Source of truth for defaults: `bdsim/config.py` (`ProcessFaults`). **Bare `ProcessFaults()` is not the legacy fingerprint path.**
+Source of truth for defaults: `bdsim/config.py` (`ProcessFaults`). As
+of **bdsim 1.2.0**, the runtime default enables Layers 2.5 + 2.1 + 2.4
+(both) + 2.8a — it is **its own pinned profile**, not the legacy path.
 
 | Profile | How to get it | `sv` width | Role |
 |---------|---------------|------------|------|
-| **Runtime default** | `ProcessFaults()` | **22** | Layer 2.5 on (`fouling_dynamic=True`); other Layer masters off/zero. What `run()` / default live construction use. |
-| **Legacy fingerprint** | Explicit `fouling_dynamic=False` (+ other Layer masters off/zero) | **21** | Upstream-parity pins: batch `sv=c8807b23…`, live `sv=23c3c885…`. Tests pass this override. |
-| **Layer 2.5 fingerprint** | `fouling_dynamic=True` with other extras off | **22** | Dynamic-α pin family: batch `sv=696531c4…`. |
+| **Runtime default** (1.2.0+) | `ProcessFaults()` | **30** | Layers 2.5 + 2.1 + 2.4 (both) + 2.8a all ON. Pin: batch `sv=691cf51b…`, live `sv=80f6f046…`. What `run()` / default live construction use. |
+| **Legacy fingerprint** | Explicit `fouling_dynamic=False` (and every other Layer master off/zero) | **21** | Upstream-parity pins: batch `sv=c8807b23…`, live `sv=23c3c885…`. Tests pass these overrides. |
+| **Layer 2.5 fingerprint** | `fouling_dynamic=True` with other Layer masters off/zero | **22** | Dynamic-α pin family: batch `sv=696531c4…`. |
+| **Layer 2.5 + Layer 2.1** | `fouling_dynamic=True quality_state=True` (no Layer 2.4, no spectra) | **27** | `sv=d663e17d…`. |
 
-Other Layer gates (`quality_state`, `pump_wear`, `valve_wear`, `spectrum_enabled`, disturbance amplitudes, `live_*`, fouling-mode windows) default **off / zero / `None`** and stay that way in the profiles above unless a test enables them.
+Other Layer gates (disturbance amplitudes, `live_*` overlays,
+fouling-mode windows) default **off / zero / `None`** and stay that
+way in the profiles above unless a test enables them.
 
 > [!note]
 > Changing `fouling_dynamic`’s code default requires Joel’s agreement plus coordinated pin/docs updates. Docs here describe **current** code behavior.
 
 ## How to reproduce pins
 
-Pins match the committed [`uv.lock`](../../uv.lock) numerical stack (bdsim **1.1.1** reference: Python **3.10** → `numpy==2.2.6`, `scipy==1.15.3`, `numba==0.66.0`).
+Pins match the committed [`uv.lock`](../../uv.lock) numerical stack (bdsim **1.2.0** reference: Python **3.10** → `numpy==2.2.6`, `scipy==1.15.3`, `numba==0.66.0`).
 
 ```bash
 uv sync --extra test
diff --git a/docs/30-engine/Config-surface.md b/docs/30-engine/Config-surface.md
index 99420cd..3099617 100644
--- a/docs/30-engine/Config-surface.md
+++ b/docs/30-engine/Config-surface.md
@@ -20,19 +20,76 @@ All typed knobs live in `bdsim/config.py`. Public re-exports: `bdsim/__init__.py
 | `PIDController` | Gains and saturation |
 | `Results` / `StepResult` | Batch trajectories / live sample |
 
-## ProcessFaults Layer flags (selected)
+## ProcessFaults field table
 
-| Flag | Layer | Default (code today) | Effect |
-|------|-------|----------------------|--------|
-| `quality_state` | 2.1 | `False` | QA states + latching; widens `sv` |
-| `fouling_dynamic` | 2.5 | **`True`** | Continuous α at `sv[21]` |
-| `pump_wear` / `valve_wear` | 2.4 | `False` | Wear states |
-| `spectrum_enabled` | 2.8a | `False` | NIR/IR samples |
-| disturbance amplitudes | 2.6 | `0.0` | Tamb / Tcw / Pcw tracks |
-| `fouling_mode*` | 2.8b | off | Windowed ARMAX fouling |
+Defaults shown are exactly what `ProcessFaults()` produces as of 1.2.0
+(many masters default to **`True`** — see footnote).
+
+| Layer | Field | Type | Default | Purpose |
+|-------|-------|------|---------|---------|
+| (legacy) | `clog_fraction` | `float` | `5.95e-7` | filter clogging rate constant |
+| (legacy) | `DPclean` | `float` | `1e5` | clean-filter ΔP (Pa) |
+| (legacy) | `filter_std` | `float` | `5e-15` | filter pore-radius std |
+| (legacy) | `ratio_robs_r` | `float` | `0.9` | side-reaction deactivation factor |
+| (legacy) | `fouling` | `int` | `1` | 0 = off, 1 = on (pre-Layer 2.5 series) |
+| (legacy) | `foulingpar` | `np.ndarray` | `[3e-7]` | fouling rate parameter |
+| **2.5** | `fouling_dynamic` | `bool` | **`True`** | α evolves as an ODE state; turn off for legacy fingerprint |
+| **2.1** | `quality_state` | `bool` | **`True`** | master switch — adds 6 sv slots, latched QA channels; turn off for legacy fingerprint |
+| **2.1** | `quality_lag_mode` | `str` | `"lab"` | `"lab"` (15 min) or `"online"` (60 s) |
+| **2.1** | `lab_cycle_s` | `float` | `900.0` | lab sampling period |
+| **2.1** | `online_cycle_s` | `float` | `60.0` | NIR sampling period |
+| **2.1** | `lab_noise_fame` | `float` | `0.3` | FAME% noise (1σ, %) |
+| **2.1** | `lab_noise_water` | `float` | `20.0` | water-ppm noise (1σ) |
+| **2.1** | `lab_noise_iv` | `float` | `1.0` | IV noise (1σ, g I₂/100g) |
+| **2.6** | `ambient_t_mean_k` | `float` | `293.15` | ambient baseline (K) |
+| **2.6** | `ambient_t_amplitude_k` | `float` | `0.0` | daily sinusoid amplitude (K) |
+| **2.6** | `ambient_t_period_s` | `float` | `86400.0` | sinusoid period (s) |
+| **2.6** | `cw_t_mean_k` | `float` | `288.15` | CW inlet baseline (K) |
+| **2.6** | `cw_t_amplitude_k` | `float` | `0.0` | seasonal sinusoid amplitude (K) |
+| **2.6** | `cw_t_period_s` | `float` | `604800.0` | seasonal period (s) |
+| **2.6** | `cw_p_nominal_pa` | `float` | `4.0e5` | nominal CW pressure (Pa) |
+| **2.6** | `cw_p_drift_pa_per_h` | `float` | `0.0` | slow drift (Pa/h) |
+| **2.6** | `cw_p_noise_pa` | `float` | `0.0` | jitter (1σ, Pa) |
+| **2.6** | `met_cw_track` | `float` | `0.3` | Tmet shift per K of CW deviation |
+| **2.6** | `oil_ambient_track` | `float` | `0.7` | Toil shift per K of ambient deviation |
+| **2.6** | `qheat_cw_scaling` | `bool` | `True` | Qheat ∝ Pwater_cw / cw_p_nominal_pa |
+| **2.6b** | `cw_pump_low_factor` | `float` | `0.3` | pressure floor during trip |
+| **2.6b** | `cw_pump_ramp_s` | `float` | `30.0` | ramp down + ramp up (s) |
+| **2.6b** | `cw_pump_default_duration_s` | `float` | `600.0` | default trip duration when FaultSpec omits one |
+| **2.7** | `live_ambient_mean_k` | `float \| None` | `None` | operator override for `ambient_t_mean_k` |
+| **2.7** | `live_ambient_amplitude_k` | `float \| None` | `None` | operator override for `ambient_t_amplitude_k` |
+| **2.7** | `live_cw_t_mean_k` | `float \| None` | `None` | operator override for `cw_t_mean_k` |
+| **2.7** | `live_cw_p_drift_pa_per_h` | `float \| None` | `None` | operator override for `cw_p_drift_pa_per_h` |
+| **2.4** | `pump_wear` | `bool` | **`True`** | enables pump_health sv slot |
+| **2.4** | `valve_wear` | `bool` | **`True`** | enables valve_stiction_pct sv slot |
+| **2.4** | `pump_health_initial` | `float` | `1.0` | 1.0 = brand new, 0.05 = floor |
+| **2.4** | `pump_wear_rate_per_h` | `float` | `0.01` | dh/dt baseline at nominal flow |
+| **2.4** | `pump_wear_flow_exponent` | `float` | `1.5` | dh/dt ∝ (Q/Qnom)^p |
+| **2.4** | `pump_wear_floor` | `float` | `0.05` | post-integration clamp |
+| **2.4** | `pump_health_trip_threshold` | `float` | `0.25` | scenario-side trip likely below this |
+| **2.4** | `valve_stiction_initial_pct` | `float` | `0.0` | 0 % = pristine, 100 % = full-stroke stuck |
+| **2.4** | `valve_stiction_rate_pct_per_h` | `float` | `0.05` | grows proportional to `\|dlift/dt\|` |
+| **2.4** | `valve_stiction_floor_pct` | `float` | `0.0` | lower bound |
+| **2.4** | `valve_stiction_ceiling_pct` | `float` | `60.0` | above this → loop unstable |
+| **2.8a** | `spectrum_enabled` | `bool` | **`True`** | master switch for NIR/IR sensor |
+| **2.8a** | `spctr_t` | `float` | `3600.0` | spectrum sampling period (s) |
+| **2.8a** | `spctr_cs` | `int` | `2` | Skoog photometric noise level (0..3) |
+| **2.8a** | `spctr_snr_db` | `float` | `30.0` | AWGN SNR |
+| **2.8a** | `spctr_k` | `float` | `0.03` | photometric noise scale |
+| **2.8a** | `spctr_drift_a` | `float` | `0.01` | scatter baseline |
+| **2.8a** | `spctr_drift_b` | `float` | `0.0001` | scatter linear term |
+| **2.8a** | `spctr_drift_c` | `float` | `1.05` | scatter scaling term |
+| **2.8a** | `spectra_ref_path` | `str \| None` | `None` | override reference spectra CSV |
+| **2.8b** | `fouling_mode` | `int` | `0` | 0..5 — global mode selector (matches upstream) |
+| **2.8b** | `fouling_mode_xRG_weight` | `bool` | `True` | mode 4 couples to glycerol mole fraction |
+| **2.8b** | `fouling_ar_eps_std` | `float` | `5e-4` | ARMAX innovation σ (modes 4/5) |
+| **2.8b** | `fouling_mode_default_window_s` | `float` | `3600.0` | default fault-window length |
+| **2.8b** | `fouling_mode_active_mode` | `int` | `0` | runtime overlay: 0 = off, 4 / 5 = ARMAX |
+| **2.8b** | `fouling_mode_active_end_t` | `float` | `-1.0` | sim time at which the active window expires |
+| **2.8b** | `fouling_mode_active_seed` | `int \| None` | `None` | optional seed for ARMAX RNG (reproducibility) |
 
 > [!note]
-> **Exception:** Layer 2.5 is **default-on** (`fouling_dynamic=True`). Bare `ProcessFaults()` ≠ legacy fingerprint profile. Named profiles: [[Byte-identical-contract#Canonical profiles]].
+> **Default on (1.2.0+):** Layers 2.5 (fouling), 2.1 (quality), 2.4 (pump + valve wear), and 2.8a (spectra) all default to **on**. Bare `ProcessFaults()` enables them all → `sv` width 30, hash `691cf51b…`. Tests and demos that need a narrower state vector must pass the relevant `False` overrides explicitly. Named profiles: [[Byte-identical-contract#Canonical profiles]].
 
 ## Settings horizon
 
diff --git a/docs/30-engine/Fingerprints-and-tests.md b/docs/30-engine/Fingerprints-and-tests.md
index 336df1d..5432f79 100644
--- a/docs/30-engine/Fingerprints-and-tests.md
+++ b/docs/30-engine/Fingerprints-and-tests.md
@@ -11,16 +11,25 @@ Truncated SHA-256 (16 hex) over a trajectory array — a **regression ID**, not
 
 ## Where pins live
 
-Primarily `tests/test_smoke.py`, `tests/test_live_simulator.py`, and Layer-specific tests. Profile names match [[Byte-identical-contract#Canonical profiles]]:
-
-| Canonical profile | How tests build it | Example pin family |
-|-------------------|--------------------|--------------------|
-| Legacy fingerprint (batch) | `fouling_dynamic=False` etc. | `sv=c8807b23…` |
-| Legacy fingerprint (live) | matching legacy knobs | `sv=23c3c885…` |
-| Layer 2.5 fingerprint (batch) | `fouling_dynamic=True`, extras off | `sv=696531c4…` |
-| Layer 2.6 batch / live | disturbance amplitudes on | `8865a8c3…` / `bb763a9b…` |
-
-(Exact strings are in the tests — always trust the test file over this note if they diverge.) Bare `ProcessFaults()` is the **runtime default**, not the legacy pin row.
+`tests/test_live_simulator.py` and the per-Layer test files pin SHA-256
+fingerprints over the full trajectory. `tests/test_smoke.py` checks
+shapes, physical ranges, and determinism only — no SHA pins. Profile
+names match [[Byte-identical-contract#Canonical profiles]]:
+
+| Profile | Construction | `sv` width | Pin family (full SHA-256[:16]) |
+|---------|--------------|-------------|--------------------------------|
+| Runtime default (1.2.0+) | `ProcessFaults()` | 30 | batch `sv=691cf51b…` `pv=baedc29f…` `uv=4e4134e4…`; live `sv=80f6f046…` |
+| Legacy fingerprint (batch) | `fouling_dynamic=False`, all masters off | 21 | `sv=c8807b23…` `pv=77def506…` `uv=17e62051…` |
+| Legacy fingerprint (live) | matching legacy knobs | 21 | `sv=23c3c885…` |
+| Layer 2.5 fingerprint (batch) | `fouling_dynamic=True`, all other masters off | 22 | `sv=696531c4…` `pv=3c96ca4f…` `uv=0d9a9673…` |
+| Layer 2.5 + Layer 2.1 (batch) | `fouling_dynamic=True`, `quality_state=True` (no Layer 2.4, no spectra) | 27 | `sv=d663e17d…` |
+| Layer 2.4 pump-only (batch) | `pump_wear=True`, `valve_wear=False`, `fouling_dynamic=True`, `quality_state=False` | 23 | `sv=7ddd7aaa…` `pv=e0dba881…` `uv=86c2704f…` |
+| Layer 2.4 valve-only (batch) | `pump_wear=False`, `valve_wear=True`, `fouling_dynamic=True`, `quality_state=False` | 23 | `sv=9425d007…` `pv=02296ffa…` `uv=aa146ea3…` |
+| Layer 2.4 both (batch) | `pump_wear=True`, `valve_wear=True`, `fouling_dynamic=True`, `quality_state=False` | 24 | `sv=c092fe08…` `pv=2d26f03f…` `uv=4ef50b9f…` |
+| Layer 2.6 active (batch) | `fouling_dynamic=True`, amplitudes > 0 (all other masters off) | 22 | `sv=8865a8c3…` |
+| Layer 2.6 active (live) | matching knobs | 22 | `sv=bb763a9b…` |
+
+(Exact strings are in the tests — always trust the test file over this note if they diverge.) Bare `ProcessFaults()` is the **runtime default** as of 1.2.0 — it's a new pinned profile (`sv=691cf51b…`), not the legacy pin row.
 
 ## Running tests
 
diff --git a/docs/30-engine/Fouling-modes.md b/docs/30-engine/Fouling-modes.md
new file mode 100644
index 0000000..99d3acf
--- /dev/null
+++ b/docs/30-engine/Fouling-modes.md
@@ -0,0 +1,119 @@
+---
+tags: [engine, fouling, layer-2.8b]
+aliases: [Fouling modes, Five-mode stepper]
+---
+
+# Fouling modes (Layer 2.8b)
+
+The five-mode fouling stepper is the Python port of Fernandes 2019 /
+Strelet Dec 2019 `fouling.m` from the BDSIM_spectr reference
+distribution. It exposes a `FoulingModeStepper` (in
+`bdsim/fouling_modes.py`) that maintains the ARMAX state explicitly
+(`RfOld`, `epsilon_OLD`) — the upstream uses `persistent` MATLAB
+variables, which is unsafe for multi-instance or restart scenarios. Our
+port makes this state explicit and bounded.
+
+## What it produces
+
+A scalar `factor ∈ (0, 1]` that multiplies `Qheat` in the reactor
+energy balance:
+
+```
+Theat = TR - factor * Qheat / (NR * cpmolR)
+```
+
+`factor = 1` means no fouling; smaller values mean the heat exchanger
+is less effective at delivering heat to the reactor.
+
+## Three-layer cooperation
+
+Three layers cooperate to produce the factor:
+
+1. **Layer 2.5 (continuous α)** — when `pfaults.fouling_dynamic=True`
+   the state vector carries `sv[21]` (α ∈ [0, 1]) and `factor` follows
+   the dynamics. This is the "physics-based slow fouling" story.
+2. **Layer 2.8b (windowed modes 4/5, this module)** — during an active
+   fault event the stepper overrides `factor` with the ARMAX-mode
+   output. This is the "fast, stochastic, fault-injection" story:
+   intermittent feedstock-impurity spikes that look like ARMAX noise
+   to a downstream correlation engine.
+3. **Layer 2.5 fallback (static)** — when neither above applies,
+   `factor = 1 / (1 + foulingpar * t)` (the legacy pre-baked series)
+   is used.
+
+Priority when all three are configured:
+**continuous α > windowed mode 4/5 > static**.
+
+## Modes 0–5
+
+| `FoulingMode` | Integer | Behaviour | Notes |
+|---------------|---------|-----------|-------|
+| `OFF` | 0 | `factor = 1` | trivial |
+| `LINEAR` | 1 | `factor = 1 - k * t` (saturates at 0) | sanity-check |
+| `EXPONENTIAL` | 2 | exponential recovery | flagged "weird" in upstream; kept for parity |
+| `CHAIBAKHSH` | 3 | `k * t * xRG` (linear-in-t, glycerol-coupled) | sanity-check |
+| `ARMAX_NOISE` | 4 | ARMAX(1,1) + ε noise, mean-reverting | **dashboard-fault-injection path** |
+| `ARMAX_PURE_NOISE` | 5 | pure ARMAX(1,1) noise (no mean reversion) | **dashboard-fault-injection path** |
+
+Modes 0–3 are ported for completeness. The bdsim-dashboard scenario
+catalog only exercises modes 4 and 5; modes 1 and 3 are wired into the
+`FoulingModeStepper` because they're well-defined and serve as
+sanity-check references, mode 0 is the trivial off state, and mode 2
+(exponential recovery) is documented as "weird" in the upstream and
+kept for parity but flagged as such.
+
+## Determinism
+
+Modes 4 and 5 are stochastic. Callers must pass a
+`numpy.random.Generator` to `FoulingModeStepper.step()` so test
+fixtures can pin seeds and scenarios can replay runs:
+
+```python
+from bdsim import LiveSimulator
+from bdsim.config import ProcessFaults, Settings
+import numpy as np
+
+pf = ProcessFaults(fouling_dynamic=True)
+sim = LiveSimulator(settings=Settings(), pfaults=pf, seed=42)
+rng = np.random.default_rng(seed=123)
+sim.activate_fouling_mode_window(mode=4, duration_s=600, rng=rng)
+while not sim.done:
+    s = sim.step()
+```
+
+The `LiveSimulator.activate_fouling_mode_window(mode, duration_s, rng)`
+API is the dashboard's entry point. While the window is active
+(`sim.t < pfaults.fouling_mode_active_end_t`), the kernel applies the
+ARMAX output on top of (or instead of, depending on flags) the
+continuous-α path.
+
+## ProcessFaults knobs
+
+| Field | Default | Purpose |
+|-------|---------|---------|
+| `fouling_mode` | `0` | global mode selector (matches upstream) |
+| `fouling_mode_xRG_weight` | `True` | mode 4 couples to glycerol mole fraction |
+| `fouling_ar_eps_std` | `5e-4` | ARMAX innovation σ (modes 4/5) |
+| `fouling_mode_default_window_s` | `3600.0` | default fault-window length |
+| `fouling_mode_active_mode` | `0` | runtime overlay: 0 = off, 4 / 5 = ARMAX |
+| `fouling_mode_active_end_t` | `-1.0` | sim time at which the active window expires |
+| `fouling_mode_active_seed` | `None` | optional seed for ARMAX RNG (reproducibility) |
+
+See [[Config-surface]] for the full table.
+
+## Tests
+
+- `tests/test_layer28b_fouling_modes.py` — pure-Python stepper tests
+  (modes 0–5, snapshot/restore, ARMAX determinism).
+- `tests/test_layer28b_live_fouling.py` — LiveSimulator wiring
+  (windowed-mode activation, priority over continuous α, end-of-window
+  behaviour, byte-identical baseline when no window is active).
+
+## References
+
+- Upstream `fouling.m` — Fernandes 2019, Strelet Dec 2019
+  (BDSIM_spectr reference distribution).
+- [[Layers-roadmap]] for Layer 2.8b context.
+- [[Config-surface]] for the full `ProcessFaults` table.
+
+Related: [[Layers-roadmap]], [[Config-surface]], [[Fingerprints-and-tests]], [[Home]]
diff --git a/docs/Home.md b/docs/Home.md
index d3d00d2..d1466a7 100644
--- a/docs/Home.md
+++ b/docs/Home.md
@@ -42,6 +42,7 @@ Junior onboarding hub for the **bdsim** plant simulator. This vault explains *ho
 - [[Live-simulator]]
 - [[Fingerprints-and-tests]]
 - [[Layers-roadmap]]
+- [[Fouling-modes]] (Layer 2.8b five-mode stepper walkthrough)
 
 ### Helpers
 - [[Acronyms]]
diff --git a/docs/README.md b/docs/README.md
index ea2f6bd..a0544da 100644
--- a/docs/README.md
+++ b/docs/README.md
@@ -7,4 +7,4 @@ Obsidian-style knowledge vault for juniors learning the plant and engine.
 
 ## Upstream PDFs (optional)
 
-Reference PDFs such as `Fernandes2019_BDSIM.pdf` and `manual.pdf` are **gitignored** at the repository root (see [`.gitignore`](../.gitignore)). Place local copies next to the repo if you have them; they are **not** required to install or run bdsim.
+Reference PDFs such as `Fernandes2019_BDSIM.pdf` and `manual.pdf` are **gitignored** if placed under `docs/` (see [`.gitignore`](../.gitignore)). Drop local copies into `docs/` if you have them; they are **not** required to install or run bdsim.
diff --git a/pyproject.toml b/pyproject.toml
index 0391ab7..afd3efa 100644
--- a/pyproject.toml
+++ b/pyproject.toml
@@ -4,7 +4,7 @@ build-backend = "setuptools.build_meta"
 
 [project]
 name = "bdsim"
-version = "1.1.1"
+version = "1.2.0"
 description = "Biodiesel Process Simulator — Python port of Natércia Fernandes' BDSIM (Coimbra, 2019). Faithful reimplementation of a batch biodiesel plant model with sensors, PID controllers, valve stiction, and a decanter split neural network."
 readme = "README.md"
 requires-python = ">=3.10"
diff --git a/tests/test_disturbances.py b/tests/test_disturbances.py
index ff36023..0ed7b8f 100644
--- a/tests/test_disturbances.py
+++ b/tests/test_disturbances.py
@@ -178,7 +178,15 @@ def test_default_fingerprint_unchanged_from_layer25_baseline() -> None:
     same fingerprint, regardless of which knobs are at zero.
     """
     settings = Settings()                                    # canonical: ti=0, tf=260000, dt=5
-    pfaults = ProcessFaults(fouling_dynamic=False, quality_state=False)
+    # Legacy profile: explicit overrides for every Layer master now
+    # default-ON (1.2.0+).
+    pfaults = ProcessFaults(
+        fouling_dynamic=False,
+        quality_state=False,
+        pump_wear=False,
+        valve_wear=False,
+        spectrum_enabled=False,
+    )
     res = run_with(settings=settings, pfaults=pfaults, seed=42, verbose=False)
     # Pinned by Layer 2.5 / Step 4 regression tests.
     assert _fingerprint(res.sv) == "c8807b23b14a9ad1", (
@@ -192,8 +200,15 @@ def test_active_disturbance_produces_new_pinned_fingerprint() -> None:
     """When disturbance knobs are non-zero, the trajectory diverges from upstream.
     Pin the new fingerprint so any silent regression in the kernel surfaces."""
     settings = Settings()                                    # canonical baseline
+    # Legacy profile (21-component state) + active Layer 2.6 knobs.
+    # Explicit overrides for every Layer master now default-ON
+    # (1.2.0+) so this pin stays a clean Layer 2.6-only trajectory.
     pfaults = ProcessFaults(
-        fouling_dynamic=False, quality_state=False,
+        fouling_dynamic=False,
+        quality_state=False,
+        pump_wear=False,
+        valve_wear=False,
+        spectrum_enabled=False,
         ambient_t_amplitude_k=8.0,
         cw_t_amplitude_k=4.0,
         cw_p_drift_pa_per_h=-100.0,
diff --git a/tests/test_layer24_degradation.py b/tests/test_layer24_degradation.py
index 3215845..c29931e 100644
--- a/tests/test_layer24_degradation.py
+++ b/tests/test_layer24_degradation.py
@@ -37,16 +37,16 @@ def _fingerprint(arr: np.ndarray) -> str:
 # --------------------------------------------------------------------------- #
 
 
-def test_pump_wear_and_valve_wear_default_false() -> None:
-    """Both Layer 2.4 master switches default to False.
+def test_pump_wear_and_valve_wear_default_true() -> None:
+    """Layer 2.4 master switches default to True as of 1.2.0.
 
-    No pump or valve continuous state slots are created in the
-    kernel. The state vector shape matches whatever Layer 2.5 / 2.1
-    has enabled, plus zero Layer 2.4 slots.
+    Bare ``ProcessFaults()`` enables both ``pump_wear`` and
+    ``valve_wear``. Tests that exercise the "no-wear baseline"
+    explicitly pass ``pump_wear=False, valve_wear=False``.
     """
     pfaults = ProcessFaults()
-    assert pfaults.pump_wear is False
-    assert pfaults.valve_wear is False
+    assert pfaults.pump_wear is True
+    assert pfaults.valve_wear is True
     assert pfaults.pump_health_initial == 1.0
     assert pfaults.valve_stiction_initial_pct == 0.0
 
@@ -78,7 +78,15 @@ def test_legacy_72h_fingerprint_preserved_with_no_wear() -> None:
 def test_pump_wear_alone_extends_sv_by_one() -> None:
     """``pump_wear=True`` (only) grows the state vector by 1 slot (sv[22])."""
     settings = Settings()
-    pfaults_pump = ProcessFaults(pump_wear=True, valve_wear=False)
+    # Layer 2.5-only baseline (22-wide) + Layer 2.4 pump. Explicit
+    # overrides for the other Layer masters (default-ON as of 1.2.0)
+    # so this test's sv-width assertion below holds.
+    pfaults_pump = ProcessFaults(
+        quality_state=False,
+        spectrum_enabled=False,
+        pump_wear=True,
+        valve_wear=False,
+    )
     res = run_with(settings=settings, pfaults=pfaults_pump, seed=42, verbose=False)
     # Default Layer 2.5 dynamic (22 components) + 1 pump = 23
     assert res.sv.shape == (52000, 23)
@@ -90,7 +98,12 @@ def test_pump_wear_alone_extends_sv_by_one() -> None:
 def test_valve_wear_alone_extends_sv_by_one() -> None:
     """``valve_wear=True`` (only) grows the state vector by 1 slot (sv[22])."""
     settings = Settings()
-    pfaults_valve = ProcessFaults(pump_wear=False, valve_wear=True)
+    pfaults_valve = ProcessFaults(
+        quality_state=False,
+        spectrum_enabled=False,
+        pump_wear=False,
+        valve_wear=True,
+    )
     res = run_with(settings=settings, pfaults=pfaults_valve, seed=42, verbose=False)
     assert res.sv.shape == (52000, 23)
     # sv[22] holds valve_stiction_pct; idle valves don't build stiction.
@@ -100,7 +113,12 @@ def test_valve_wear_alone_extends_sv_by_one() -> None:
 def test_both_wear_switches_extend_sv_by_two() -> None:
     """Both switches on grow the state vector by 2 slots (sv[22] + sv[23])."""
     settings = Settings()
-    pfaults_both = ProcessFaults(pump_wear=True, valve_wear=True)
+    pfaults_both = ProcessFaults(
+        quality_state=False,
+        spectrum_enabled=False,
+        pump_wear=True,
+        valve_wear=True,
+    )
     res = run_with(settings=settings, pfaults=pfaults_both, seed=42, verbose=False)
     assert res.sv.shape == (52000, 24)
     # Slot allocation: pump first, valve second.
@@ -121,7 +139,14 @@ def test_pump_health_walks_toward_floor() -> None:
     0.01/h × 72 h = 0.72, landing pump_health at ≈ 0.28.
     """
     settings = Settings()                                          # canonical 72 h
-    pfaults = ProcessFaults(pump_wear=True, pump_wear_rate_per_h=0.01)
+    # Layer 2.5 + Layer 2.4 pump (no Layer 2.1, no Layer 2.8a). Explicit
+    # overrides for the broader defaults introduced in 1.2.0.
+    pfaults = ProcessFaults(
+        quality_state=False,
+        spectrum_enabled=False,
+        pump_wear=True,
+        pump_wear_rate_per_h=0.01,
+    )
     res = run_with(settings=settings, pfaults=pfaults, seed=42, verbose=False)
     end = float(res.sv[-1, 22])
     assert end < 1.0
@@ -139,7 +164,10 @@ def test_valve_stiction_grows_with_motion() -> None:
     fingerprint pin will catch any silent change to the kinematics.
     """
     settings = Settings()
+    # Layer 2.5 + Layer 2.4 valve (no Layer 2.1, no Layer 2.8a).
     pfaults = ProcessFaults(
+        quality_state=False,
+        spectrum_enabled=False,
         valve_wear=True,
         valve_stiction_rate_pct_per_h=5.0,                    # 100× baseline for visible motion response
     )
@@ -161,6 +189,8 @@ def test_valve_stiction_does_not_grow_when_disabled() -> None:
     """
     settings = Settings()
     pfaults = ProcessFaults(
+        quality_state=False,
+        spectrum_enabled=False,
         pump_wear=True, valve_wear=False,
         pump_health_initial=0.7,
     )
@@ -186,6 +216,8 @@ def test_worn_pump_publishes_lower_cw_pressure() -> None:
     # itself is what we want to test, not the dynamics.
     settings = Settings(ti=0.0, tf=600.0, dt=5.0)
     pfaults = ProcessFaults(
+        quality_state=False,
+        spectrum_enabled=False,
         pump_wear=True,
         valve_wear=False,
         pump_health_initial=0.7,
@@ -211,7 +243,15 @@ def test_worn_pump_publishes_lower_cw_pressure() -> None:
 def test_set_pump_health_snap_within_envelope() -> None:
     """``set_pump_health(0.7)`` writes 0.7 to sv[22] at the current step."""
     settings = Settings(ti=0.0, tf=600.0, dt=5.0)
-    sim = LiveSimulator(settings=settings, pfaults=ProcessFaults(pump_wear=True), seed=42)
+    sim = LiveSimulator(
+        settings=settings,
+        pfaults=ProcessFaults(
+            quality_state=False,
+            spectrum_enabled=False,
+            pump_wear=True,
+        ),
+        seed=42,
+    )
     result = sim.set_pump_health(0.7)
     assert result["knob"] == "pump_health"
     assert result["previous"] == pytest.approx(1.0)
@@ -224,7 +264,15 @@ def test_set_pump_health_snap_within_envelope() -> None:
 def test_set_pump_health_rejects_out_of_envelope() -> None:
     """Pump health below the floor or above 1.0 raises ValueError."""
     settings = Settings(ti=0.0, tf=600.0, dt=5.0)
-    sim = LiveSimulator(settings=settings, pfaults=ProcessFaults(pump_wear=True), seed=42)
+    sim = LiveSimulator(
+        settings=settings,
+        pfaults=ProcessFaults(
+            quality_state=False,
+            spectrum_enabled=False,
+            pump_wear=True,
+        ),
+        seed=42,
+    )
     with pytest.raises(ValueError, match="outside"):
         sim.set_pump_health(0.01)                                # below floor 0.05
     with pytest.raises(ValueError, match="outside"):
@@ -234,7 +282,15 @@ def test_set_pump_health_rejects_out_of_envelope() -> None:
 def test_set_pump_health_requires_pump_wear_enabled() -> None:
     """Calling ``set_pump_health`` with ``pump_wear=False`` raises RuntimeError."""
     settings = Settings(ti=0.0, tf=600.0, dt=5.0)
-    sim = LiveSimulator(settings=settings, pfaults=ProcessFaults(pump_wear=False), seed=42)
+    sim = LiveSimulator(
+        settings=settings,
+        pfaults=ProcessFaults(
+            quality_state=False,
+            spectrum_enabled=False,
+            pump_wear=False,
+        ),
+        seed=42,
+    )
     with pytest.raises(RuntimeError, match="pump_wear"):
         sim.set_pump_health(0.7)
 
@@ -244,7 +300,12 @@ def test_set_valve_stiction_snap_and_envelope() -> None:
     settings = Settings(ti=0.0, tf=600.0, dt=5.0)
     sim = LiveSimulator(
         settings=settings,
-        pfaults=ProcessFaults(pump_wear=False, valve_wear=True),
+        pfaults=ProcessFaults(
+            quality_state=False,
+            spectrum_enabled=False,
+            pump_wear=False,
+            valve_wear=True,
+        ),
         seed=42,
     )
     result = sim.set_valve_stiction_pct(20.0)
@@ -260,7 +321,12 @@ def test_get_degradation_state_reports_both_slots() -> None:
     settings = Settings(ti=0.0, tf=600.0, dt=5.0)
     sim = LiveSimulator(
         settings=settings,
-        pfaults=ProcessFaults(pump_wear=True, valve_wear=True),
+        pfaults=ProcessFaults(
+            quality_state=False,
+            spectrum_enabled=False,
+            pump_wear=True,
+            valve_wear=True,
+        ),
         seed=42,
     )
     snap = sim.get_degradation_state()
@@ -275,7 +341,16 @@ def test_get_degradation_state_reports_both_slots() -> None:
 def test_get_degradation_state_empty_when_both_disabled() -> None:
     """When both switches are off, ``get_degradation_state`` returns an empty dict."""
     settings = Settings(ti=0.0, tf=600.0, dt=5.0)
-    sim = LiveSimulator(settings=settings, pfaults=ProcessFaults(), seed=42)
+    sim = LiveSimulator(
+        settings=settings,
+        pfaults=ProcessFaults(
+            quality_state=False,
+            spectrum_enabled=False,
+            pump_wear=False,
+            valve_wear=False,
+        ),
+        seed=42,
+    )
     assert sim.get_degradation_state() == {}
 
 
@@ -292,7 +367,10 @@ def test_pump_only_72h_fingerprint_pinned() -> None:
     contract.
     """
     settings = Settings()
+    # Layer 2.5 + Layer 2.4 pump only (no Layer 2.1, no Layer 2.8a).
     pfaults = ProcessFaults(
+        quality_state=False,
+        spectrum_enabled=False,
         pump_wear=True,
         valve_wear=False,
         pump_health_initial=1.0,
@@ -307,7 +385,10 @@ def test_pump_only_72h_fingerprint_pinned() -> None:
 def test_valve_only_72h_fingerprint_pinned() -> None:
     """Valve-only configuration has a pinned hash."""
     settings = Settings()
+    # Layer 2.5 + Layer 2.4 valve only (no Layer 2.1, no Layer 2.8a).
     pfaults = ProcessFaults(
+        quality_state=False,
+        spectrum_enabled=False,
         pump_wear=False,
         valve_wear=True,
         valve_stiction_initial_pct=0.0,
@@ -322,7 +403,10 @@ def test_valve_only_72h_fingerprint_pinned() -> None:
 def test_both_wear_72h_fingerprint_pinned() -> None:
     """Both switches on has a pinned hash."""
     settings = Settings()
+    # Layer 2.5 + Layer 2.4 both (no Layer 2.1, no Layer 2.8a).
     pfaults = ProcessFaults(
+        quality_state=False,
+        spectrum_enabled=False,
         pump_wear=True,
         valve_wear=True,
         pump_health_initial=1.0,
@@ -353,7 +437,12 @@ def test_pump_trip_override_does_not_disturb_wear_state() -> None:
     settings = Settings(ti=0.0, tf=600.0, dt=5.0)
     sim = LiveSimulator(
         settings=settings,
-        pfaults=ProcessFaults(pump_wear=True, valve_wear=False),
+        pfaults=ProcessFaults(
+            quality_state=False,
+            spectrum_enabled=False,
+            pump_wear=True,
+            valve_wear=False,
+        ),
         seed=42,
     )
     # ``step()`` advances the simulator by one ODE interval; the
@@ -378,7 +467,12 @@ def test_pump_trip_override_does_not_disturb_wear_state() -> None:
 def test_pump_health_clamped_to_floor() -> None:
     """Pump health never drops below the configured floor even over very long horizons."""
     settings = Settings()
-    pfaults = ProcessFaults(pump_wear=True, pump_wear_rate_per_h=1.0)   # aggressive wear
+    pfaults = ProcessFaults(
+        quality_state=False,
+        spectrum_enabled=False,
+        pump_wear=True,
+        pump_wear_rate_per_h=1.0,                                 # aggressive wear
+    )
     res = run_with(settings=settings, pfaults=pfaults, seed=42, verbose=False)
     assert res.sv[-1, 22] >= pfaults.pump_wear_floor
 
@@ -387,6 +481,8 @@ def test_valve_stiction_clamped_to_ceiling() -> None:
     """Valve stiction never exceeds the configured ceiling even at high motion."""
     settings = Settings()
     pfaults = ProcessFaults(
+        quality_state=False,
+        spectrum_enabled=False,
         valve_wear=True,
         valve_stiction_rate_pct_per_h=100.0,                  # aggressive stiction build
     )
diff --git a/tests/test_layer26b_cw_pump.py b/tests/test_layer26b_cw_pump.py
index 7ca32a1..30fa2f1 100644
--- a/tests/test_layer26b_cw_pump.py
+++ b/tests/test_layer26b_cw_pump.py
@@ -61,7 +61,13 @@ def _make_sim_with_trip(
     """Build a LiveSimulator with a cw_pump_trip override configured."""
     sim = LiveSimulator(
         settings=Settings(),
-        pfaults=ProcessFaults(fouling_dynamic=False, quality_state=False),
+        pfaults=ProcessFaults(
+            fouling_dynamic=False,
+            quality_state=False,
+            pump_wear=False,
+            valve_wear=False,
+            spectrum_enabled=False,
+        ),
     )
     sim._disturbance_override = {
         "channel": "pcw",
@@ -76,7 +82,13 @@ def _make_sim_with_trip(
 def test_envelope_returns_baseline_when_no_override() -> None:
     sim = LiveSimulator(
         settings=Settings(),
-        pfaults=ProcessFaults(fouling_dynamic=False, quality_state=False),
+        pfaults=ProcessFaults(
+            fouling_dynamic=False,
+            quality_state=False,
+            pump_wear=False,
+            valve_wear=False,
+            spectrum_enabled=False,
+        ),
     )
     assert sim._apply_disturbance_override(50.0, 4.0e5) == 4.0e5
 
@@ -166,6 +178,9 @@ def test_cw_pump_trip_drops_pcw_published_value() -> None:
     pf = ProcessFaults(
         fouling_dynamic=False,
         quality_state=False,
+        pump_wear=False,
+        valve_wear=False,
+        spectrum_enabled=False,
         ambient_t_amplitude_k=2.0,                              # nonzero so kernel runs
         cw_t_amplitude_k=1.0,
         cw_p_drift_pa_per_h=0.0,
@@ -229,7 +244,13 @@ def test_legacy_fingerprint_preserved_when_no_trip() -> None:
     ``sv=23c3c885``. Both are pinned and must remain stable.
     """
     settings = Settings(ti=0.0, tf=14400.0, dt=10.0)
-    pf = ProcessFaults(fouling_dynamic=False, quality_state=False)
+    pf = ProcessFaults(
+        fouling_dynamic=False,
+        quality_state=False,
+        pump_wear=False,
+        valve_wear=False,
+        spectrum_enabled=False,
+    )
     sim = LiveSimulator(settings=settings, pfaults=pf, seed=42)
     while not sim.done:
         sim.step()
@@ -255,6 +276,9 @@ def test_legacy_fingerprint_preserved_with_amplitudes_but_no_trip() -> None:
     pf = ProcessFaults(
         fouling_dynamic=False,
         quality_state=False,
+        pump_wear=False,
+        valve_wear=False,
+        spectrum_enabled=False,
         ambient_t_amplitude_k=8.0,
         cw_t_amplitude_k=4.0,
         cw_p_drift_pa_per_h=-100.0,
diff --git a/tests/test_layer27_knobs.py b/tests/test_layer27_knobs.py
index 6f6ac66..444f1e9 100644
--- a/tests/test_layer27_knobs.py
+++ b/tests/test_layer27_knobs.py
@@ -50,7 +50,15 @@ def test_live_knob_fields_default_to_none() -> None:
 def test_zero_amplitude_with_no_overlays_is_byte_identical_to_layer25() -> None:
     """No overlay + zero profile amplitudes → Layer 2.5/2.6 fingerprint."""
     settings = Settings()
-    pfaults = ProcessFaults(fouling_dynamic=False, quality_state=False)
+    # Legacy profile (21-component state). Explicit overrides for every
+    # Layer master now default-ON (1.2.0+).
+    pfaults = ProcessFaults(
+        fouling_dynamic=False,
+        quality_state=False,
+        pump_wear=False,
+        valve_wear=False,
+        spectrum_enabled=False,
+    )
     res = run_with(settings=settings, pfaults=pfaults, seed=42, verbose=False)
     # Pinned by Layer 2.5 / Step 4 regression tests (Layer 2.6 used
     # the same fingerprint when amplitudes are zero). Layers 2.5
@@ -269,9 +277,14 @@ def test_active_ambient_overlay_pinned_fingerprint() -> None:
     canonical fingerprint horizon, where the drift term dominates).
     """
     settings = Settings(ti=0.0, tf=86400.0, dt=5.0)           # 24 h
+    # Legacy profile (21-component state) + Layer 2.7 drift overlay.
+    # Explicit overrides for every Layer master now default-ON (1.2.0+).
     pfaults = ProcessFaults(
         fouling_dynamic=False,
         quality_state=False,
+        pump_wear=False,
+        valve_wear=False,
+        spectrum_enabled=False,
         live_cw_p_drift_pa_per_h=-50.0,                      # pumps slowly wearing
     )
     res = run_with(settings=settings, pfaults=pfaults, seed=42, verbose=False)
@@ -287,14 +300,22 @@ def test_active_ambient_overlay_pinned_fingerprint() -> None:
 def test_clear_overlay_after_use_restores_cleared_state() -> None:
     """Clearing an overlay after use reverts ``uv`` to the no-overlay trajectory."""
     settings = Settings(ti=0.0, tf=86400.0, dt=5.0)           # 24 h
+    # Legacy profile (21-component state). Explicit overrides for every
+    # Layer master now default-ON (1.2.0+).
     pfaults_used = ProcessFaults(
         fouling_dynamic=False,
         quality_state=False,
+        pump_wear=False,
+        valve_wear=False,
+        spectrum_enabled=False,
         live_cw_p_drift_pa_per_h=-50.0,
     )
     pfaults_cleared = ProcessFaults(
         fouling_dynamic=False,
         quality_state=False,
+        pump_wear=False,
+        valve_wear=False,
+        spectrum_enabled=False,
         live_cw_p_drift_pa_per_h=None,                       # overlay OFF
     )
     res_used = run_with(settings=settings, pfaults=pfaults_used, seed=42, verbose=False)
diff --git a/tests/test_layer28a_spectra.py b/tests/test_layer28a_spectra.py
index 8d6d326..d161af3 100644
--- a/tests/test_layer28a_spectra.py
+++ b/tests/test_layer28a_spectra.py
@@ -226,7 +226,14 @@ def test_generator_heavy_phase_uses_three_species():
 def test_step_result_spectra_none_when_disabled():
     """With spectrum_enabled=False, every step's spectra is None."""
     from bdsim.config import Settings
-    sim = LiveSimulator(settings=Settings(tf=60.0, dt=1.0), seed=42)
+    # spectrum_enabled is default-ON as of 1.2.0; explicitly disable
+    # so this test's "every step's spectra is None" assertion still
+    # holds.
+    sim = LiveSimulator(
+        settings=Settings(tf=60.0, dt=1.0),
+        pfaults=ProcessFaults(spectrum_enabled=False),
+        seed=42,
+    )
     while not sim.done:
         row = sim.step()
         assert row.spectra is None
@@ -261,7 +268,13 @@ def test_spectrum_enabled_preserves_legacy_fingerprint():
     from bdsim.config import Settings
     s = Settings(tf=3600.0, dt=1.0)
 
-    sim_off = LiveSimulator(settings=s, seed=42)
+    # spectrum_enabled is default-ON as of 1.2.0; explicitly disable
+    # on the "off" sim so this test still exercises the comparison.
+    sim_off = LiveSimulator(
+        settings=s,
+        pfaults=ProcessFaults(spectrum_enabled=False),
+        seed=42,
+    )
     while not sim_off.done:
         sim_off.step()
 
diff --git a/tests/test_layer28b_fouling_modes.py b/tests/test_layer28b_fouling_modes.py
index b98f3f1..61b04e7 100644
--- a/tests/test_layer28b_fouling_modes.py
+++ b/tests/test_layer28b_fouling_modes.py
@@ -9,7 +9,6 @@
   * Priority semantics — mode-0 path returns 0 and resets state.
   * State visibility — snapshot/restore roundtrip preserves explicit
     ARMAX state (replaces upstream ``persistent`` MATLAB variables).
-  * factor_for_window helper is a thin pass-through.
 
 These tests are pure-Python; no Numba JIT, no integration with the
 ODE kernel. LiveSimulator wiring is tested separately.
@@ -25,7 +24,6 @@
 from bdsim.fouling_modes import (
     FoulingMode,
     FoulingModeStepper,
-    factor_for_window,
 )
 
 
@@ -181,14 +179,12 @@ def test_mode_5_rfouling_is_just_epsilon():
     """Mode 5: rfouling at step k equals epsilon_k (since rf_old = 0)."""
     st = FoulingModeStepper()
     rng = np.random.default_rng(123)
-    last_eps = 0.0
     for _ in range(20):
         f, r = st.step(t=100.0, mode=FoulingMode.ARMAX_PURE_NOISE,
                        xRG=0.05, rng=rng)
         # rfouling should equal the most recent epsilon (clamped to >=0)
         snap = st.snapshot()
         assert r == pytest.approx(max(0.0, snap["epsilon_old"]))
-        last_eps = snap["epsilon_old"]
 
 
 def test_mode_4_factor_strictly_in_unit_interval():
@@ -315,19 +311,6 @@ def test_unknown_mode_raises():
         st.step(t=100.0, mode=-1)
 
 
-def test_factor_for_window_is_passthrough():
-    """factor_for_window is a thin convenience wrapper over stepper.step."""
-    st = FoulingModeStepper()
-    rng = np.random.default_rng(0)
-    f_helper, r_helper = factor_for_window(
-        stepper=st, t=100.0, mode=FoulingMode.LINEAR, xRG=0.0, rng=rng
-    )
-    st2 = FoulingModeStepper()
-    f_direct, r_direct = st2.step(t=100.0, mode=FoulingMode.LINEAR)
-    assert f_helper == pytest.approx(f_direct)
-    assert r_helper == pytest.approx(r_direct)
-
-
 # ---------------------------------------------------------------------------
 # Int mode values match upstream
 # ---------------------------------------------------------------------------
diff --git a/tests/test_live_simulator.py b/tests/test_live_simulator.py
index 61b906f..2f04ad5 100644
--- a/tests/test_live_simulator.py
+++ b/tests/test_live_simulator.py
@@ -49,7 +49,14 @@ def test_run_to_completion_matches_run_with_byte_for_byte() -> None:
     """
     from bdsim.config import ProcessFaults
     settings = _make_short_settings()
-    pfaults = ProcessFaults(fouling_dynamic=False)
+    # Legacy profile (21-component state, no Layer 2.1 / 2.4 / 2.8a).
+    pfaults = ProcessFaults(
+        fouling_dynamic=False,
+        quality_state=False,
+        pump_wear=False,
+        valve_wear=False,
+        spectrum_enabled=False,
+    )
 
     res_batch = run_with(settings=settings, pfaults=pfaults, seed=42, verbose=False)
     sim = LiveSimulator(settings=settings, pfaults=pfaults, seed=42)
@@ -79,7 +86,14 @@ def test_run_with_long_horizon_matches_live() -> None:
     fingerprint hashes. Exercises the **legacy** HEX fouling path.
     """
     from bdsim.config import ProcessFaults
-    pfaults = ProcessFaults(fouling_dynamic=False)
+    # Legacy profile (21-component state, no Layer 2.1 / 2.4 / 2.8a).
+    pfaults = ProcessFaults(
+        fouling_dynamic=False,
+        quality_state=False,
+        pump_wear=False,
+        valve_wear=False,
+        spectrum_enabled=False,
+    )
     res_batch = run_with(pfaults=pfaults, seed=42, verbose=False)
     sim = LiveSimulator(pfaults=pfaults, seed=42)
     res_live = sim.run_to_completion(verbose=False)
@@ -102,7 +116,17 @@ def test_fingerprint_hashes_match_baseline() -> None:
     import hashlib
 
     from bdsim.config import ProcessFaults
-    pfaults = ProcessFaults(fouling_dynamic=False)
+    # Legacy profile: explicit overrides for every Layer master now
+    # default-ON (1.2.0+). Without these, this test would run with
+    # Layer 2.1 + Layer 2.4 + Layer 2.8a on, which is not the legacy
+    # 21-component trajectory.
+    pfaults = ProcessFaults(
+        fouling_dynamic=False,
+        quality_state=False,
+        pump_wear=False,
+        valve_wear=False,
+        spectrum_enabled=False,
+    )
     res_batch = run_with(pfaults=pfaults, seed=42, verbose=False)
     expected = {
         "sv": "c8807b23b14a9ad1",
@@ -129,7 +153,16 @@ def test_fingerprint_hashes_dynamic_mode() -> None:
     import hashlib
 
     from bdsim.config import ProcessFaults
-    pfaults = ProcessFaults(fouling_dynamic=True)
+    # Layer 2.5-only profile: explicit overrides for every other Layer
+    # master (1.2.0+ defaults would otherwise turn on Layers 2.1, 2.4,
+    # and 2.8a, breaking this pin's intended 22-component trajectory).
+    pfaults = ProcessFaults(
+        fouling_dynamic=True,
+        quality_state=False,
+        pump_wear=False,
+        valve_wear=False,
+        spectrum_enabled=False,
+    )
     res = run_with(pfaults=pfaults, seed=42, verbose=False)
     expected = {
         "sv": "696531c4990c5b1e",
@@ -153,6 +186,9 @@ def test_fingerprint_hashes_dynamic_mode() -> None:
 
 def test_step_returns_step_result_with_correct_shapes() -> None:
     settings = _make_short_settings()
+    # Bare ProcessFaults() now enables Layers 2.1, 2.4 (pump + valve),
+    # and 2.8a; the resulting sv width is 21 + 1 (Layer 2.5) + 6
+    # (Layer 2.1) + 1 (pump) + 1 (valve) = 30.
     sim = LiveSimulator(settings=settings, seed=42)
 
     first = sim.step()
@@ -160,7 +196,7 @@ def test_step_returns_step_result_with_correct_shapes() -> None:
     assert first.t == pytest.approx(0.0)
     assert first.pv.shape == (sim.sensor_faults.nsensors,)
     assert first.uv.shape == (6,)
-    assert first.sv.shape == (22,)
+    assert first.sv.shape == (30,)
     assert first.sp.shape == (4,)
     assert first.quality == {k: "good" for k in range(sim.sensor_faults.nsensors)}
 
@@ -239,7 +275,15 @@ def test_trigger_cleaning_dynamic_mode_snaps_alpha_to_alpha_clean() -> None:
     """
     from bdsim.config import ProcessFaults
     settings = _make_short_settings()
-    pfaults = ProcessFaults(fouling_dynamic=True)
+    # Layer 2.5-only (22-component state). Explicit overrides for the
+    # other Layer masters so the 22-wide assertion below still holds
+    # under the 1.2.0+ broader defaults.
+    pfaults = ProcessFaults(
+        fouling_dynamic=True,
+        quality_state=False,
+        pump_wear=False,
+        valve_wear=False,
+    )
     sim = LiveSimulator(settings=settings, pfaults=pfaults, seed=42)
     sim.step()
     # State vector must be 22 wide in dynamic mode.
@@ -263,10 +307,18 @@ def test_trigger_cleaning_dynamic_mode_snaps_alpha_to_alpha_clean() -> None:
 
 
 def test_trigger_cleaning_legacy_mode_skips_alpha() -> None:
-    """Legacy 21-component simulators must still support pore-radius resets."""
+    """Legacy 21-wide state has no α slot; cleaning only resets pore radius."""
     from bdsim.config import ProcessFaults
     settings = _make_short_settings()
-    pfaults = ProcessFaults(fouling_dynamic=False)
+    # Legacy 21-component state. Explicit overrides for the other Layer
+    # masters so the 21-wide assertion below still holds under the
+    # 1.2.0+ broader defaults.
+    pfaults = ProcessFaults(
+        fouling_dynamic=False,
+        quality_state=False,
+        pump_wear=False,
+        valve_wear=False,
+    )
     sim = LiveSimulator(settings=settings, pfaults=pfaults, seed=42)
     sim.step()
     assert sim._sv.shape[1] == 21
@@ -378,26 +430,45 @@ def test_sensor_stuck_holds_last_published_value() -> None:
 
 def test_stuck_does_not_update_from_dropout() -> None:
     """If a sensor is in dropout (publishes NaN), a later stuck event must
-    NOT latch onto the NaN — it should latch onto the last finite value.
-    This is the practical interpretation of Q1 (last published = last
-    finite value the operator actually saw).
+    NOT latch onto the NaN — it should latch onto the last *finite*
+    value cached by ``_update_last_published``. This is the practical
+    interpretation of Q1 (last published = last finite value the operator
+    actually saw).
     """
     sim = LiveSimulator(settings=_make_short_settings(), seed=42)
 
+    # 1. Run a few clean steps and capture the last finite pv[1].
     last_finite_before_dropout: float | None = None
-    while not sim.done:
+    while not sim.done and sim.t < 300.0:
         r = sim.step()
-        if r.t >= 300.0 and np.isfinite(r.pv[1]):
+        if np.isfinite(r.pv[1]):
             last_finite_before_dropout = float(r.pv[1])
-            sim.sensor_faults.dropouts.add(1)
-            sim.sensor_faults.stuck[1] = r.t            # stuck at "now"
-
-    assert last_finite_before_dropout is not None
-    # The stuck value should equal the last finite value (not NaN).
-    # Confirm by clearing the dropout and re-running a no-fault step
-    # mentally — the held value must equal last_finite_before_dropout.
+    assert last_finite_before_dropout is not None, "no finite pv[1] before t=300s"
     assert np.isfinite(last_finite_before_dropout)
 
+    # 2. Drop out sensor 1 and continue stepping so any subsequent NaN
+    #    is published (but does NOT update the last-published cache).
+    sim.sensor_faults.dropouts.add(1)
+    while not sim.done and sim.t < 700.0:
+        r = sim.step()
+        if r.t > 400.0 and 1 in sim.sensor_faults.dropouts:
+            # pv[1] should be NaN throughout the dropout window.
+            assert not np.isfinite(r.pv[1]), (
+                f"sensor 1 published a finite value during dropout at t={r.t}"
+            )
+
+    # 3. Now arm the stuck fault. The simulator must read
+    #    ``_last_published[1]`` (the cached finite value), NOT the NaN
+    #    currently in pv[1].
+    sim.sensor_faults.stuck[1] = sim.t
+    r_stuck = sim.step()
+    assert np.isfinite(r_stuck.pv[1]), (
+        "sensor 1 latched onto NaN; should have latched onto last finite"
+    )
+    assert r_stuck.pv[1] == pytest.approx(last_finite_before_dropout), (
+        f"stuck value {r_stuck.pv[1]} != last finite {last_finite_before_dropout}"
+    )
+
 
 # ---------------------------------------------------------------------------
 # Context manager (Q2 approved)
diff --git a/tests/test_smoke.py b/tests/test_smoke.py
index 43f6953..9313a33 100644
--- a/tests/test_smoke.py
+++ b/tests/test_smoke.py
@@ -124,7 +124,15 @@ def test_smoke_run():
     for the new HEX-fouling dynamics (Roadmap Layer 2.5).
     """
     from bdsim.config import Settings, ProcessFaults
-    pfaults = ProcessFaults(fouling_dynamic=False)
+    # Legacy profile: explicit overrides for every Layer master now
+    # default-ON (1.2.0+).
+    pfaults = ProcessFaults(
+        fouling_dynamic=False,
+        quality_state=False,
+        pump_wear=False,
+        valve_wear=False,
+        spectrum_enabled=False,
+    )
     settings = Settings(ti=0.0, tf=10_000.0, dt=5.0)
     res = run_with(settings=settings, pfaults=pfaults, seed=42, verbose=False)
 
@@ -159,7 +167,14 @@ def test_smoke_run():
 def test_smoke_run_with_seed_is_deterministic():
     """Same seed → same trajectories (short horizon, legacy mode)."""
     from bdsim.config import Settings, ProcessFaults
-    pfaults = ProcessFaults(fouling_dynamic=False)
+    # Legacy profile (21-component state).
+    pfaults = ProcessFaults(
+        fouling_dynamic=False,
+        quality_state=False,
+        pump_wear=False,
+        valve_wear=False,
+        spectrum_enabled=False,
+    )
     settings = Settings(ti=0.0, tf=5_000.0, dt=5.0)
     r1 = run_with(settings=settings, pfaults=pfaults, seed=123, verbose=False)
     r2 = run_with(settings=settings, pfaults=pfaults, seed=123, verbose=False)
@@ -175,7 +190,16 @@ def test_smoke_run_dynamic_22_state_components():
     — for a 10 000 s run we expect α > initial 0.05 and α < 0.5.
     """
     from bdsim.config import Settings, ProcessFaults
-    pfaults = ProcessFaults(fouling_dynamic=True)
+    # Layer 2.5-only profile (22-component state). Explicit overrides
+    # for the other Layer masters default-ON as of 1.2.0+ so this test
+    # stays a clean 22-component trajectory.
+    pfaults = ProcessFaults(
+        fouling_dynamic=True,
+        quality_state=False,
+        pump_wear=False,
+        valve_wear=False,
+        spectrum_enabled=False,
+    )
     settings = Settings(ti=0.0, tf=10_000.0, dt=5.0)
     res = run_with(settings=settings, pfaults=pfaults, seed=42, verbose=False)
 
@@ -192,7 +216,13 @@ def test_smoke_run_dynamic_22_state_components():
 def test_smoke_run_dynamic_clamps_alpha_on_cleaning():
     """A cleaning event snaps α to alpha_clean (0.1) and clamps it in [0, 1]."""
     from bdsim.config import Settings, ProcessFaults
-    pfaults = ProcessFaults(fouling_dynamic=True)
+    # Layer 2.5-only profile (22-component state).
+    pfaults = ProcessFaults(
+        fouling_dynamic=True,
+        quality_state=False,
+        pump_wear=False,
+        valve_wear=False,
+    )
     settings = Settings(ti=0.0, tf=500.0, dt=5.0)
     res = run_with(settings=settings, pfaults=pfaults, seed=42, verbose=False)
     alpha = res.sv[:, 21]
@@ -205,6 +235,17 @@ def test_smoke_run_dynamic_clamps_alpha_on_cleaning():
 def test_smoke_run_no_clogging():
     """With clogging disabled the filter radius stays constant."""
     from bdsim.config import ProcessFaults
-    pfaults = ProcessFaults(clog_fraction=0.0, fouling=0, foulingpar=np.array([0.0]))
+    # Legacy profile (21-component state). Explicit overrides for the
+    # other Layer masters default-ON as of 1.2.0+ so the assertion on
+    # sv[:, 18] (filter pore radius) is unaffected by the wear / quality
+    # slots.
+    pfaults = ProcessFaults(
+        clog_fraction=0.0, fouling=0, foulingpar=np.array([0.0]),
+        fouling_dynamic=False,
+        quality_state=False,
+        pump_wear=False,
+        valve_wear=False,
+        spectrum_enabled=False,
+    )
     res = run_with(pfaults=pfaults, seed=7, verbose=False)
     np.testing.assert_allclose(res.sv[:, 18], res.sv[0, 18], atol=1e-6)
\ No newline at end of file