[DML] Re: DMCH headlight switch problem/trouble

[James Espey <james@xxxxxxxxxxxx>]

Josh,

I'm sure you've tried to make this as clear as you can, and I understand 
the difficulty in explaining it. My "test jig" is on a truck right now 
on it's way back from the Georgia event, and will not be back until 
tomorrow. Our "test car" is on that same truck.

I've just played with one car still here with this installed and was 
unable to replicate the issues you are having here. You're the first to 
raise any issues with the new switch/controller.

I've inserted some notes below for some things that come immediately to 
mind...

James

Joshua Schwartz wrote:
> List & James
> 
> I am having some difficulty with the new switch from DMCH. I followed 
> the instructions very carefully, double checking myself at each step. I 
> opted to connect the "auto off" feature. There seems to be a problem 
> with it and was wondering if any other people have had the same 
> problem(s). I checked all crimps, connections for play, etc.

These are critical - connectors that are loose (or pushed out of the 
connector block) can cause erratic operation and/or damage to the unit.

>  From what I understand, when the switch is turned on, either in parking 
> lights only mode or headlight mode, the unit will "auto off" when the 
> power is cut to the unit via key being turned to the "0" and/or removed 
> from the ignition cylinder. This doesn't seem to be the case with my unit.

If the key is turned off within a set amount of time (don't see it in my 
notes here, but it is less than a minute) after the lights are switched 
on, it will NOT auto-off. The switch presumes that you would not turn on 
the lights and them shortly thereafter shut-off the car without intent 
to do so.

> With the key inserted and turned to the "I" position, headlight switch 
> engaged fully (headlights), if the key is turned back to "0" the 
> headlights turn off immediately.

This is not normal.

> With the key inserted and turned to the "II" position, headlight switch 
> engaged fully (headlights), if the key is turned back to "0" the 
> headlights turn off immediately.

This is not normal. For both of these I am wondering if the orange wire 
was connected to the correct wire in the ignition switch harness. There 
are several white wires there, though only ONE solid white (not striped 
with another color) wire. I know that depending on how you look at them, 
it is sometimes not always easy to see the stripe and is easy to select 
the wrong wire.

The other thing that came to mind is that on an early car like 1292, 
there may be an issue with something being different in the wiring. 
Interestingly, one of our test cars that got this new switch (though not 
the one I just looked at here ) was VIN 1293. I'll track this one down 
and see how it behaves, though I would have been told if it was anything 
other than normal.

> With the key inserted and turned to the "II" position, headlight switch 
> engaged fully (headlights), if the key is turned back to the "I" the 
> headlights will "auto off" in 20-22 seconds (the LED [in the switch] 
> will blink rapidly during this period). Though this scenario works, it 
> doesn't work every time. At times, the LED will not blink; it will stay 
> lit and the headlights will remain on.

This may be related to the aforementioned timing issue. If the key is 
turned off within a set amount of time (don't see it in my notes here, 
but it is less than a minute) after the lights are switched on, it will 
NOT auto-off. The switch presumes that you would not turn on the lights 
and them shortly thereafter shut-off the car without intent to do so.

> Also, my parking lights stuck in the ON position (once) regardless of 
> how many times I pushed in the switch and cycled the key in the 
> ignition. The only way to turn off the parking lights was to disconnect 
> the battery.

I have never been able to make a switch behave like this.

> There were times where the headlights would not engage if 
> the switch was depressed too quickly, but most times, the speed didn't 
> affect its operation. I played with different lengths of time between 
> actions, but it didn't make the switch auto off any different. Actually, 
> this seemed to confuse the switch and caused the above mentioned  
> scenarios (more than once).

The only difference the amount of time between actions should have is 
the aforementioned timing in regards to ignoring the auto-off function 
when the lights have just been turned on seconds before the key sis 
switched off AND the feature where a "push and hold for one second" will 
go directly to parking and headlamps on. You do not mention whether or 
not your switch exhibits this functionality.

> When engaging parking lights, the LED would blink once, dim and then 
> come to full brightness. When pressing a second time, to engage 
> headlights, the LED would blink twice, dim and then come to full 
> brightness.

This is normal functionality.

> Should the "auto off" feature work when the key is turned to the "0" 
> and/or removed from the ignition cylinder? This would make sense, right? 
> Am I wrong with the way this feature works? Has anyone else experienced 
> this scenario? Could I have a defective switch/control box?

If you'd like to send me photos of your wiring connections (auto-off, 
wires to switch, 6-way black connector, 6-way white connector) I'd like 
to see them. I'd like to verify those before sending out another 
switch/controller, though if the wiring checks out, I will be happy to 
do that right away.

James


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