Well, after this project completely going off the rails due to the designer deciding he didn't really want to work on it anymore I may have come up with something that could work and is mostly off the shelf. The
Directed 535T Window Module like this one on ebay will do not everything but a lot of what was in the original spec. The original spec is below:
WINDOW OPERATION
1) window controls will work for 120 seconds after the ignition is turned off (gives time to put roof up, remove packages from car, etc.)
2) tapping for 1/4 second or less provides automatic full up/down operation depending on which direction you've indicated
3) holding for more than 1/4 second gives you the manual control that we all have now
4) a double tap on the down direction driver's side switch (within half a second or so) gives you the "re-seal" function - see below for reseal function details
5) the reseal function will also operate automatically - see below for reseal function details
6) windows wind all the way up when doors are locked (a micro switch on module will disable this)
7) windows drop an inch or so when unlocked for easier door opening over the seals (and possibly new seals with a different profile).
8 ) the module will contain a programming port so that additional features can be added in the future (likely by the designer and not you or me).
9) the module will have a master switch to disable it and return window operation to normal for servicing the windows if desired
WINDOW RESEAL LOGIC
1) The manual reseal is triggered through a double tap (within half a second) of the driver’s side switch (right or left depending if its RHD or LHD) in the down direction. The manual trigger is one step in that it drops for half a second then immediately winds all the way up. It doesn’t affect the automatic reseal function. This action will only occur when the door is closed.
2) The automatic reseal action is essentially two distinct steps triggered by door open/door unlock and door close/door lock.
3) The first step is triggered by either a door open or door unlock action and immediately drops the window for half a second and leaves it in that position.
4) The module will sense the current state of the window action and “know” that if the door is unlocked then opened it doesn’t need to drop it again.
5) If the window has been dropped due to the first step of the reseal action then, and only then will it be ready to activate the second step. In other words, if you drop the window manually (some car alarms have this feature on a button on the fob) or had left the window down when you exited the car there is no need to either drop the window when we unlock or open the door or run the second step (roll up).
6) If the module is in a “ready state” for the second step of the automatic reseal function then when the door is closed or locked the windows roll all the way up AFTER a 2.5 second delay. This will be important because the locking system has a failsafe that needs to be factored in. If you try to lock the door while its open it will automatically unlock itself after 2 seconds. So, its possible to “lock” the door while its open then have the system unlock itself. We need to wait until this cycle completes before winding up the windows or the windows will wind up (because the door locked) then drop again (because the system unlocked the doors).
7) Hitting the window switch at any time while the module is activating the automatic reseal function cancels the cycle and provides manual window control.
8 ) There is another “function” that is different but related to the automatic reseal function. This function winds the windows all the way up when the door is locked. This is important to consider because someone may cancel the automatic reseal (through a fob button let’s say) or the windows may be part way down to begin with but we still need to run windows all the way up function when its locked. This will be an "optional" feature enable through a switch on the module.
The 535T's programmable features include:
1) Auto up/down (one touch) with interrupt (you tap the switch again and the window stops)
2) Windows will roll up completely when the alarm is activated (or, if you prefer, will only roll up if the alarm is triggered)
3) "Venting" featured that is triggered by an input which could be door unlock or door open as preferred (windows crack open then close after 2 seconds)
4) Most features are user programmable and can be highly customized if you're an electronics enthusiast (or know a guy who does alarms, etc.)
Here's what it won't do:
1) No manual reseal function (unless you consider cracking the door open again acceptable)
2) No ability to manually control the window - it's auto up or down until you tap the switch again
3) No window operation for 120 seconds after the ignition is turned off (windows work like they do now)
4) No programmable port or master switch to disable it
5) No sensing of the "state" of the window (up or slightly open) before triggering a vent action
6) No two second delay before the windows go up in the event that the door wasn't closed and the car unlocks itself
Personally, I'm not worried about the things it won't do from the original spec. Partly because I like the idea of an off the shelf component that can be replaced if it goes bad and partly because a few of the things it won't do can actually be done if you hire someone to install it or know what you're doing (like the manual reseal, 120 seconds of window operation after ignition is off, etc.). Although you could get away with using one unit I think I'll use two - one for each side. That way the venting feature will be side dependant (no need to vent the passenger side if only the driver's door opens). Also, I think each unit only handles 20 amps which is what one window motor draws. I'll be working on this in the spring but I have a test unit now with two more ordered. There is one thing I could use some help with though.
I have always tried to make every modification I do completely reversible and I'd like to do the same here. To do so, I need to source the connector plugs used in the wiring harness to the doors. These are white, 5 pin connectors. Does anyone have an idea who makes them (I could not find any markings on mine)? Thanks!
