So I pulled out the switch and re-wired everything.
Doing some testing I found the following
On
Line to Load: 116 acv
Line to Neutral: 120 acv
Off
Line to Load: 30acv
Line to Neutral: 120 acv
So when I got the bypass in there - it dropped down to 5acv and everything started working.
- no idea why it didn’t work the 1st time.