Updating Joystick Cards - Leo Bodnar BU0836X Joystick Card

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Leo Bodnar BU0836X joystick card and enclosure

Most flight simulators require regular maintenance to ensure that all systems function correctly. During a routine overhaul, which included replacing the potentiometers that are used to calibrate the flight controls, it was discovered that a Leo Bodnar joystick card had been damaged. Rather than replace the card with the same type (BU0836A), I decided to change-out to a Leo Bodnar BU0836X joystick interface card and protect it with a dedicated metal enclosure. 

I will not duplicate the detailed information that has already been written about the BU0836X on the Leo Bodnar website.   Rather, I will examine the advantages of using this particular card. 

The card and its protective enclosure can be purchased separately from Leo Bodnar Electronics in the United Kingdom. 

BU0836A and BU0836X Joystick Card

The BU0836X 12-bit joystick interface card has been available for some time and is very similar to the BU0836A joystick card; the latter being the mainstay for interfacing various hardware.  Both cards enable calibration of the joystick axes used for controls such as the ailerons, elevator, rudder, and the steering tiller, as well as interfacing with a various simulator buttons and knobs. 

Key Advantages 

The primary advantage of the larger BU0836X card, aside from its additional inputs and outputs, is that it does not use the JR connectors found on the BU0836A card.  JR connectors can be fiddly, prone to breaking (if not connected properly), and may become loose unless soldered directly to the card’s pins.

Over the years, I and cannot recall how many times a JR connector had worked its way loose from the vibration generated by the trim wheels rotating, and depending on the location of the card, a repair can be time consuming.

In contrast to using JR connectors, the BU0836X features push-to-secure connectors. This design allows wires between the gauge of 24-20 AWG (stripped to 9mm) to be easily inserted into the correct terminals and locked in place without requiring screws, solder, or JR connectors.  It’s only a matter of pushing the tab on the card inwards and inserting the wire into the hole. 

The push-to-secure design not only simplifies connection but also makes it easier to replace components like potentiometers or other hardware devices when necessary.  Additionally, the terminal bar is colour-coded with clearly printed labels, making identification straightforward, thereby reducing the risk of wiring errors.

The card has 8 analogue inputs (potentiometers, knobs), 32 inputs (button, switches) and 1 joystick HAT controller.

I find that working with a slightly larger card is much easier than its smaller sister, although an obvious downfall is the space required to mount the BU0836X card. I also like the fact that the card is made in the United Kingdom; therefore, production inconsistencies that occur with many less expensive Chinese cards is not as prevalent.

BU0836X Protection 

The card can be mounted on a base plate using standoffs and screws.  However, as with any hardware component, it is susceptible to damage from movement, accidental knocks, or falling objects - especially during maintenance (screwdrivers, pliers, eye glasses, coffee cups, mobile phones, i-pads, etc). 

To address this, Leo Bodnar offers a protective enclosure that has been specifically designed for the BU0836X and BU0836A cards respectively. The enclosure comprises two pieces of metal with the inner piece (called the slider) designed to slide into and out of the outer casing.  The card clips firmly into the inner slider and a small hex screw fastens the slider into the outer casing.  Realistically, the hex screw is overkill as the inner slider fits quite firmly, and I very much doubt that the slider will accidentally slide out of the outer casing.  The enclosure can then be attached to a base plate using four screws.

Once secured inside the enclosure, the card remains firmly in place and does not move or wiggle, ensuring excellent stability. This setup provides robust protection against physical damage while keeping the terminals fully accessible.

The enclosure has been well designed, is fabricated from metal, powder coated, and coloured black.

Additional Considerations 

Despite the protective enclosure, the wiring remains exposed to the environment, leaving it vulnerable to dust and dirt accumulation.  If this is a concern, a simple and effective solution is to fabricate a small plastic cover to shield the card and its wiring.  A repurposed plastic takeaway container works well for this purpose, providing an inexpensive and practical way to keep the card clean and secure. 

Calibration

The BU0836X card is calibrated in the same way as the BU0836A card: initial registration in windows using the Game Controller (type JOY in the computer’s search bar) and then calibration in either flight simulator, ProSim737 or FSUIPC.

Final Call

The BU0836X card stands out for its well-thought-out design. Its larger size makes terminal identification and access easier, while the push-to-secure connectors provide reliable, solder-free connections.  Although its size could be a disadvantage in tighter spaces, it works well for most applications where space constraints are not a concern.  Additionally, the optional metal enclosure offers protection against physical damage, enhancing the card’s long-term durability.

For further information detailing how to use the BU086X joystick card.

  • This article is not endorsed by Leo Bodnar Electronics. Furthermore, I paid full price for the products discussed. 

Below: Gallery showing photographs of the BU0836X and BU0836A joystick cards and enclosures.

Batch Files to Open and Close Flight Simulator

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Opening and closing the various files and ancillary programs to operate a flight simulator can be onerous and time consuming.  While there have been several programs released that enable you to launch flight simulator with a press of a key, they seldom work with complicated platforms such as flight decks. 

One of the most commonly used methods to open files and programs is to use the start menu within Windows.  However, this is not without it’s shortcomings, and specialist knowledge is required.  An easy and trouble free approach is to use batch files.

What is a Batch File

A batch file is a script file that stores commands to be executed in a serial order.  It helps automate routine tasks without requiring user input or intervention. Some common applications of batch files include loading programs, running multiple processes or performing repetitive actions in a sequence in the system.

Also known as a batch job, a batch file is a text file created in Notepad or some other text editor.  A batch file bundles or packages a set of commands into a single file in serial order.  Without a batch file these commands would have to be presented one at a time to the system from a keyboard.

Usually, a batch file is created for command sequences when a user has a repetitive need.  A command-line interpreter takes the file as an input and executes the commands in the given order.  A batch file eliminates the need to retype commands, which saves the user time and helps to avoid mistakes.  It is also useful to simplify complex processes.

Windows usually uses the .bat extension for batch files.

Whilst there are several methods that can be used to write a batch file, I have found that the examples below operate flawlessly.

Writing a Batch File

It's a simple process to write a batch file. 

Prior to beginning, it’s wise to think about the order you want the programs to open, and whether you want a pause between opening particular files and programs.  While a pause is probably not necessary, it’s a good idea as it allows a file or program to complete its opening sequence, prior to the next file or program opening.

When you have completed writing the batch file in notepad save the file with a .bat extension.  To test the batch file double click on the saved .bat extension.

Although others will disagree, I always open the MSFS-2020 or P3d and allow the program to settle before opening any batch file or other programs.

The following examples of batch files are user-specific.  You will need to substitute the file structure with the file structure you are using.

Opening Files and Programs

  • An example of a batch file to open the main flight simulator computer (server).

@Echo  off

//Alpha Main Server Computer (ALPHA-SERVER-P3)  - 09:38 - 25/08/2023

//ProSim738 V3

//ProSim Ancillary Programs

start /d "D:\Flight Simulator Files\SimStacks October 2021\SimStackSwitchv702" Switch.jar

Timeout 0.5

start /d "D:\Flight Simulator Files\FS Set Volume" FSSetvol.exe

Timeout 0.5

start /d "D:\Flight Simulator Files\SimSounds 4.0" SimSounds.exe

Timeout 1

start /d "D:\REX WeatherForce.exe

//ProSim Main Programs

start /d "D:\Flight Simulator Files\ProSim738 V3\ProSimAudio" ProsimAudio.exe

Timeout 1

start /d "D:\Flight Simulator Files\ProSim738 V3\ProSimB738" ProSimB738.exe

An example of a batch file to open the avionics suite on the second computer (client 1).

@Echo off

//Client 1 - ProSim-AR B738 Avionics Suite V3    14:07 5/09/20

//PS738 V3

//Ancillary Programs

start /d "C:\Users\user name\Documents\FSF\Programs\MSFS WideFS7" kilo

start /d "C:\Users\user name\Documents\FSF\Programs\Landing Rate Monitor" LRM.exe

start /d "C:\Users\user name\Documents\FSF\Programs\SimSounds 4.0" SimSounds.exe

//Hardware Connector

start /d "C:\Users\user name\Documents\FSF\ProSim738 V3\ProSimB738-HardwareConnector" ProSimB738-HardwareConnector.exe

//ProSim737 Displays and Indicators

start /d "C:\Users\user name\Documents\FSF\ProSim738 V3\Displays\CAPT PFD" ProsimDisplay.exe

start /d "C:\Users\user name\Documents\FSF\ProSim738 V3\Displays\CAPT ND" ProsimDisplay.exe

start /d "C:\Users\user name\Documents\FSF\ProSim738 V3\Displays\FO PFD" ProsimDisplay.exe

start /d "C:\Users\user name\Documents\FSF\ProSim738 V3\Displays\FO ND" ProsimDisplay.ex

start /d "C:\Users\user name\Documents\FSF\ProSim738 V3\Displays\EICAS" ProsimDisplay.exe

start /d "C:\Users\user name\Documents\FSF\ProSim738 V3\Displays\FLAPS" ProsimDisplay.exe

start /d "C:\Users\user name\Documents\FSF\ProSim738 V3\PS738ChronoCaptain" ProsimDisplay.exe

Timeout 3

start /d "C:\Users\user name\Documents\FSF\ProSim738 V3\ProSimIOS" ProSimIOS.exe

Closing Files and Programs

Likewise, you can also use a batch file to close files and programs sequentially or simultaneously (kill all).

An example of a batch file used to close programs on the main flight simulation computer (server).

@Echo off

//Alpha Main Server Computer (ALPHA-SERVER-P3)  - 09:38 - 25/08/2023

//ProSim738 V3 – closure batch

taskkill /IM wideclient.exe

Timeout  2

taskkill /IM ProSimAudio.exe

Timeout  1

taskkill /IM PMSounds.exe

Timeout 1

taskkill /IM Prosim737.exe

Timeout  4

taskkill /IM fs2020.exe

  • im specifies the image name of the process to be terminated (for example, PMSounds.exe or ProSim737.exe).

  • @echo on/off defines whether a name or message will be displayed on the console.  It’s also used for other tasks such a script troubleshooting.  I have used it in my batch files because I was told it was a good idea to do so, but if you don’t use the @echo command the batch file still works.  If you do use the @echo command I recommend you use @echo off as this will turn off this feature.

  • The // syntax is used to stop the line from being read by the batch file. 

In the examples, the Taskkill command has been used to close the programs.  Taskkill will cause the program to terminate gracefully, asking for confirmation if there are unsaved changes.

To forcefully kill a process, add the /F option to the command line. Be careful with the /F option as it will terminate all matching processes without confirmation.

An example using the /F command is: Taskkill /F /IM ProSimAudio.exe.

There is debate in the computer community to the validity of closing files and programs simultaneously, as ‘killing a program’ may not allow the program enough time to save information it may be saving during the closure process.

For this reason, I'm hesitant to close flight simulator (or other programs) using a closure batch file without a timeout or delay sequence.  Needless to say, it's an easy process to configure a time delay into a batch file to create a delay before closing each program.

Timeouts

Depending upon your computer specifications, some programs may open and close at differing speeds.  If you want a program is open or close before the next program, then a delay sequence will need to be timed into your batch file. 

The timeout command is used to trigger a delay between the programs, enabling any read/write requirements to occur prior to the next program beginning it closure routine.  The numeral denotes seconds or part thereof. 

Streamlining

Once you have created and saved the batch file, a suggestion is to create a shortcut to the file.  Doing this will enable you to make changes to the batch file such as how the file is executed (minimised or maximised), the position on the screen, colour and font style used, and whether to use an icon for easy identification.  Additionally, by creating a shortcut it enables you to place the shortcut on your task bar.

To create a shortcut, right click the batch file and save as a shortcut.

Using Batch Files and ProSim IOS

ProSim-TS IOS screen in opened to network page.  Rather than explain everything, copy the details and use trial and error to achieve your desired result

If you are using multiple computers, you may want to use the ProSim Instructor Operator Station (IOS) to trigger the opening or closure of programs (via the batch file).  When IOS is configured correctly, you will be able to open and close a batch file on one or more networked computers from one computer screen.

To configure IOS, open the network tab, select add a new action or type and select start program.  In the path to executable file on client box type the file address of the batch opening file.  Choose the start option you prefer and ensure that enabled in checked.

To close your programs, open a second action and type in to the path to executable on client box the file address of the batch closure file.

The accompanying image should be self explanatory.

There are other ways to do this, however, this method is probably the simplest.

Caveat

I am not computer technician.  I have used batch files similar to the examples shown for many years without issues.

Final Call

Batch files are but one way to minimise workload and automate the opening and closure of ancillary programs that are used with flight simulator.  The use of IOS to trigger batch files also enables the user to open and close ancillary programs from the one computer screen (instructor station).

Changing Sound in the ProSim 737 Aircraft with MSFS-2020

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Many enthusiasts like to change the sound files that come with ProSim-TS 737 aircraft.  In my simulator I use an assortment of sounds including those from ProSim, PMDG, the immersion CFM engine sound pack, and audio recordings that have been made from the real aircraft.

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