Bozzio Joysteer Generation 2.0 User manual

a product of the company Bozzio AG
Universal System Manual
EN_Universal_System_Manual_2_V15-190131.docx
Aarbergstrasse 5
2560 Nidau
Switzerland

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Content
1GENERAL...................................................................................................................... 4
2DISCLAIMER................................................................................................................. 5
3SYSTEM ........................................................................................................................ 6
3.1 What is joysteer®...................................................................................................... 6
3.2 Conventional driving with J-PAS function.............................................................. 6
3.3 System overview....................................................................................................... 7
3.4 Service and repairs................................................................................................... 8
4BASIC ASSEMBLY GROUP ......................................................................................... 9
4.1 EnergyAlarm module................................................................................................ 9
4.2 Converter module steer, brake ...............................................................................11
4.3 Cable harness..........................................................................................................12
4.4 CAN Adapter ............................................................................................................13
4.5 Steering actuator module (SAM).............................................................................14
4.6 Brake actuator module (BAM).................................................................................16
4.7 Pulse test box ..........................................................................................................17
4.8 Display module........................................................................................................18
4.9 Steering sensor module..........................................................................................19
4.10 SmartGas2................................................................................................................20
4.11 Software and Servicemanager................................................................................21
5MMI’S (MEN MACHINE INTERFACE)..........................................................................24
5.1 MMI: Micro wheel.....................................................................................................24
5.2 MMI: One hand joystick...........................................................................................24
5.3 MMI: Two hand joystick...........................................................................................25
5.4 MMI: Gas-/brake slide..............................................................................................26
5.5 MMI: Handlebar........................................................................................................27
5.6 MMI: Low force joystick ..........................................................................................32
5.7 MMI: 4 way joystick .................................................................................................33
5.8 MMI: Gas-/ brake Tilter ............................................................................................34
5.9 MMI: 2 way joystick .................................................................................................34
5.10 MMI: Basic sensor unit brake .................................................................................35
5.11 MMI: Basic sensor unit gas.....................................................................................35
5.12 Gas- / brake sensor adjustment..............................................................................35
6BACKUP-BATTERY.....................................................................................................36

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7ACCESSORIES............................................................................................................37
7.1 Communication toolbox..........................................................................................37
7.2 CAN Dongle..............................................................................................................37
7.3 Remote access Kit...................................................................................................38
7.4 Module rack..............................................................................................................40
7.5 Instructor Switch .....................................................................................................41
7.6 Quick exchange Kit .................................................................................................42
7.7 8 shaped brackets ...................................................................................................42
7.8 Instructor Plug Kit ...................................................................................................43
8SAFETY INFORMATION..............................................................................................44
9FUNCTIONAL TEST.....................................................................................................45
10 ANNEX 1: SYSTEM ERROR MESSAGES AND TROUBLESHOOTING..................46
11 DOCUMENT INFORMATION....................................................................................55
11.1 Fundamentals ..........................................................................................................55
11.2 Document history ....................................................................................................55

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1 General
This document describes the joysteer® system.
The handling and installation is to take place by trained personnel exclusively, whereby all
points need to be carried out as described.
This document describes all non-vehicle specific installation steps. Refer to the
corresponding vehicle specific manuals for details.
This document applies to the joysteer® system generation 2.0.
The main change from generation 1.0 to generation 2.0 is as following:
Display module Alarm module
joysteer® generation 2.0 joysteer® generation 1.0

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2 Disclaimer
Bozzio AG refuses their product liability if one or more of the following facts are given:
•Driving the system by users who do not possess an appropriate driving licence
Exception: driving accompanied by an authorized driving instructor
•Driving with accompanying driving instructor without installation of an instructor
Switch
•Installation/ maintenance/ repairs by companies not trained by Bozzio AG
•Installation/ maintenance/ repairs by personnel not trained by Bozzio AG
•Installation/ maintenance/ repairs not according to the manuals
•Installation/ maintenance/ repairs of components/ modules, which are not mentioned
in the part list
•Installation/ maintenance/ repairs of any MMI (Man Machine Interface), which has not
been released by Bozzio AG in written form
•Usage of parameter-sets which do not correspond to the “rules” of the
Servicemanager
•Any modifications to the cable harness
Important:
•By opening the modules any warranty of the manufacturer is omitted
(Exception: EnergyAlarm module).

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3 System
3.1 What is joysteer®
joysteer® offers the opportunity to people with a disability (users) to steer their vehicle via a
very flexible "user interface", if they are not able to drive by using a steering wheel.
joysteer® provides a mechanical interface, to which all MMI’s can be mounted (One hand -
/two hand joysticks, micro-wheel, handlebar, etc.). The broad pallet of MMI’s allows
correspondence with all consumer needs.
joysteer® is designed for additional installation in ordinary road vehicles. The conventional
steer, brake and accelerating systems remain; therefore, driving by using the steering wheel
and pedals is still possible.
joysteer® is modular. The system can be upgraded with further modules at any given time.
3.2 Conventional driving with J-PAS function
The vehicle can either be driven by with the MMI or conventionally with the steering wheel.
When driving with the steering wheel, the motors are also commutated with the J-PAS
function. This allows the steering wheel coming back to the zero position at all the time.
Important:
Assure, that the installation is done in such a way, that the joysteer® System is always “ON”
while driving, either operated with the MMI or with the J-PAS function. Driving with System
OFF is not allowed!
The J-PAS Parameters has to be set in such a way that the steering wheel returns to zero at
all the time.

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3.3 System overview
Important:
The backup-battery is not included in joysteer® s delivery pack (storage and security
aspects).
CAN-
Adapter

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3.4 Service and repairs
The joysteer® system is a safety-critical application. Therefore, the user and the nominated
car adaption company are not allowed to open the modules or to modify them in any way.
In case of any faulty parts, the entire module is replaced and repaired by the producer of
joysteer® only. Nominated car adaption companies are not allowed to repair any modules.
Exchanging of modules can only be carried out by the nominated car adaptation
company.
Exception:
EnergyAlarm module:
This module contains electrical fuses. Nominated car adaption companies are allowed to
change these.

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4 Basic assembly group
4.1 EnergyAlarm module
Before connecting the cable harness to the EnergyAlarm module, all live wires need to be
mounted in place with cable shoes, M6 screws and lock nuts. These connectors are to be
insulated sufficiently. The provided 125A fuses are to be mounted next to the board and
backup-battery.
Refer to the vehicle specific manual for the correct positioning of the EnergyAlarm module.
Important:
To fix the cable harness to the EnergyAlarm module only lock nuts are to be used.
Connections are to be sufficiently insulated. (Risk of short circuit)
The ground cable of the vehicle electric system and backup electric system has to be
connected to the battery.
The housing needs to be grounded by connecting it to the vehicle chassis. If this is
done with a cable, its cross section must be at least 2.5 mm2. The cable is to be as
short as possible.

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4.1.1 Fuses in the EnergyAlarm module
Diagram above: Layout of fuses within the EnergyAlarm module
5 A
5 A
F9
BOARD: Steering-/ braking actuator
30 A
F8
BACKUP: Braking converter
30 A
F7
BOARD: Braking converter 20 A F1
BOARD-BACKUP Connection
20 A F2
BOARD-BACKUP Connection
30 A
F3
BOARD: Steering converter
30 A
F4
BACKUP: Steering converter
10 A
F5
BOARD: Steering sensor
10 A
F6
BACKUP: Steering sensor
F10
BACKUP: Steering -/ braking actuator
5 A F12
BACKUP: Energy alarm
5 A F11
BOARD: Energy alarm
F10F9F8F7
F1 F2
F12 F11
F3F4F5F6

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4.2 Converter module steer, brake
The positioning is vehicle specific. Refer to the vehicle specific manuals for details. In each
case the order from top to bottom is always as following:
S1 = Steering converter module 1
S2 = Steering converter module 2
B1 = Braking converter module 1
B2 = Braking converter module 2
Important:
The housing needs to be grounded by connecting it to the vehicle chassis. If this is
done with a cable, its cross section must be at least 2.5 mm2. The cable is to be as
short as possible.

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4.3 Cable harness
The cable harness is available in different versions:
•steer, brake, gas
Or
•steer only
Or
•gas brake
More details can be found in the “Universal Cabling diagrams” manual.
It is necessary to ensure that the harness is not damaged or it could be damaged by any
sharp edges. If required, the cables are to be protected with an appropriate product. It is
important to ensure that the plugs don’t experience any tension.
The shielding of the cable harness has to be grounded by connecting it to the vehicle
chassis.
Important:
The cable harness is not allowed to be modified at all.

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4.4 CAN Adapter
There can be found 2 installation methods, depending on the car type. CA2X or CA2B.
CA2X Park / Shutdown behaviour 0:
The CAN Adapter gives only the Speed Signal. The Park Signal is detected with the separate
mechanical and redundant P-Switches.
CA2B Park / Shutdown behaviour 1:
There are no P-Switches to be mounted and the “Gear in Park” signal is read from the CAN
Adapter. For safety reasons, the shutdown behaviour is confirmed with a button, operated by
the user.
The detailed description for installation can be found in the enclosed description with the
CAN Adapter.

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4.5 Steering actuator module (SAM)
The steering actuator module is installed between the steering column and the steering
wheel. It is not required to dismantle the steering column.
The steering actuator module and its bracket is vehicle specific.
In all cases the steering lock has to be disabled or removed unless the customer uses the
original ignition lock / key.
Refer to the vehicle specific manual for installation instructions.
The installation is as following:
1. Ensure a straight-ahead wheel position
2. Dismantling of the steering wheel and the foot space cover following instructions of
the vehicle producer (attention airbag)
3. Mounting of the brackets (refer to vehicle specific manual)
Temporarily only tighten the screws by hand
4. Mounting of the steering actuator module (straight-ahead position)
The steering actuator module should not be rotated
Four complete rotations are possible; therefore the centre position is pre-set
The respective seal is only to be removed immediately prior to installation
5. Ensure all functionalities of the vehicles cable drums (Clock-Spring)
Indicators etc. remain
6. Remounting of the steering wheel
Tighten the screw according to the specification of the vehicle producer
7. Tighten the screws of the brackets with the indicated torque and secure with Loctite
243.
8. Install the airbag and the foot space cover according to the vehicle producer’s
specifications
9. Check: the rotation of the steering wheel needs to be uniform and with low force
within the complete rotation range

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Important:
Should the window for the airbag be located in another spot than “straight, up”, then the
central disc can be rotated.
Please contact the producer or distributer before doing so otherwise the potentiometer risks
to get destroyed.
Notes:
Check if the installation is correct by driving the car conventionally after having installed the
steering actuator. As the worm wheel and the motors are rotated passively, there is an
increase of friction. Whilst the joysteer® system is turned off the friction of the steering
actuator should not increase significantly. If this is the case, the steering actuator is
misaligned and the screws of the brackets need to be loosened slightly. By sequential
tightening of the screws, the alignment of the steering column to the steering actuator is
ensured and thus the friction can be minimized.
Please contact the system provider if turning the steering wheel remains too heavy.
The Parameters of the J-PAS Function has to be set such as the steering wheel returns back
to zero at any time.

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4.6 Brake actuator module (BAM)
The positioning is vehicle specific. Refer to the vehicle specific manuals for details.
Important:
After installation of the brake actuator module the pedals need to be protected against
accidental pushing/ operation or jamming of the user’s feet. Suitable covering is not
included in the delivery pack.

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4.7 Pulse test box
The pulse test box is connected to the backup-battery.
The length of the double core cable to the plug X331 can be adapted to the vehicle.
Following the provided plug (type "Super Seal") is to be placed according to the schematic
below.
Important:
Both 10mm2cables are not to be shortened nor lengthened.
Puls Test Box
Backup Battery
10mm2
10mm2
125 A
Adjust length
EnergyAlarm
module
X 331

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4.8 Display module
The display module needs to be installed within sight of the user, as it provides visual and
acoustic signals regarding the safety status of the joysteer® system.
The display module is to be connected directly to the EnergyAlarm module.
Important:
The housing needs to be grounded by connecting it to the vehicle chassis. If this is
done with a cable, its cross section must be at least 2.5 mm2. The cable is to be as
short as possible.

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4.9 Steering sensor module
The steering sensor module captures the steering request of the user and generates the
force feedback of the joysteer® system.
Following criteria’s must be taken into consideration while positioning the steering sensor
module:
•No hindrance of the airbag functionality. Otherwise the airbag needs to be
deactivated by a professional dealer.
•Solid mechanical form fit fixations to the vehicle
•Proper laying of the cables to avoid damage by the user
Important:
The housing needs to be grounded by connecting it to vehicle chassis. If this is done
with the cables, the cable cross section must be at least 2.5 mm2. The cables are to be
as short as possible.

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4.10 SmartGas2
See universal and car specific SmartGas2 manual.