Introduction

The K-Box is an ideal solution for applications that require a large number of thermocouples and analog inputs. The K-Box’s accurate sensor data is transmitted periodically on the CAN bus, enabling multiple devices to be connected. The K-Box CAN bus settings, calibration, and sampling rates are all easily configurable, and these settings are stored within the K-Box even when the device is not powered.

Advantages:

• Wide switchable software voltage input ranges ±80V, ±40V, ±20V or ±10V.

• Accuracy: - Analog ±0.0015%, Thermocouples ±0.08%.

• High input impedance.

• They have isolated Differential Inputs to prevent earthing problems.

Key features:

• Stackable enclosure.

• Simple signal configuration using a DBC file.

• Each unit enables up to 8 K-type connections at a 20Hz sampling rate and 8 analog inputs at a 1kHz sampling rate.

• Pulse Width Measurement: 3 inputs frequency measurements or pulse measurements.

• Regulated +5V and +12V output power supply for external sensors.

• Instrumentation data time is synchronised with the recorded vehicle network data.

• Analog inputs and thermocouple inputs are galvanically isolated.

• Connect and measure data from up to 4 IEPE sensors using the K-IEPE addon.

• Measure temperature using RTDs with K-PT100/1000 addon.

Technical Specification:

The K-Box is powered via the CAN and power connectors. It has been designed with CiA® 102 pinout for the CAN bus and power to connect the device as easily as possible.

Most commonly, it will be powered from a Rebel Logger using the Multi-Connect Cable, but you can also power it via pin 9 (4.5 to 36V) and pin-5 PowerGND of the nine-pin Sub-D connectors. If connected via the Multi-connect cable, the CAN 1 (MS) bus is also connected, allowing the logger to record the data transmitted from the K-Box.

a) Setup for interfacing ReXgen Device with K-Box

b) Setup for interfacing Rebel Device with K-Box.

The pinout of the required Cable between the two K-Boxes is as follows:

If you power it from the Logger, the Logger will need to be powered from the vehicle or an external power source (NOT just via USB), and you will need to ensure the AUX power feature in the Configuration is set to “On”. To do this, follow the Steps Below:

Once the Edit Configuration window is displayed, click the “Settings” tab and checkmark Aux Power On.

Click “OK” to set the Aux Power on Setting in the Configuration.

Send the Configuration to the Logger by right-clicking on the “Project” and choosing “Send Configuration to the Logger.”

If you have the CAN bus that the K-Box is connected to set to the correct speed within your project, you will see the Status Light on Solid Orange and the CAN Light on Solid Green. If it is flashing green, the CAN bus is misconfigured; check the speed and termination.

The K-Box comes pre-configured, but the configuration is programmable using the K-Box Calibration utility. It requires installing a Kvaser Leaf Light, Memorator or an Influx Rebel CT or LT and installing the K-Box Calibration utility.

For the above example, please install the Kvaser Drivers.

For the above example, please install the Rebel Drivers.

Download the Kavaser Drivers for Windows. They are located at:

Run kvaser_drivers_setup.exe

Click Next to start the Installation.

Click Next after viewing the documentation (optional).

Select the item(s) you wish to install (at least one is needed to install the Drivers).

Choose or confirm the location where you wish to install the drivers.

The Drivers will be installed. Click “Close” once the process is complete.

Download the ReXgen J2534 Driver by clicking the below link and execute the file. - https://downloads.influxtechnology.com/ReXdesk/Rexgen_J2534_Installer.zip

Double click on ReXgen j2534 Installer.

Click 'Cancel' to abort installation.

Click 'Install'.

Click 'Close'.

The Rebel drivers must be correctly installed to ensure the Rebel functions perfectly.

If DiaLog is installed, a driver installation application will be available, which can be found in the Influx Technology folder of the Start Menu, as shown below.

Ensure the Rebel is not plugged in and click ‘Next’ to continue.

Please read and accept the EULA, then click ‘Next’ to continue.

The driver installation will begin and may take a few moments.

Once the installation is complete, click ‘Finish’ to close the application.

Plugin the Rebel to allow the drivers to be recognised.

Run the K-BoxCal.msi

Click Next to start the installation.

After the K-BoxCal software is installed, click 'Finish'.

Once you launch the K-Box Configuration utility, you will see the settings for the interface you are using. If the K-Box is on and connected, its serial number (S.N.) and firmware (Fw) version will be displayed at the bottom of the screen.

On the General Tab, you can change the following parameters:

You can change to the Analog Channel Configuration by clicking on the Tab: Not Connected.

On this screen, you can change the following parameters:

• The additional board allows users to select the addon board type if connected.

• The CAN Ident and rate that the K-Box will broadcast ADC channels 0-3.

• The CAN Ident and rate that the K-Box will broadcast ADC channels 4-7.

• The Voltage range you wish to use for the ADC channels is either -10 to +10V, -20 to +20V or -40 to +40V, individually selectable per channel or -20 to +20V, -40 to +40V or -80 to +80V, individually selectable per channel depending on whether you choose hardware range 1 or 2.

• The CAN Ident and rates that the K-Box will broadcast thermocouple channels 0-3.

• The CAN Ident and rates that the K-Box will broadcast thermocouple channels 4-7.

• The Thermocouple type may be selected from K, T and J Types.

By clicking on the tab RTD (Resistance thermometer detectors), you can configure the KBox to work with add boards by selecting the board type from the drop-down menu.

On this screen, you can change the following parameters:

• The CAN Ident and rates that the K-Box will broadcast RTD channels 0-3.

• Select the type of RTD for each channel. RTD (0-3). Pt 100 or Pt1000 is individually selectable per channel.

• The CAN Ident and rates that the K-Box will broadcast Thermocouple channels 0-3.

• The CAN Ident and rates that the K-Box will broadcast Thermocouple channels 4-7.

• The Thermocouple Type may be selected from K, T and J Types.

Click the tab IEPE (Integrated Electronics Piezoelectric) to change to the Analog Channel configuration.

On this screen, you can change the following parameters:

For more configuration options, refer to Appendix 4.

• The CAN Ident and rates that the K-Box will broadcast IEPE channels 0-3.

• IEPE Transmit-Measure:

  • Combined: All the IEPE data is sent in one CAN message with one CAN ID.

  • Individual: Sends each IEPE channel data with a separate CAN ID.

• The sensitivity and offset of the IEPE 0, 1, 2 and 3.

• The CAN Ident and rates that the K-Box will broadcast Thermocouple channels 0-3.

• The CAN Ident and rates that the K-Box will broadcast Thermocouple channels 4-7.

• The Thermocouple type may be selected from K, T and J Types.

You can change to the Digital Channel Configuration by clicking on the tab:

Here, you can configure the Digital Channels:

• The CAN Ident and rates that the K-Box will broadcast channels used as input.

• The CAN Ident and rates that the K-Box will receive data to be output.

• In output mode, it should output 3.3V (Digital 1-3) or operate in Open Collector mode (Digiatl4).

• PINs 1-3 can be configured to measure pulse duration, frequency, duty cycle, count events, cycle duration, or RPM when in’ Input’ mode.

• PIN 4 can be used as an output for wake-up or to supply power, for example, to another daisy-chained K-Box.

  The 4 Digital Pins can all be configured as outputs: If that mode is used, then they either act in open collector mode (the base of the internal NPN transistor is energised according to the data that the K-Box receives via CAN message to the Outputs CAN ident configured) or they can act in 3.3V mode in which case they will output 3.3V or 0V depending on the to the data that the K-Box receives via CAN message to the Outputs CAN ident configured. If using the pins as outputs, you must set up CAN Messages with the same IDents as you have set up that broadcast data to the K-Box… The data format required is specified in the DBC file, and you can use the DiaLog DBC Editor (in the Presets section) to look at this.

  The first 3 Digital Pins can also be used as inputs and measure pulse duration, frequency, duty cycle, count events, cycle duration or RPM, and output. They calculated measurements as CAN messages on the CAN Ident configured for the Inputs.

Digital 1-3 can be used to measure input signals, process them, and output the result as a CAN message with a Defined CAN ID (e.g. Pulse duration could be measured and output as a CAN message on CAN ID 0x310)

The K Box send CAN messages with a defined ID (in this example, 0x300 and rate 100 ms), containing information about the logical level of the Digital signals. This information is contained in the 1st byte of the message.

To measure Pulse duration, select Pulse duration in the drop-down box:

Also, set the CAN ID rate, where The K Box will transmit the result.

Set the Rate you wish to measure at:

Select the edge on which you wish to start measuring the pulse duration.

The KBox will not send CAN messages (although the rate is met) until the required measurement is finished.

The KBox will re-calculate the message and Rate to prevent CAN bus overloading.

Examples:

Pulse frequency: 2000Hz (0.5ms). Rate: 50ms. CAN bus Speed: 125 kbps.

If there is no overloading of the CAN bus, a corresponding CAN Message will be sent every 50ms.

Pulse frequency: 2000Hz (0.5ms). Rate: 1ms. CAN bus Speed: 125 kbps.

If there is no overloading of the CAN bus, a corresponding CAN Message will be sent every 2ms.

To measure frequency, select ‘Frequency’ in the drop-down box:

Also, set the CAN ID where The K Box will transmit the result.

Set the Rate you wish to measure at:

The Rate parameter affects measurement precision.

The K Box measures frequency using a pulse counter for the selected rate and normalises it to 1 second to calculate the value in Hz = 1 s * N pulses / Rate.

The K-Box averages measured values if the frequency changes for a measurement interval (Rate).

Example:

Selected Rate: 100ms.

The sensor sends at a frequency of 10kHz for 60ms, and the K-Box registers 600 pulses (60ms * 10kHz).

The sensor sends at a frequency of 8kHz. For 40ms and the K-Box registers 320 pulses (40ms * 8kHz).

For the whole measurement interval of 100ms, The K-Box registers a total of 920 pulses.

Normalised to Hz, the measured frequency is 9.2kHz (1 s * 920 pulses / 100ms).

If the Rate is set to 1000 ms, the measurement's accuracy will be 1Hz.

To measure high frequency, select ‘High Frequency’ in the drop-down box:

Also, set the CAN ID where The K Box will transmit the result.

Set the Rate you wish to measure at:

The Rate parameter affects measurement precision.

The K Box measures high frequency using a pulse counter for the selected Rate and normalises it to 1 second to calculate the value in Hz = 1 s * N pulses / Rate.

The K-Box averages measured values if the high-frequency changes for a measurement interval (Rate).

Example:

Selected Rate: 100ms.

The sensor sends at a frequency of 10kHz for 60ms, and the K-Box registers 600 pulses (60ms * 10kHz).

The sensor sends at a frequency of 8kHz. For 40ms, the K-Box registers 320 pulses (40ms * 8kHz).

For the whole measurement interval of 100ms, The K-Box registers a total of 920 pulses.

Normalised to Hz, the measured frequency is 9.2kHz (1 s * 920 pulses / 100ms).

If the Rate is set to 1000 ms, the measurement's accuracy will be 1Hz.

To measure the duration of a cycle, select Cycle Duration in the drop-down box:

Frequency can then be calculated using the following formula:

F = 1 / T

In this case, this frequency is NOT average frequency. It is instantaneous frequency.

The KBox will wait until the cycle measurement is finished before sending a CAN message with the duration. If the cycle duration is long, the messages may be sent slower than the selected Rate.

If the Cycle duration is shorter than the time between messages set by the Rate, the duration will be re-calculated before being sent.

To calculate the Duty cycle of a PWM signal, select Duty cycle/PWM in the drop-down box:

Also, set the CAN ID where The K Box will transmit the result.

Set the Rate you wish to measure at:

Select the edge you wish to start measuring the duty cycle on.

Pulse Wave Modulation examples:

e.g. 1) Modulation on the falling edge:

e.g. 2) Modulation on the rising edge:

To count digital events, select Event Counter in the drop-down box:

Also, set the CAN ID where The K Box will transmit the result.

Set the Rate you wish to measure at:

Select the edge on which you wish to start measuring the events.

The Event counter will be incremented on any received registered event edge.

To calculate Revolutions per Minute, select RPM in the drop-down box:

Also, set the CAN ID where The K Box will transmit the result.

Set the Rate you wish to measure at:

Select the edge you wish to normalise measuring the revolutions on.

The Rate parameter affects the measurement precision.

The K-Box measures RPM using a pulse counter for the selected rate and normalises it to 1 minute to calculate the output value.

RPM = Ratenute * N pulses / Rate.

The K-Box averages the measured values if RPM changes over the measurement interval.

Example:

If the Selected Rate = 500ms.

If a Sensor sends 2000rpm for 300ms (sensor generates 2000 pulses per minute)

The KBox registers 10 pulses (10 = 2000rpm * 0.3s/60s).

If it then sends 4800 rpm for 200ms (sensor generates 4800 pulses per minute).

The KBox registers a further 16 pulses (16 = 4800rpm * 0.2s/60s)

For the whole measurement interval (500ms), the KBox registers will register a total of 26 pulses.

The Normalised value calculated will be 3120 rpm (60s * 26 pulses/0.5s).

The increment size of 120rpm limits the accuracy of measurement.

If the parameter Rate were= 1000 ms, the measurement’s accuracy would be limited by the increment size of 60rpm.

Frequency can then be calculated using the following formula:

RPM = 60 / T

In this case, this RPM is NOT average RPM; it is instantaneous RPM.

The KBox will wait until the cycle measurement is finished before sending a CAN message with the duration. If the cycle duration is long, the messages may be sent slower than what is selected as the Rate.

RateIf the Cycle duration is shorter than the time between messages set by the Rate, the duration will be re-calculated before being sent.

Important: Configuring the Output Mode:

Unless you have special hardware, build your K-Box Digital 1, Digital 2 and Digital 3 MUST be configured as 3.3V if used in output Mode due to the Outputsign of the circuitry:

Unless you have a unique hardware build, your K-Box Digital 4 MUST be configured as Open Collector (if used in output Mode due to the design of the circuitry):

Operation of the Output Signals

If any of the PINs are set to an “Output”, the output CAN ID becomes active, and you can select the CAN ID, which will receive messages that will be output on the appropriate pins of the K-BOX.

If the CAN ID were set to 0x400, when the Kbox receives a CAN message with Ident 0x400, the first byte is interpreted as an 8-bit command as follows:

OutLevel indicates whether the PIN should give output 1 or 0. “OutSet” sets the OutLevel on the PIN if it is = 1 (enable); if the OutLevel is 0 (disable), then the OutLevel value in the message is not set.

Example:

If the KBox receives a CAN message with DLC = 1 and CAN ID = 0x400.

Data byte = 0x30 (00110000 ) High Level on Digital 3, Digital 3 enabled. Outputbyte = 0x20 (00100000 ) don’t care about Digital 3; keep old level on Digital 3.

In this, the command controls all Digital Outputs at once and at any time.

The Output level can only be changed with a new CAN message with Ident 0x400, re-configuration with B-Box Cal, or turning the KBox power off.

If NONE of the PINs is set to Output, the Outputs CAN ID will become greyed out, and the K-Box will not enable the Output on the Digital pins when CAN messages are received.

You can change to the Reprogramming Function by clicking on this tab. The following window appears:

Locate the hex file that you wish to program into the K-Box. Generally, this will be located in C:\Program Files (x86)\Influx Technology\K-Box Config\firmware.

Then click the Open Button.

Click the Commit button. The following progress indicator at the bottom of the screen becomes visible:

When the progress indicator reaches the right-hand side, reprogramming is complete.

To improve the accuracy, one can calibrate the K-Box measurements. The software allows the user to cycle through several measurement points. Once done committing, the calibration applies to the K-Box, improving the measurement accuracy.

Alternatively, press the start button and attach the appropriate voltages/thermocouple test signals to the inputs of the K-Box to cycle through the test points to calibrate the K-Box for maximum accuracy:

Select the Voltage of the Calibration Point you wish to calibrate, and make these points appropriate to the range of inputs you expect. For example, if you expect input signals to be between 0V and +38V, Influx recommends you calibrate the +40V and OV calibration points for that channel:

Select the Channel of the Calibration Point you wish to calibrate by either clicking the Radio Button of the channel

Or, by clicking on the point, you wish to calibrate in the field to the right.

Adjust the input voltage from the calibrated test equipment that you are using to match the voltage for the test point:

If the input voltage is stable and correct, the calibration of the channel will be updated as follows:

If it is not, you will receive a warning:

Repeat the steps above until you have calibrated all the calibration points.

Doing this will save the calibration to the K-Box and create a report detailing the calibration:

To erase the calibration, follow the following steps:

Click Yes to confirm that you want to clear the calibration.

Check that you can see the status messages at the bottom of the K-Box Cal Application if you can’t click on the light blue line and drag it upwards.

Wait until the status messages at the bottom of the window show that the Calibration table has been cleared:

The user can use the K-Box Cal application to display the Analog voltages being measured by the K-Box visually.

Click on the radio button of the channel you wish to display. The Actual Measured Value will be displayed. If a ‘Conversion Table’ or ‘Formula’ is assigned to that channel, the converted value and units will be shown along with the formula or name of the conversion table:

Use the following steps to apply a Conversion Table to a channel.

Click the Channel you want to assign the Conversion Table to:

If the Channel already has a Conversion Table or Formula assigned, the corresponding button will be highlighted in red.

Click the name of the Table you wish to apply to the Channel.

The Conversion Table will immediately be applied. You will see the name of the conversion table in use for the selected Channel.

Use the following steps to apply a Formula to a channel:

Click the Channel you want to assign the Formula to:

If the Channel already has a Conversion Table or Formula assigned to it, the corresponding button will be highlighted in red:

Select Formula / Edit:

Enter the Formula you would like to use, e.g. Y=0.75*X+12.3 and also the units of the output:

Click OK to apply the Formula to the Channel.

The Formula will immediately be applied, and you will see the Formula in use for the selected Channel.

All Channels can be added to the Oscilloscope by following the following steps:

Right-click in the Item Information Area and Select Add All:

All channels will be added to the Oscilloscope.

Right-clicking in the Item Information Area brings up the following menu:

The Menu Items allow the following functionality:

The ‘Oscilloscope’ functionality is controlled by a dedicated toolbar, which is considered below. Each feature is then considered individually.

Right-clicking on the oscilloscope also brings up a menu with several further options. These include changing the scale of the time axis to several different resolutions and changing the axis colour, clearing the data, and printing and exporting the image displayed on the scope.

The DBC Export feature allows you to export the Conversion tables and Formulas Applied to the various Analog channels for use in other tools such as DiaLog.