All Features - easymetal/Korrostop4.0-EN GitHub Wiki

General

The KORROSTOP4.0 is a reliable and precise measuring device that stands out thanks to the latest technology. It can be adapted to all EDM machine manufacturers and can be fully integrated into your existing corporate IT system with its large number of communication channels. We only support highly secure standards.

Ongoing analysis of water quality is essential for consistent product quality, process optimization and improved safety.

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Recommended as an ideal extension of the E.KO IONISER series from easymetal.

Special properties

  • Compatible with all EDM machines
  • All components required for connection are included in the Korrostop4.0 Measuring Kit or in the Connect4 Connection Kit
  • Plug & Play with EASY quick coupling
  • Quick and easy replacement of the E.KO IONISER, even during operation
  • High flexibility and ease of use
  • Only to be used as a simple measuring device or as an Industry 4.0 enabled device to automate your production processes
  • Visualization of water quality, temperature and flow rate, as well as water quality of the E.KO IONISER
  • Stand-alone operation, or operation in a local network, or on the internet are possible
  • A cloud connection option is currently being prepared
  • The most up-to-date communication channels for your process optimization
  • Connect to your automation via your network and / or directly via signal lines to a PLC
  • Controlling external devices is possible. For example, warning lights etc. or for process optimization
  • Conditions and faults in the system are monitored in an optimal manner and contribute to your process optimization
  • Attractive appearance
  • You can choose between different data presentation options
  • A bar display and a traffic light system facilitate a quick overview
  • Operation is conveniently carried out via resistive touchscreen or rotary encoder

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Technical features

Hardware

  • High life expectancy as there are no moving parts (e.g. fan - except for flow sensor)
  • Resistive touchscreen
  • Encoders (rotary and pushbutton operation)
  • 1 SD card slot (data logging, websites, updates)
  • Various LEDs: One operational LED, 2 LEDs for status indication and 2 LEDs for USB data transfer and 2 LEDs on the network connector
  • WLAN (both as an access point and / or WiFi via an external access point)
  • LAN 10/100 Mbit (Ethernet, RJ45 socket)
  • 2 x PLC output up to 70V/30mA with additional 5.3V/250mA output (unfused)
  • External plug-in power supply unit (electrically isolated)
  • USB serial port for data retrieval (cannot be used for USB sticks)
  • Resetbutton
  • Maintenance button
  • 1 x temperature sensor for water temperature
  • 2 x conductance sensors (input & output)
  • 1 x flow rate sensor
  • Real time clock with SuperCap buffering (up to one month without power)
  • Preparation for future E.KO IONISER detection
  • Extension options via an expansion slot (to be fitted by consultation with easymetal)
  • High power dual core processor 2 x 240MHz/16MB RAM/EEPROM.
  • Internal temperature sensor to measure the temperature of the electronics
  • Simulator for automation testing and software development available (not included)

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Software

  • Operating system: based on freeRTOS
  • TCP/IP stack
  • Integrated WEB server with active pages and extension options
  • In-house websites on SD cards - currently in preparation
  • Integrated REST server (for integration of telemetry data in business applications)
  • SD card logging (up to 2 GB)
  • UTC time logging
  • Real time clock (integration into operating time)
  • Time synchronization through the internet (integration into operating time)
  • Time zones according to Posix standards
  • Quick selection of important time zones
  • Automatic adjustment to daylight savings time
  • Date Time Settings (display, time server, ...)
  • Transparent hardware check at startup
  • Various modes of data display: Graphic, text and history
  • System overviews or management information
  • Extensive configurability
  • Languages (up to 12 different languages are supported)
  • Configurable **alarm values or color system **
  • Programmable PLC outputs
  • User administration with ** up to 6 users **
  • Role system: Setup, user admin, consoles (USB serial)
  • Adjustable device name for better central management and identification of devices
  • Sequence demos (for demonstration and test purposes)
  • Simulator for software developers and process automation engineers
  • Adaptable to various E.KO IONISERs (automatic recognition in preparation)
  • Adjustable time intervals for history and logging
  • Main or start screen can be freely selected and configured
  • Adjustable screen brightness and sleep mode
  • Calibration of the touch display
  • Controls can be switched off separately (touch screen, rotary encoder, USB serial console - either touch or rotary encoder must remain active)
  • Adjustable units (°Celsius / Fahrenheit / µSiemens/cm / Ohm)
  • Can be reset to factory settings
  • Actions via interface such as restart, login, logout
  • Display of internal information (boot information, SD card directory, internal EEPROM directory, running tasks) Measurement information (display of all internally measured values)
  • Virtual keyboards (alphanumeric, password, integer, decimal, date, time, IP address, ...)
  • Network: Each channel can be configured individually (custom hostname or device name, static IP addresses, gateway, netmask or DCHP server or client)
  • WiFi scan with AP selection for easy configuration.
  • Text console can be operated via USB serial through terminal emulation. Commands for data retrieval and system commands are available

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Physical specifications

Property Value 1)
Dimensions 2) Width=235mm, height=212mm, depth=125mm
USB driv port Width=17mm, height=38mm, depth=23mm
Material ABS, glass fiber reinforced 3)
Storage temperature 5°C to 70°C
Operating temperature 5°C to 50°C
Air humidity 4) 10% to 90% relative air humidity
Water connections 4 5)
Maximum measurable flow rate 0 L/min to 25 L/min
Maximum water pressure 6 bar (ToDo easymetal)
  1. : Please note that the limiting factor is not Korrostop4.0, it is your EDM machine and the E.KO IONISER, or more specifically, its operating parameters!
  2. : Without connections
  3. : Various state-of-the-art materials were used for connections
  4. : Storage and operation
  5. : Input/output to machine and input/output to E.KO IONISER

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Electrical specifications

Area Property Value
Plug-in power supply unit Input voltage 230 VAC +/- 6/10 %
Plug-in power supply unit Maximum power consumption 300mA
Plug-in power supply unit Frequency 50/60 Hz
PLC connection Channels 2 (potential-free), electrically isolated, max. 70V/20mA
PLC connection Switching element Optocoupler ILD213T 1)
PLC connection Max. voltage per channel up to 70V
PLC connection Max. current duration per channel up to 20mA
PLC connection Max. current peak per channel up to 30mA
  1. : Please also refer to the datasheet) for the Optocoupler ILD213T

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Connection specifications

WLAN Value
Access point up to 4 connections
Station 1 connection to access point
Special features Access point, station and network scan simultaneously
Special features If station connection fails, network scan is not possible
Modes WPA / WPA2 / PSK
Standards 802.11 b/g/n (802.11n up to 150 Mbps)
Frequency range 2.4 GHz ~ 2.5 GHz (2412 - 2484 MHz)

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The values indicated here refer to operation of the WLAN antenna without housing. These values are reduced significantly depending on the components between the WLAN antenna and your receiver-transmitter (e.g. the screen or water pipes).

WLAN standard Transfer Sensitivity
11b 1 Mbps –98 dBm
11b 11 Mbps –89 dBm
11g 6 Mbps –92 dBm
11g 54 Mbps –74 dBm
11n HT20, MCS0 –91 dBm
11n HT20, MCS7 –71 dBm
11n HT40, MCS0 –89 dBm
11n HT40, MCS7 –69 dBm

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WLAN standard Transfer Adjacent channel rejection
11g 6 Mbps 31 dB
11g 54 Mbps 14 dB
11n HT20, MCS0 31 dB
11n HT20, MCS7 13 dB

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LAN Value
Connection RJ45 socket
Data transfer 10 MBit / 100 MBit
Connection Link and data trasfer LED
Compliant with IEEE802.3/802.3u (fast ethernet)
Compliant with Compliant with ISO 802-3/IEEE 802.3 (10BASE-T)
ESD HBM ESD Performance via JEDEC JESD22-A114 Class 3A
ESD IEC61000-4-2 Contact Discharge ESD Performance (Note 5-5) +/-8kV
ESD IEC61000-4-2 Air-Gap Discharge ESD Performance (Note 5-5) +/-15kV
ESD Latch-up Performance via EIA/JESD +/-150mA

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USB serial Value
Port Micro-USB-B
Port Special Features ID-signal to mass
Serial configuration 115200 Baud, Databits=8, Stopbit=1, Parity=NONE, Flow=XON/XOFF
Serial terminal VT100 POSIX compatible
Chip FT231X
Driver siehe https://www.ftdichip.com/Drivers/D2XX.htm
Cable length maximum 1200mm 1)
USB mode Compatible with USB 2.0 specification
  1. : USB cable not included

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Measuring accuracy and measuring range

Sensor Unit Min Max Deviation
Water conductance input µSiemens/cm 0,1 50,0 <+-5%
Water conductance output µSiemens/cm 0,1 5,0 <+-2,5%
Water temperature °C 5 60 <+-0,1 1)
Flow rate Liter/min 0 25 < +-10%
Water quality of the E.KO IONISER % 0 100 --
  1. : Offset errors < 2°C

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Applications

Access Point WiFi LAN USB serial SPS signal Use case
X - - - - Measurement data display on smartphone, laptop, tablet
- X X m X Central monitoring in the company
- X X m X Central monitoring of home workstations (company LAN must be configured accordingly)
- X X m X Integration into corporate IT (business applications)
- X X m X Process security
- X X m X Integration into process control
m - - X - Ad-hoc data query with laptop
m m m X m Troubleshooting
X X X X X Programming & testing of in-house developments (USB serial is the tool of choice for this)
- - - X X Network connections not possible or undesirable

Key:

  • - : Not possible
  • X : Recommended option
  • m : Possible, but not recommended

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