The greenBOX is the central controller in an Ecogate dust collection system. It controls automatic blast gates and adjusts fan speed through a Power Master variable frequency drive (VFD).
As machines start and stop, it matches extraction airflow to the work in progress while maintaining the conveying airflow needed to move dust through the ductwork.
Workstation activity sensors tell the controller which machines need extraction. Smart Gates measure duct pressure, air velocity, and air volume.
The greenBOX opens gates serving active workstations. Configured off delays allow residual dust to clear after a machine stops.
The controller totals workstation airflow requirements and checks minimum conveying velocity in each configured duct zone. The greenBOX opens additional gates at non-operating machinery or bleed gates until the minimum airflow is reached.
The greenBOX sends a command to the Power Master VFD, which adjusts fan speed to meet the system’s airflow requirement.
These functions depend on the configured Smart System, compatible gates and sensors, and the commissioned duct and fan settings.
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Expand galleryUse the interface to set up the system, check daily operation, and investigate faults.
Use a built-in touchscreen where equipped, or access the web interface from an authorized browser on the facility network.
Review connected Modbus devices, communication quality, voltage, current, power, and available per-port settings.
Set up workstations, gates, duct zones, collectors, fan control, operating sequences, and alarm behavior around the engineered system.
Use the built-in monitoring and historical charts to review operation. Ecogate Analytics adds cloud reporting and remote access to operating data.
All four current Smart System models use EcogateOS, support Smart Gates, provide browser access, and receive software updates over the internet. They differ in gate capacity, touchscreen, inputs and outputs (I/O), and power supplies.
The greenBOX Pro controls up to 36 Smart Gates and uses the same core software platform as the larger controllers.
The greenBOX Nxt includes a 10.1-inch industrial touchscreen and controls up to 75 gates.
The greenBOX Max adds six Modbus ports, capacity for up to 150 gates, expanded I/O, a 15.6-inch display, and dual redundant power.
The highest-capacity current controller supports very large factories and multi-system facilities with nine Modbus ports, expanded I/O, and four power supplies arranged as two redundant pairs.
| Model | Maximum gates | Best fit | Modbus ports | Built-in display | Redundant power |
|---|---|---|---|---|---|
| greenBOX Pro | 36 | Smaller Smart Systems | 3 | None | No |
| greenBOX Nxt | 75 | Most industrial installations | 3 | 10.1 inch | No |
| greenBOX Max | 150 | Larger systems needing redundant power | 6 | 15.6 inch | Dual |
| greenBOX Master | 225 | Maximum-capacity and complex facilities | 9 | 15.6 inch | Four supplies, 2 + 2 |
Controller selection also depends on system count, I/O requirements, power demand, power-supply redundancy, installation conditions, and the engineered control strategy. Ecogate can confirm the correct model.
The controller contains an industrial computer, interface boards, power supplies, and cooling components in a serviceable enclosure.
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A fan drive changes fan speed. A system controller decides how much extraction is needed and which gates should open. Here is how the main control approaches differ.
Operators open and close gates by hand. The fan runs at its set speed, even when fewer machines need extraction.
A VFD changes fan speed in response to a control signal. By itself, it does not decide which workstation gates to open or how much airflow each duct needs.
A PLC can coordinate gates and fans when the required sensors, control logic, and operator interface are programmed and integrated for the installation.
The greenBOX receives machine activity signals and measurements from Smart Gates. It opens the required gates, adjusts fan speed through the Power Master VFD, and opens additional gates at non-operating machinery or bleed gates until the minimum airflow is reached. Operators can view and manage the system through its interface.
Actual capabilities depend on the equipment and configuration. An Ecogate Smart System requires compatible gates, sensing, fan control, and an engineered system setup.
The greenBOX 12 controls Standard Gates in smaller systems. The greenBOX ONE connects compatible third-party gates to a Smart System.
A Standard System controller for up to 12 gates. It uses Standard Gates, supports one duct zone, and can coordinate a Power Master VFD. It does not include the Smart System web interface, gate-level airflow measurement, OTA updates, or Analytics.
View the greenBOX 12
An interface for connecting certain third-party or machine-integrated 24 V DC gates to an Ecogate Smart System. It reports workstation demand to the greenBOX controller and can add pressure-based airflow information at that connection.
Read about the greenBOX ONEIt is the central Ecogate controller. The greenBOX receives demand and system information, calculates required airflow, coordinates gates and operating sequences, and sends the fan command to a compatible Power Master VFD. The VFD regulates fan speed, but it does not replace the greenBOX control logic.
Current Smart System models provide a web-based interface that authorized users can access from a browser on the facility network. The greenBOX Nxt, Max, and Master also include built-in touchscreens. The greenBOX Pro does not include a built-in screen.
The current Smart System models, the greenBOX Pro, Nxt, Max, and Master support Smart Gates. The greenBOX 12 is a separate Standard System controller and uses Standard Gates rather than Smart Gates.
Start with gate count, then check the rest of the system requirements. Selection also considers the number of controlled systems, Modbus devices, I/O, touchscreen needs, power requirements, redundancy, duct zones, and future expansion. Ecogate engineering can confirm the right controller during system design.
Often, yes. The correct path depends on the legacy controller, gates, sensors, VFDs, wiring, and current operating condition. Some existing hardware may be reusable, while other components may need replacement. Ecogate should review the installed system before an upgrade scope is finalized.
No single controller guarantees total facility compliance. A properly designed, installed, and calibrated Ecogate system is designed to support the relevant control-system requirement by maintaining configured minimum transport velocities when gates operate. Complete compliance depends on the broader system design, hazard analysis, equipment, installation, housekeeping, and Authority Having Jurisdiction.
Send Ecogate your workstation count, duct layout, fan and collector details, operating hours, and expansion plans. An engineer can confirm the controller capacity, connections, and power supplies required.
