Ecogate Systems: Standard vs Smart
Ecogate has historically offered two distinct system types: the Standard System, focusing on fundamental automation, and the Smart System, which elevates ventilation with intelligent controls. Both are On-Demand Control Systems for industrial ventilation, we’ll cover the differences more in detail.
Ecogate System Components
An Ecogate system consists of 4 main components;
Gates - open and close at drops to regulate airflow
Sensors - detect when workstations become active
VFD - adjusts collector/fan based on demand
Control Unit - the brain of the system
The primary distinction between Standard and Smart Systems lies in the greenBOX Control Unit and the motor type driving the gates . While both systems can incorporate any gate style (rotating-blade or butterfly style), the Smart System stands out with its advanced greenBOX options and Smart Gates (powered by Smart Motor)—yes, everything is smart.
Standard Gates (powered by Standard Motor) do not have limit switches nor a processor board.
Ecogate Standard System
The Standard System incorporates older control units like the greenBOX 12 and the now-retired greenBOX 8. Designed for simplicity and cost-effectiveness, these units are straightforward to install, often by the users themselves in smaller shops. They support a limited number of gates—12 for the greenBOX 12 and 8 for the greenBOX 8—reflecting their names. For many years, these units got the job done.
The greenBOX 12, in particular, is celebrated for its remarkable durability, with some units reliably functioning for over two decades. While not featured in our main product lineup, we continue to offer the greenBOX 12 to customers upon request, subject to availability.
If you were indeed interested in a Standard System, what would you get? The greenBOX 12 lets you adjust the minimal airflow in one duct zone and controls up to 12 Standard Gates (powered by a Standard Motor). The Standard Motor provides the basic functionality of opening and closing the gate using limit switches but does not measure pressure, air volume or velocities at drops.
Connection
To setup your greenBOX 12, a Windows PC is necessary, given that the setup software is compatible only with the Windows operating system. We offer a Netbook that comes preloaded with all the essential software, including LogMeIn for easy remote access, and a cable that connects directly to your greenBOX 12.
For Small Operations
This solution works for small shops who don’t need all the advanced functionality Smart Systems bring. You can plug in a Power Master VFD to the greenBOX 12 using Modbus communication. For small operations who just need a simple open/close gate function, an Ecogate Standard System could get the job done.
Upgrade Program Available
If you currently operate a system with a prehistoric greenBOX 8, we offer an Upgrade Program. The greenBOX 8 and its system components are no longer supported and replacements are not available. While the greenBOX 12 is not a Smart System packed with all the advanced control and features, it is still a significant upgrade from a greenBOX 8. Check out our Upgrade Program, it offers discounts of up to 54%.
Ecogate Smart System
Ecogate’s Smart Systems harness the power of the latest generation of greenBOX Control Units, which were recently upgraded from the inside out, boasting state-of-the-art hardware and cutting-edge software. These units can handle the biggest factories that span multiple systems.
Connection
To setup and access your Ecogate Smart System you do not require a Netbook nor additional software. Because our controllers have a built-in web server, you can access it from any browser on any device (Android, iPhones, computers, tablets) and any operating system (Windows, iOS, Linux).
Controller
Engineered to effortlessly manage the demands of the largest factories across multiple systems, our lineup is available in three sizes—small, medium, and large. Each unit is capable of supporting an unlimited number of systems, constrained only by the total number of gates. This scalability ensures that as your operations grow, Ecogate grows with you.
Latest generation greenBOX control units (small, medium, and large)
These control units intelligently automate your ventilation system and give you insights into your system health, performance, and key measurements. The Smart System uses Smart Gates, which are essentially Ecogate gates powered by a Smart Motor.
Ecogate Smart Gates
Ecogate Smart Gates are designed to measure pressure, air velocity, and air volume, seamlessly communicating this data to the greenBOX controller via Modbus communication. This capability is thanks to the embedded processor in the Smart Motor. The greenBOX controller takes live readings from all gates, adjusting your system to ensure the exact air volume required is consistently maintained throughout the entire ducting system.
Both Smart and Standard Ecogate gates are built to industrial-grade standards, ensuring durability. This durability is crucial given the significant forces exerted on gate bodies by duct systems. Unlike pneumatically operated gates, our gates use 24V DC motors, making them less expensive to install and operate--considering how costly compressed air is.
Ecogate Analytics
Ecogate Analytics transforms the data collected from Smart Gates into actionable insights. By processing this information through Ecogate's cloud, it's structured in an easily understandable format and directly sent to your inbox. With the capability to measure air volume at each workstation, these reports offer a deep dive into workstation utilization, identifying trends and patterns. This wealth of data empowers managers to make informed decisions, optimizing operations for efficiency and productivity.
Daily Emails
Daily emails provide key ventilation system metrics—fan/filter pressures, power, duct air volume, velocities—enabling maintenance teams to preempt issues, ensuring system efficiency and reliability.
Monthly Emails
Monthly emails deliver a strategic overview of business performance, spotlighting average workstation utilization over recent months and ventilation system's electricity savings. Ideal for management, these insights facilitate trend analysis, efficiency evaluation, and cross-facility comparisons.
Power Master VFD
The Power Master VFD is an integral component of every Smart System, designed to automate your collector's start/stop function and modulate your fan's speed to match real time demand. While it's technically possible for a greenBOX Control Unit to integrate with a third-party VFD, there are significant drawbacks to such an approach. These disadvantages are thoroughly explored in this article.
Side by Side
Here's side by side comparison of the key differences between an Ecogate Smart System and the Standard OG system.
System | Standard System | Smart System |
Control Unit | greenBOX 12 | greenBOX Pro, Nxt, Max, Master |
Software Setup | Windows PC required | Via any web browser |
Remote Access to greenBOX | via Windows PC with LogMeIn software preinstalled by Ecogate | from any internet connected device (Windows, Mac, Linux PCs; Apple and Android tablets, Apple and Android smartphones) |
Max number of gates | 12 | 36 / 72 / 144 / 288 |
Communication with gates | No; +/- 24V DC is used to Open/Close gates | Industry Standard Modbus (serial communication over RS-485) |
Gate wiring | STAR (each gate has own cable to greenBOX) | DAISY-CHAIN (cable is connected from gate to gate) |
Number of dust collecting systems | 1 | Any number of systems (limited by number of gates, see above) |
Data Collection and Analytics | NO | YES |
Number of duct zones to maintain minimal airflow | 1 | 30 |
Pressure, Air Velocity, Air Volume monitoring at drops | NO | YES |
Power Master VFD connection | Industry Standard Modbus (serial communication over RS-485) | Industry Standard Modbus (serial communication over RS-485) |
Automatic dust collector Start/Stop | Yes (with Power Master VFD) | Yes (with Power Master VFD) |
Fan, and Filter Pressure Sensors | Yes (with Power Master VFD) | Yes (with Power Master VFD) |
Automatic (greenBOX controlled), Manual (all gates open, full fan speed), and Stop Mode Selector | Yes (with Power Master VFD) | Yes (with Power Master VFD) |
Workstation Activity Sensors | Volt, Current, Laser | Volt, Current, Laser |
Averaging Air Velocity Sensor | NO | YES |
Automatic Winter Mode | NO | YES |
Software Update | from Windows PC | Over The Air (OTA) |
Which System Should You Go With?
If you have a small shop, perhaps one in your garage, then the Ecogate Standard System makes sense. For businesses focused on improving their bottom line, Ecogate’s Smart System is a clear choice. The advanced functionality and key metrics it reports offers a lot of leverage for managers and business owners and add to that the significant electricity savings it unlocks and this truly is the best way to operate an industrial ventilation system.
Want to know what sets the Ecogate Smart System apart as the premier solution for dust collection? Check out the Ecogate system features that no other system does.
Author, David Vera
