How To Calibrate Air Velocity and Air Volume Measurements for Ecogate Smart Gates

One of the key advantages of Ecogate Smart Gates for industrial on-demand ventilation systems (dust, mist, and fume collection) is their ability to measure pressure, air velocity, and air volume in real-time. Each Smart Gate transmits these measurements to the greenBOX Controller via industry-standard Modbus communication. No other solution on the market provides gates that can measure and report these critical parameters to an automated on-demand ventilation system.

This capability allows users and maintenance personnel to monitor system performance continuously, ensuring it operates per design specifications. These real-time measurements are displayed on the greenBOX Controller screen or accessed remotely.

Why Calibration Matters

Ecogate’s On-Demand Control System for industrial ventilation continuously monitors airflow parameters, ensuring that your system operates at optimal efficiency. Without proper calibration, incorrect air velocity readings can lead to inefficient dust collection, increased energy consumption, and potential system malfunctions. Calibration ensures:

• Accurate air velocity and volume measurements

• Optimal dust and fume extraction

• Compliance with safety and industry regulations

• Energy-efficient operation

Step-by-Step Calibration Process

Step 1: Set Zero Pressure Reading

Before measuring airflow, it's crucial to set a zero-pressure reference point:

1. Ensure the ventilation system is in Stop mode, meaning the fan is off.

2. Navigate to the Advanced Gate Configuration in the gate settings.

3. Press the SET PRESSURE ZERO OFFSET button.

4. Confirm that the pressure reading is now at zero.

Fig. 1: At Stop mode when the fan is not running use “SET PRESSURE ZERO OFFSET” to reset pressure reading.

Fig. 2: after pressing “SET PRESSURE ZERO OFFSET” pressure reading is zero.

Step 2: Run the System in Bypass Mode

To obtain an accurate airflow measurement, the system must be running at a stable speed:

1. In System Settings, activate Bypass Mode to open all gates (except those set to "Open Only By Sensor").

2. If any gates are set to "Open Only By Sensor," temporarily disable this setting during calibration.

3. Adjust the fan speed in Advanced Fan Settings → Bypass Fan Speed to maintain a steady airflow.

Fig. 3: Set system to Bypass mode to open all gates and run fan at constant speed

Fig 4: Fan speed at Bypass mode can be set in Advanced Fan Settings → Bypass Fan Speed.  

Step 3: Measure Air Velocity

Now that the system is stable, take precise air velocity readings:

1. Use a high-quality air velocity meter with an averaging function, such as the Fluke 922 paired with a Pitot tube.

2. Perform a full cross-sectional scan of the duct to measure the actual airflow velocity.

3. Record the measured velocity value for input into the Ecogate system.

Step 4: Calibrate Air Velocity in the System

Fig. 5: Press CALIBRATE button, enter measured air velocity, and press CALIBRATE button.

Using the measured velocity data, calibrate the system:

1. In Advanced Gate Configuration, press the CALIBRATE button.

2. Enter the measured air velocity and press CALIBRATE again.

3. The greenBOX control unit will assess pressure over a 10-second period, calculate the average, and adjust the air velocity reading accordingly.

4. Once air velocity is calibrated, the system will automatically calculate air volume based on the gate diameter.

Fig. 6: After calibration gate will show measured Pressure, Air Velocity, and Air Volume

The Advantage of Automated Airflow Monitoring

Conventional dust collection systems require time-consuming manual air velocity measurements, which become outdated whenever system configurations change. Ecogate’s On-Demand Control System eliminates these inefficiencies by providing continuous real-time monitoring. This ensures that airflow remains optimized, leading to:

• Reduced downtime for recalibration

• Lower energy costs

• Enhanced system longevity

Final Thoughts

Regular calibration of Ecogate Smart Gates is a simple yet essential practice to maintain accuracy in airflow management. By following this process, maintenance teams can ensure efficient system performance, compliance with industry standards, and maximized energy savings.

For more information or technical support, reach out to support@ecogate.com

Ales Litomisky