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Dust Collector Controller & Interface

Dust Collector Controller & Interface

The Ecogate Dust Collector Controller gives each dust collector its own intelligent interface. Facilities can choose between two configurations:
  • Dust Collector Controller: Full monitoring and control of all dust collector motors via VFDs. (Main option)
  • Dust Collector Interface: Monitoring-only package with identical hardware, upgradeable later to full Controller.
 
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  • Monitoring vs Monitoring + Control

    Dust Collector Interface (Monitoring Only)

    • Collects detailed status from the dust collector (fan pressure, filters, airflow).

    • Provides alarms, dashboards, and remote visibility via the greenBOX®.

    • Ships with Modbus Master included – ready to upgrade with VFDs later.

    • Air Quality Sensor provides Air Quality Index, temperature, humidity, & atmostpheric pressure (optional dust sensor can be installed externally)

     

    Dust Collector Controller (Monitoring + Control)

    • Includes all monitoring features of the Interface.

    • Adds direct control and monitoring of dust collector motors (fan, transport fan, cleaning pump, cleaning arm, airlock).

    • Automates start/stop and sequences with proper delays.

    • Provides motor underload/overload fault detection for early warnings.

     

  • Dust Collector Controller – Key Capabilities

    Core Functions

    • Automatically stops all dust collector motors when workstations are idle and restarts them as they become active.

    • Reduces electricity consumption and manual labor (savings up to $10,000 annually for a 200 HP collector).

    • Integrates motor monitoring: voltage, current, power, speed.

    • Controls supplementary equipment via relay contacts.

     

    VFD Advantages

    • Reliability: Higher MTBF than contactors.

    • Cost Savings: Eliminates need for Zero Speed sensors.

    • Gentle Starts: Prevents costly power peaks and reduces mechanical stress.

    • Unlimited Start/Stop Cycles: VFD-controlled motors can cycle without limits.

    • Fault Indication: Detects broken belts or mechanical locks early.

    • Simplified Wiring: Single twisted-pair daisy-chain between VFDs.

     

    Integration with greenBOX

    • Connects via Ecogate Master Cable (same as Smart Gates).

    • Status displayed on the greenBOX touchscreen or remotely via any web browser.

    • Firmware updated automatically through Modbus RTU.

    • Easy programming via greenBOX UI (“listbox style”) or remote support by Ecogate.

    • Supports setup of motors and equipment naming in plain English, editable motor delays, safety sequences (fire alarm, spark detection, pressure limits), and basic functionalities (remote start/stop, enable signals, status lights, buzzer).

     

    Advanced Features

    • Manual Start/Stop buttons and status lights (OK, Warning, Error) with buzzer.

    • Programmable digital and analog inputs for additional sensors (e.g., vibration).

    • Remote dust collector Start/Stop integration with Power Master VFD.

    • Automatic safety responses (fire alarm, spark detection, pressure limits).

     

    Benefits

    • Saves electricity and reduces downtime.

    • Provides early fault detection for proactive maintenance.

    • Improves workplace conditions (quieter during breaks).

    • Empowers maintenance teams with full system visibility.

     

  • Optional Add-On

    External Air Quality Sensor (available 2026)

    • Monitors ambient temperature, humidity, PM1/2.5/10 dust levels, TVOC, and eCO2.

    • Can be mounted in the clean air duct to detect broken filter bags.

     

  • Technical Specifications

    (subject to change)

    Enclosure: NEMA Type 12, UL listed

    Power supply: 3-phase 460V AC (230V AC on special order)

    Main input: Fused disconnect, interlocked with door

    Dimensions: 72”H x 36”W x 16”D, wall mounted

    Front Door: Manual Start/Stop buttons, status indicators (Green = OK, Yellow = Warning, Red = Error), main power disconnect, Ecogate decal and labeling

    Cooling: Cabinet fan and exhaust filter, 24VDC

    Motor Circuit Protection: Each VFD protected separately

    VFDs: ABB ACS880-01, usable with motors down to 20% of rated capacity

    • 1 HP 3-phase 460V AC for Cleaning Arm

    • 5 HP 3-phase 460V AC for Air Lock

    • 15 HP 3-phase 460V AC for Cleaning PD Pump

    • 40 HP 3-phase 460V AC for Transport Fan

    Power Supply: Mean Well SDR-240-24 V DC (240W total) for cooling fans, Dust Collector Interface, and external sensors

     

    Dust Collector Interface:

    Green metal enclosure, 10.5” x 7.5” x 3.5” with mounting bracket

    Power: 24V DC, 10W max, redundant supply inputs (from greenBOX via Ecogate Master Cable, Mean Well 24V DC, or USB-C terminal)

    Communication: Modbus RTU Slave (to greenBOX), Modbus RTU Master (to VFDs and Modbus sensors)

    Pressure sensors:

    • Fan Total Static Pressure (10 kPa = 40” w.c.)

    • Filter Differential Pressure (2.5 kPa = 10” w.c.)

    • Averaging Air Velocity Sensor (1 kPa = 4” w.c.)

    • Optional: Cleaning PD Pump Pressure (100 kPa = 400” w.c.)

    • Optional: Second Filter Differential Pressure (e.g., HEPA, 2.5 kPa = 10” w.c.)

    I/O:

    • 5 programmable digital inputs

    • 3 programmable analog inputs (4–20 mA)

    • 4 programmable dry relay contacts (2 NO, 2 NO/NC)

    • Input for manual Start/Stop

    • Outputs for LED status lights (24V DC, max. 8W each)

    Interface: 1.1” OLED display with touch button to scroll status pages

    Terminals: Phoenix contact pluggable screw type (same as greenBOX)

    Software Updates: Automatic via Modbus RTU from greenBOX; optional via USB-C using Rockhopper service software

    Programming: From greenBOX UI via “listbox programming” (Adelie Programming Language – APL)

     

  • What You Need

    The Controller and Interface can operate standalone, but pairing with the greenBOX unlocks:

    • Comprehensive monitoring across the system.

    • Remote access and dashboards.

    • Flexible programming.

    • OTA software updates.

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