Ecogate GreenBOX 12 Benutzerhandbuch

greenBOX®12

Startup Guide

Updated: May 2019

Intelligent Industrial Ventilation

Ecogate, Inc.

5669 Whitnall Hwy

North Hollywood

CA 91601, USA

Phone: +1-818-506-6016

www.ecogate.com

info@ecogate.com

2. INTRODUCTION & CONTENT

The ECOGATE®System completesdust collecting systems. The greenBOX can control gates

for twelve workstationsand a Variable Frequency Drive (VFD) to adjust fan RPM. In a typical

factory, about half of the machines arenot in use at any given time. The ECOGATE®System

automatically turns onthe vacuum system tomachinesinusewhile turning it off to those not in

use; moreover, it can control (optional) a variable frequency drive toadjust fan RPM. This

generally savesapproximately 55-70% of fan electrical consumption, and active workstations

havebetter suction. Based on thenumber of workstations in operationata giventime, a larger

number of workstations may be connected to the same system. The greenBOX also

automatically maintains minimum air flow toavoid saw dust settling.

Important Warning

Nevertouch the high-voltage terminalsin thegreenBOX. Failure to observe this warning may result in an electrical

shock. Onlyauthorized personnel should be permitted to perform installation, maintenance, inspections, or part

replacement.

Wiring

Begin wiring only after verifying that the power supply is turned OFF. Only qualified personnel

should perform wiring. Failure to observethis warning may result inan electrical shock or fire.

IMPORTANTNOTE:ECOGATE, Inc.doesnotassumeany liabilityregardingthe interpretation of theinformationinthis document.

Theinformationcontained inthisUserandInstallation Guideisarecommendedmethodforinstallingand operatingadustcollectionsystem andis

offered as aguideonly.You are individuallyresponsiblefor the safety anddesignofyourparticular dust collectionsystem. Thismanual may be

modifiedwhennecessarybecauseofimprovementsoftheproduct, modification,orchanges inspecifications.

Your particular systemmust adhere to all rules andregulationssetby federal,stateor localgoverningcodesandrequirements where applicable.

This“User andInstallationGuide” doesnotattempt to describeevery aspectofsafety, implementation,andoperation ofanyparticulardust

collectionsystem.Industrial applications alsoinvolvemanymorevariablesand trade-offdecisions as wellas strictcompliancewithOSHA and

other regulatory agencies.Especiallyimportant is tofollowrules for thecombustibledusthazards; asanintroduction, seehttp://

www.youtube.com/watch?v=3d37Ca3E4fA&feature=player_embedded orvisit CSB -US ChemicalSafety Board at http://www.csb.gov/.

Allterms inthismanual thatareknownto be trademarksor service marksarelistedbelow.Use ofa termin thismanual, whether listedbelow or

otherwise,shouldnot beregardedasaffectingthe validityofany trademark or servicemark.

other patents pending. greenBOX®,ECOGATE®,and ECOGATE logo are registered trademarks of ECOGATE, Inc.

Thank you for purchasing the

ECOGATE®greenBOX 12control unit.

Read this User Guidethoroughly

beforesystem installation, setup, and

use.

Table of Content:

User Guide..…………….………. 3

Schematic Diagram..….……….. 4

Gate Connection…………..…… 7

VOLT Sensor..………………..... 9

CURRENT Sensor.…………..... 10

Software Installation...…………. 11

PC Software SETUP……...…… 13

PC Software STATUS.….……… 14

PC Software TEST…..….……… 15

PC Software SERVICE...….…… 16

Bypass Switch, Security Input..17,18

Fan On, Off Contactor, VFD.. 19-21

Specifications…………………… 25

Main Board Overview..………….. 23

Troubleshooting………………… 24

Specifications…………………… 25

Service & Support……………… 26

3. greenBOX 12 USER GUIDE

The ECOGATE®System completes dust collecting systems. The greenBOX controls gates at each workstation, starts and stops the

dust collector automatically by using workstation activity sensors. The greenBOX also automatically maintains minimum air flow to

avoid dust settling (if Smart Minimum airflow is set). The power supply to the greenBOX should be connected at all times. The dust

collector will start automatically with the start of any of the workstations.

All the safety and operating instructions in the Ecogate greenBOX 12 User Guide and for the other parts of the ventilation system

(fan, filter, transport) should be read before the product is operated. The dust collecting system (gates, fan, filter, cleaning

mechanisms, transport etc.) can run automatically at any time without warning. Keep hands away from gates because they are

connected to the control unit which can run the gate automatically at any time without warning.

How does automatic mode work?

If you switch any workstation ON, the greenBOX®will leave the appropriate gate open, switch the dust collector ON, and close all

the other gates. Note: some gates on non-operating machinery will remain open to maintain the minimum required air flow in the

duct system and dust collector. Turning ON further workstations will open the corresponding gates.

Similarly, turning workstations OFF will close the appropriate gates (each gate can close with a programmable delay of up to 99

seconds). Upon turning OFF the last operating workstation, the greenBOX®will switch the dust collector OFF (with a

preprogrammed delay of up to 0…99 minutes) and will open all the gates (for security reasons and for system cleaning).

Is the gate open?

To see if the gates are working, start each workstation and monitor indicators on the gate motor housing. The GREEN gate indicator

is ON when the gate is opening (about 5 seconds for 6" gate), the RED gate indicator is ON when the gate is closing (also about 5

seconds for 6" gate).

Troubleshooting

1. If any workstation sensor is active, the yellow indicator "INPUT SIGNAL" on the greenBOX main board will be ON.

2. If any gates (1…12) are open, then the corresponding green indicator "GATE OPEN" (1…12) will be ON to reflect this status.

During the gate movement (to either the open or closed position) the corresponding "GATE OPEN" indicator flashes.

3. "POWER" indicates that a power supply is present at the greenBOX.

4. Whenever the fan should be ON, the green "FAN-RUN" light will be lit.

5. If the green light marked "SECURITY" is flashing, the SECURITY INPUT is open and greenBOX will start executing

SECURITY action (typically fan will stop, gates will open).

4. SCHEMATIC DIAGRAM

This is a simplified schematic diagram

of the greenBOX 12 system.

The gates are connected to the

terminals #1…#12 by 5-wire (or 4-

wire) cable.

The sensors are connected to the

gate by 2-wire cable, the sensor

inputs are connected to the

workstations.

The fan motor speed is controlled

by Power MASTER VFD (the Fan

and Filter pressure sensors are built-in

the VFD). Controlling Power MASTER

over Modbus requires firmware F05A

or later (you check firmware version at

Service Page of PC software).

The ENABLE input of the Power

MASTER enables the fan operation

(it is required for larger dust collectors

with the air lock, transport fan, and

filter cleaning).

The power supply 24V DC is built-in

to greenBOX enclosure and is used to

power greenBOX, and gates.

A Windows PC can be connected

via USB to serial adapter – it is

required for setup only.

VOLT

SENSOR #12

GATE #12

A T T E N T I O N

C A U T I O N

A T T E N T I O N

C A U T I O N

S Y S T E M

E N A B L E D

F A N

R U N N I N G

V F D

E R R O R

A U T O M A T I C M O D E

S T O P

M A N U A L M O D E

P o w e r

M A S T E R

St a r t

St o p

Lo c / R e m

St a r t

St o p

Lo c / R e m

Modbus A

Modbus B

greenBOX 12

Electricity Saving Efficient Dust Collecting

For Industrial Shop

Ecogate®, Inc.

Ultimate In Dust Collecting

www.ecogate.com

888-ECOGATE

U.S. Patent 6,012,199

U.S. Patent 7,146,677

Chinese Patent ZL03127716.0

Chinese Patent ZL99811890.7

Other patents pending

CAUTION: Risk of electric shock;

high voltage up to 460V AC can be

connected to this unit!

Power supply: 24V DC or 18V AC,

max. 2 Amps. Type 1 enclosure;

dry indoor location only.

greenBOX 12 with Power MASTER VFD

Connected via Modbus (up to 12 workstations)

GATE #1 ...

VOLT

SENSOR #1

USB to

SERIAL

Windows PC with Ecogate Setup

and Monitoring software

(necessary only for setup)

Use cable with one

twisted-shielded pair

ECOGATE

SIGNAL

AC/DC VOLT

OUT

24-230VDC orAC

ECOGATE

SIGNAL

ECOGATE

SIGNAL

AC/DC VOLT

OUT

24-230VDC orAC

ECOGATE

SIGNAL

VOLT sensors inputs are connected in

parallel with cutting tool of each workstation

Options how the fan motor is controlled

Option #1: by Ecogate Power MASTER VFD (Variable Frequency Drive, see above), this is recommended option,

easiest to setup, and fully supported by Ecogate; the FAN and FILTER pressure sensors are built-in Power MASTER,

pressure values are transferred via Modbus to greenBOX. See separate Power MASTER User & Installation guide.

Option #2: by third party VFD, the fan motor speed is controlled by standard 4...20 mA signal connected from greenBOX

to VFD analog input, and VFD is started via free RUN contact connected from greenBOX to VFD digital input; installer

will need to setup the VFD parameters and debug the functionality, see schematic diagram at end of this document.

Ecogate cannot provide support for 3rd party VFD. The fan pressure transmitter (optional) can be connected via

greenBOX 4...20 mA analog input, see page 21, and 22.

Option #3: for smaller systems the fan motor can be started/stopped by a contactor (magnetic starter) controlled via

greenBOX free contact (other term is dry contact - means no voltage is provided from greenBOX). The contactor must

be supplied and installed by electrician, for schematic diagram see page 19 and 20.

Option #4: if you are using two greenBOX 12 units in MASTER-SLAVE configuration the Modbus connection for the

VFD is not available; in this case 4...20mA signal and RUN contact is used to control the VFD (same like in option 2);

proper settings of Ecogate Power MASTER is available via Ecogate Setup Assistant, See separate Power MASTER

User & Installation guide.

Fan

Motor

Enable

EM2

#11

EM2

#12

EM2

#10

DATE

SER.

NR.

GB12H03 –11/2010

EVEN CH. ODD CH.

ECOGATE © 11/2010

greenBOX 12 Industrial Shop

Prod. # EG105 MODEL 2011

BYPASS

INPUT

I - I +

VFD

OUTPUT

4 –20 mA

VACUUM

INPUT

I - I +

SECURITY

INPUT

RUN (NO) START (NO) STOP (NC)

#1 #2 #3 #4 #5 #6 #7 #8 #9 #10 #11 #12

BYPASS

FAN –RUN

POWER 24 VDC

SECURITY

GATE OPEN

INPUT SIGNAL

OPEN COLLECTOR

24 V DC contact

INPUTS MODE

GATE OPEN

INPUT SIGNAL

GATE OPEN

INPUT SIGNAL

POWER

SUPLY

24 V DC

+ -

RS - 485

G A B

WINDOWS PC

RS - 232

EM2

5. greenBOX ENCLOSURE OVERVIEW

WALL MOUNTING

HOLES

DUSTSEALING

INSTALL POWER

CABLES TO START,

STOP, ANDTO RUN

TERMINALS UNDER

THIS COVER

24 V DCPOWER

SUPPLY HOLDER

AFIX LOW-VOLTAGE

CABLES (TO GATES

ANDSENSORS) TO

THESE HOLDERS

USING PLASTIC TIES

FIX POWER CABLES TO

START, STOP, ANDTO

RUN TERMINALS TO

THESE HOLDERS

USING PLASTIC TIES

OUTLETCHANNEL FOR

LOW-VOLTAGE

CABLES ONLY OUTLETCHANNEL FOR

POWER CABLES ONLY

Install the greenBOX 12 on the wall, preferably in middle of the shop to keep the cables to the gates/sensors short.

Keep the low-voltage and the power cables properly separated; the

low-voltage cables in the left outlet, power cables in the right outlet.

Installation Procedure Step-by-Step

6. POWER SUPPLY

The power supply 24V DC power

supply adapter is built-in greenBOX

12 enclosure and 24 V DC output is

connected to the “POWER SUPPLY”

greenBOX terminal, plus polarity wire

to “+” pin, minus polarity wire to “-“

pin.

The power should be preferably

connected to the greenBOX all the

time – the baseline consumption is

low (about 5 Watt).

Keep the power supply for the

greenBOX OFF for the moment; you

will switch on the power supply after

finishing all cable installations.

greenBOX 12 BOARD

OUTPUT

24V DC, 3 A

+24V DC

0V DC

Power Supply

115V AC (or 230V)

Power Supply 24V DC

1.5-3A Amp

POWER INPUT

100-240 V AC 50/60

HZ, MAX. 100W

OUTPUT

24V DC, 3 A

BYPASS

INPUT

I - I +

VFD

OUPUT

4 –20 mA

VACUUM

INPUT

I - I +

SECURITY

INPUT

RUN (NO) START (NO) STOP (NC)

POWER

SUPLY

24 V DC

+ -

WINDOWS PC

RS - 232

RS - 485

G A B

7. 4"...18" GATES

Use “#1”...“#12” greenBOX terminals

to connect up to 12 gates and 12

sensors. The 5-pin terminal should be

connected horizontally to the board.

The terminals M1 (Motor 1) and M2

(Motor 2) are used to connect the

gate (M1 at the greenBOX to M1 at

the gate, M2 at the greenBOX to M2

at the gate).

The terminals S and - are used to

connect the VOLT sensor; (left and

right -, S terminals at the gate are

connected together – serves as

junction box, see schematic below)

Notes:

1. If 2-pin and 3-pin terminals are separated

you need to physically connect them together

(by using side slot) to create a 5-pin terminal.

2. If the gate M1, M2 wires are reversed, the

gate will be open when it should be closed

and vice versa.

RECOMMENDED CABLE SPECIFICATION

(check local code if the cable rating is appropriate for shop installation)

Cable between greenBOX and gate Ecogate EG.304: Belden 5503UE or compatible, AWG 22, 5-

conductor cable stranding 7x28, outer diameter 0.162" (4.1 mm); voltage rating 300 V, temperature

rating 75C, NEC approval (article 800)

Cable between Ecogate and VOLT sensor Ecogate EG.306: Alpha Wire P/N 6632 or compatible: two

conductor AWG 22 (7x30), core wrap by Mylar tape, voltage rating 600 V RMS, temperature rating 105C

NOTES – GATES INSTALLATION: Important rule is not to install gates close to hoods, elbows, Y,

etc. because close to these places, the airflow is turbulent and causing sawdust settling inside the gate.

Our recommendation is to install the gates at a distance 3-5 times duct diameters from the hoods,

elbows, etc. The recommended position is with the motor on the top (both in the vertical and horizontal

ducts). The gate must be supported on both sides. Orient the gate in such a way that the RED and

GREEN indicator lights on the motor enclosure are visible to the workstation operator. If the gate

is installed in a vertical duct, the motor should be on top side; if the gate is installed in a horizontal duct,

the motor should be on top (indicators will be not visible). For details check “Ecogate Gates Installation

Best Practice” document.

EC OGATE(C) 20 08

LIMI T SW.

MOTO R

Fr om gre enBO X 2 nd GA T E SENS OR

DATE

SER.

NR.

GB12H 03 –11/ 20 10

EVEN CH. ODD CH.

#1 #2 #3 #4 #5

GA TE OPEN

INPUTSIGN AL

workstation

ECOGATE

SIGNAL

AC/DC VOLT

OUT

24-230VDC orAC

ECOGATE

SIGNAL

greenBOX #1 #12

terminals

Ecogate

terminals

Gate

motor

VOLT

ECOGATE OUTIN

Ecogate

VOLT sensor

(AC or AC-DC

VOLT, or any

sensor with dry

OUTPUT contact)

BROWN

GREEN

BLUE

WHITE

RED

RED WIRE (+ 24V DC) IS NOT USED,

NO NEED TO BE CONNECTED

8. GATE TESTING

 Connect the greenBOX power

supply, gates, and check security

input jumper (installed from

factory). Do not connect the

sensors. The green “POWER”

indicator at the top of the

greenBOX board should be ON.

The GATE OPEN and INPUT

SIGNAL indicators should cycle

after power on and stay off.

 Test the gate function by using

the test button on the greenBOX

board; one press should open

the gate; a second press

should close the gate.

 When the green indicator “GATE

OPEN” is OFF, the gate should be

closed; when the green indicator

is ON, the gate should be open (if

the indication is reversed, change

the polarity of the M1, M2 wires to

the gate).

 The “GATE OPEN” indicator will

be flashing while the gate is

opening (and closing). When you

press the button, the yellow

“INPUT SIGNAL” indicator will be

flashing.

 Test all connected gates.

EM2

#11

EM2

#12

EM2

#10

DATE

SER.

NR.

GB12H03 –11/2010

EVEN CH. ODD CH.

ECOGATE © 11/2010

greenBOX 12 Industrial Shop

Prod. # EG105 MODEL 2011

BYPASS

INPUT

I - I +

VFD

OUTPUT

4 –20 mA

VACUUM

INPUT

I - I +

SECURITY

INPUT

RUN (NO) START (NO) STOP (NC)

#1 #2 #3 #4 #5 #6 #7 #8 #9 #10 #11 #12

BYPASS

FAN –RUN

POWER 24 VDC

SECURITY

GATE OPEN

INPUT SIGNAL

OPEN COLLECTOR

24 V DC contact

INPUTS MODE

GATE OPEN

INPUT SIGNAL

GATE OPEN

INPUT SIGNAL

POWER

SUPLY

24 V DC

+ -

RS - 485

G A B

WINDOWS PC

RS - 232

EM2

 Connect all gates and the power supply; do not connect sensors yet.

 One press of the button should open the gate; a second press should

close the gate.

 When the GATE OPEN green indicator is ON, the gate should be

open.

As a default setting in the greenBOX the outputs are set for 5" gates, for

larger gates change gate diameters at the Windows PC Setup page, see

page 19 of this manual.

9. VOLT SENSOR

The AC/DC VOLT sensor is

activated if the sensor input wires

are connected to AC or DC voltage

in the range from 24V to 230V (use

AC VOLT sensor for 115 – 575 V

AC range). The input & output

wires are polarity independent.

Connect the VOLT sensor to a

location inside the workstation

where voltage is present when the

dust collection should be active.

On a simple workstation you can

connect the VOLT sensor at the

output of the main power switch

(see Option #3 on left).

On complex workstations, connect

the sensor to the supply of the

motor which is driving the cutting

tool or any motor that is active

when you need active dust

collection (see Option 1, 2, 4, 5).

The output of the VOLT sensor

should be connected to the gate S

and - terminals (if it is preferable

you can connect sensor output

directly to the greenBOX S and –

terminals).

CONTACTOR

Driving the

workstation

cutting tool

A1 A2

IN OUT

TO GATE

Option 1: In Parallel with Contactor Output

A1 A2

TO GATE

ANY

VOLTAGE

TO GATE

Option 2: In Parallel with Contactor Coil

Option 3: In Parallel with Workstation Main Switch Output

IN OUT

24 – 230 V ACor DC

(use AC VOLT for 460 – 575 V AC)

MAIN SWITCH

TO GATE

Option 4: In Parallel with Cutting Tool Motor

THE PLC that is

controlling

workstation

TO GATE

24 V DC

Option 5: PLC Output

24V DC

OUT

Workstation Activity VOLT

Sensor: Connection Options

The IN (INPUT) indicator is ON if

voltage is present at your workstation

(i.e. cutting tool is active)

The OUT (OUTPUT) indicator is ON if the sensor

INPUT is activeand the output wires are properly

connected to the gate and to the greenBOX

Connect the output wires to

the - and S terminals on the

gate (wire polarity does not

matter).

Connect the Input wires to 24 - 230

V AC or DC, in this example in

parallel to the contactor coil A1, A2

wires (sensor wire polarity does

not mater).

Notes:

1. The Input Mode selector JP1 on the greenBOX (red jumper in the middle

of the greenBOX board) must be in the "Open Collector" position and the

Volt sensors must be connected between the S and - terminals.

2. If you have an available free contact at yourworkstation that is closed

whendust collecting shouldbe active you do not need the VOLTsensor:

you can connect thedry contact directlyto the S and – gate terminals

(voltage is 24V DC, current about 8 mA).

3. The inputof the VOLT sensor cannot be connected to the output of a

variable frequency drive – high voltagepeaks can destroy the sensor; use

the VFD RUN free contact instead, connect it directly to S and – gate

terminals or use current sensor (see next page).

4. If you need to connect the VOLT sensor to 460 or 575V AC, use the AC

VOLT sensor (or a current sensor, see next page).

Contactor (relay) that is

used to the drive

cutting tool of the

workstation

A1 A2

ECOGATE

SIGNAL

AC/DC VOLT

OUT

24-230VDC orAC

ECOGATE

SIGNAL

ECOGATE

SIGNAL

AC/DC VOLT

OUT

24-230VDC orAC

ECOGATE

SIGNAL

ECOGATE

SIGNAL

AC/DC VOLT

OUT

24-230VDC orAC

ECOGATE

SIGNAL

ECOGATE

SIGNAL

AC/DC VOLT

OUT

24-230VDC orAC

ECOGATE

SIGNAL

ECOGATE

SIGNAL

AC/DC VOLT

OUT

24-230VDC orAC

ECOGATE

SIGNAL

ECOGATE

SIGNAL

AC/DC VOLT

OUT

24-230VDC orAC

ECOGATE

SIGNAL

TO GATE

115 or 230V AC

(use AC VOLT for

460 – 575 V AC)

115 or 230V AC

(use AC VOLT for

460 – 575 V AC)

115 or 230V AC

(use AC VOLT for

460 – 575 V AC)

CONTACTOR

Driving the

workstation

cutting tool

MOTOR

VERISINDUSTRIES

Portland,Oregon87223

1-800-3548556

Hawkeye®

Status

Closed

Status

Open

GATE

OPEN indicator (=

workstation is not active)

CLOSED indicator (=

workstation is active)

SCREW

TERMINALS

(free contact)

1 or 3-phase

power supply

10. CURRENT SENSOR

The Hawkeye H608 Current Sensor

is an alternative to the VOLT sensor.

The H608 can read current to the

motor that is driving the cutting tool

of the workstation. Put only one

phase wire inside the sensor – not

the complete cable (it will not work).

The H608 can be used both on

single-phase and 3-phase AC

motors of any voltage with current in

the range 0.5 to 175 Amper.

To increase sensitivity of the sensor

for small loads (small motors –

fraction of HP) put several loops of

the phase wire through the sensor

hole (see inset).

The output of the H608 sensor

should be connected to the gate S

and -terminals (if preferable you

can connect the sensor output

directly to the greenBOX S and -

terminals).

If current to the motor is present, the

green “CLOSED” sensor indicators

will be ON, and also the “INPUT

SIGNAL” indicator at the greenBOX

will be ON.

The current sensitivity is adjustable with a 20 turn

potentiometer. To calibrate the sensor: start the

workstation and slowly turn the sensitivity screw

counter-clockwise until the status indicator CLOSED

just turns ON. Then turn the screw an additional 1/2

turn counter-clockwise for operational margin.

Motor at the workstation which is

driving the cutting tool (or any motor

that is active when you need active

dust collection).

Sensor

dimensions:

2.5" x 2.1" x 1"

Current

Sensor

Connection

For load currents less than 0.5

Amp: wrap the monitored wire

through the center hole and

around the sensor body to

produce multiple turns through

the opening. This increases the

current measured by the sensor.

Note: Tomakeall sensors work while they are connected

between S and – terminals the Inputs Mode selector (red

JP1 jumper in the middle of the greenBOX board, see

board overviewpage forlocation) must be in "Open

Collector" position.

INPUTS MODE

OPEN COLLECTOR

24 V DC contact

JP1

Note: it is recommended to use current sensor for workstations

that use VFD (sensor should read output current).

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