ecogate greenBOX Pro User's Installation Manual

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greenBOX Pro, Nxt, & Max User Guide

greenBOX Pro, Nxt, & Max

User & Installation Guide

Updated: July 19, 2024

greenBOX software version 8.1.67

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Summary of Contents for ecogate greenBOX Pro

Page 2: Table Of Contents
Nxt: Up to 72 Gates for Many Ventilation Systems, 10.1” LCD Screen, 24V DC 240W (360W peak) Power Supply ..10 greenBOX Pro: Up to 36 Gates for Many Ventilation Systems, No Screen, 24V DC 120W (180W peak) Power Supply ....11 Power MASTER VFDs for Controlling the Fan Speed, with One Minute Onscreen Setup Wizard ............
Page 3 Enclosure Cable Connections ...................................... 31 Power MASTER VFD Installation ............................32 How to Connect Gates to Ecogate MASTER Cable in Daisy-chain ....................33 Connecting Gates - Alternatively Use of Derivation Cables ......................34 The Gate Driver Board Overview ..............................35 Fan and Filter Pressure Tubing Connection ............................
Page 4 Pro, Nxt, & Max User Guide greenBOX Settings (Name, Localization, Time Zone, Interface Port & HW Version, Customer Name & Address) ..........57 greenBOX System Setup ................................. 58 System Mode ........................................60 Fan Settings ......................................... 60 Minimum Airflow ........................................ 61 Cleaning ..........................................
Page 5 Pro, Nxt, & Max User Guide DHCP greenBOX IP Address Reservation ............................82 Remote Access to the greenBOX via Internet – Tailscale VPN ......................82 Addendum A: Savings Page to Display Savings In kWh, $, and CO Emissions Reduction Equivalent ..........83 Addendum B: greenBOX How to Guides ............................
Page 6 Pro, Nxt, & Max User Guide Check Fan Sensor Communication (Com) ................................... 97 Check Fan Sensor Communication (Modbus) ................................98 Fan pressure high ........................................98 Fan pressure low ......................................... 99 Filter pressure exceeded limit ..................................... 99 Filter pressure below limit ......................................100 Filter pressure sensor disconnected ..................................
Page 7 Pro, Nxt, & Max User Guide Reset VFD Error from greenBOX or VFD ..................................112 VFD/Fan Not Enabled - Dust Collector is Not Running .............................. 113 Check and Reset VFD Panel Alarm .................................... 113 VFD Door Selector Set To Manual (Constant Fan Speed) ............................113 VFD in Stop - Select Automatic Mode ..................................
Page 8: Ecogate Greenbox Pro, Nxt & Max - What Is New
Difference between greenBOX Nxt and greenBOX Pro: same enclosure dimensions, greenBOX Nxt has 240W 24VDC power supply, greenBOX Pro 120W 24VDC; 2023 greenBOX Nxt has 10” front panel touchscreen while 2023 greenBOX Pro does not have touchscreen installed. It is possible to connect any HDMI compatible display during the time of setup. After installation...
Page 9: Greenbox Max: Up To 144 Gates For Many Ventilation Systems, 15.4" 4K Oled Screen, Two Redundant Power Supplies 24V Dc 480W (720W Peak)
Pro, Nxt, & Max User Guide greenBOX Max: Up to 144 Gates for Many Ventilation Systems, 15.4” 4k OLED Screen, Two Redundant Power Supplies 24V DC 480W (720W peak) The greenBOX Max is recommended for factories with up to 144 gates.
Page 10: Greenbox Nxt: Up To 72 Gates For Many Ventilation Systems, 10.1" Lcd Screen, 24V Dc 240W (360W Peak) Power Supply
Pro, Nxt, & Max User Guide greenBOX Nxt: Up to 72 Gates for Many Ventilation Systems, 10.1” LCD Screen, 24V DC 240W (360W peak) Power Supply The greenBOX Nxt is recommended for shops and factories with up to 72 gates.
Page 11: Greenbox Pro: Up To 36 Gates For Many Ventilation Systems, No Screen, 24V Dc 120W (180W Peak) Power Supply
The greenBOX PRO is cost effective solution for shops with up to 36 gates. The greenBOX Pro does not have screen, but it can be accessed via Ethernet LAN network from any device. To make setup easier you can use external HDMI monitor connected during system setup.
Page 12: Power Master Vfds For Controlling The Fan Speed, With One Minute Onscreen Setup Wizard
The front panel features a straightforward three-position selector, enabling operations in Automatic mode for the greenBOX control, a Stop function, and a Manual mode. The Manual mode is particularly useful both before the Ecogate control system is installed and as a reliable backup, ensuring all gates open and the fan runs at full speed in case of system malfunctions.
Page 13 Pro, Nxt, & Max User Guide Installation simplicity is also a key advantage, requiring just a single cable with matching labels at both the greenBOX and VFD terminals to connect. The complete status of the VFD, including warnings, errors, and input statuses, is communicated to the greenBOX through a Modbus cable.
Page 14: Ecogate Smart Gates - Available From 4" To 26
Flanges 9” ...26”: use 3/8” screws Ecogate gates are designed to be the most robust, advanced, and energy-efficient industrial gates available, providing an automated and cost-effective blast gate solution. They're equipped with an industrial 24V DC motor for automatic operation and reliable magnetic limit switches.
Page 15: Ecogate Workstation Activity Volt Sensor
The purpose of workstation activity sensors is to inform greenBOX that a particular workstation needs ventilation. We recommend to use the Ecogate Volt sensor connected in parallel to the cutting tool motor or in parallel to circuit that is active if workstation needs ventilation.
Page 16 Pro, Nxt, & Max User Guide 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).
Page 17: Workstation Activity Current Sensor
Pro, Nxt, & Max User Guide Workstation Activity Current Sensor The current sensor is an alternative to the VOLT sensor. The current sensor can read current to the motor that is driving the cutting tool of the workstation. Put only one phase wire inside the sensor –...
Page 18 Pro, Nxt, & Max User Guide Why to USE the current sensor: if you do not like to connect anything to your workstation; if you like to use a sensor at the AC output of the VFD. If you like to install sensors at receptable (electrical outlet) for the workstation, or at an electrical panel.
Page 19: Laser Sensor For Sanders, Cncs, Edgebanders To Detect Material Or Operator
Pro, Nxt, & Max User Guide Laser Sensor for Sanders, CNCs, Edgebanders to detect Material or Operator Optional: on CNCs, Edgebanders, sanders or similar machines with conveyers, it is preferable to use a laser beam sensor. It can be setup to detect material or operator at certain distance (defined by minimum and maximum) from the sensor (and not outside this distance).
Page 20: Control Unit Greenbox Functionality Description, And Sequence Of Operation
Pro, Nxt, & Max User Guide Control Unit greenBOX Functionality Description, and Sequence of Operation The greenBOX is a state-of-the-art control unit designed to optimize your dust collection, fume extraction, or mist extraction system resulting in electricity savings of 50% to 75%. The system is designed to be fully automated, so users are expected to just use their workstations.
Page 21: Automatic System Start
Pro, Nxt, & Max User Guide • The greenBOX MASTER control unit will open all the workstation gates at stop for safety reasons (this option could be switched off by user). • Automatic Stop and closing unused ventilation drops results in reduced noise levels in the factory, reduces the amount of required makeup air (if used), and dust collection system electricity consumption.
Page 22: Ecogate System Block Diagram With Greenbox, Power Master Vfd, Ecogate Gates, And Workstation Activity Sensors
1. The greenBOX 24V DC power supply is used for the gates, connected via Ecogate MASTER cable. The Ecogate MASTER cable used for the Power MASTER VFD and for the gates can be connected to any greenBOX Modbus port, it is transparent to the...
Page 23: Greenbox Nxt Terminals
Pro, Nxt, & Max User Guide greenBOX Nxt TERMINALS Modbus Port #3 for gates, Status LED Lights Terminals VFDs, and other Modbus devices From left: Common, Error (Red), Warning Terminals from left: +24VDC, (Yellow), OK (Green). Outputs are +24V DC, 0V, Modbus A, Modbus B, common is ground, max.
Page 24: View Inside Enclosure
Pro, Nxt, & Max User Guide View Inside Enclosure Ecogate Interface Board with 3x Industrial NUC PC Cooling Air Outlet with Filter Modbus, 4x Digital Inputs, 4x Relay (Next Unit of Computing) Contacts, 3x LED Status Light) Wall Mount...
Page 25: Ecogate Gates Installation
The purpose of workstation activity sensors is to inform greenBOX that a particular workstation needs ventilation. We recommend to use the Ecogate Volt sensor connected in parallel to the cutting tool motor or in parallel to circuit that is active if workstation needs ventilation.
Page 26 The recommended laser- beam sensor model and connection diagram is available from Ecogate. Optional: if free contact is available in your workstation, you can connect it directly to the gate without using a sensor. The contact...
Page 27: Greenbox Nxt, Max Installation
24 per one Modbus port. Try to connect about same number of gates per each Modbus port. 9. Use Ecogate MASTER cable to connect the Power MASTER VFD to the greenBOX Modbus port (for example use Modbus ports 1 and 2 for the gates, and Modbus port 3 for the VFD(s).
Page 28: Installation Guide For Greenbox In Environments With Higher Ingress Protection (Ip) Requirements
Pro, Nxt, & Max User Guide Installation Guide for greenBOX in Environments with Higher Ingress Protection (IP) Requirements The greenBOX control system offers an economical solution for on-demand dust, mist, and fume collection, designed to maximize energy savings for a wide range of industrial facilities. Our system is competitively priced, more affordable than just PLC touchscreen.
Page 29 Pro, Nxt, & Max User Guide greenBOX Nxt BACK SIDE VIEW WITH MOUNTING FRAME MOUNTING FRAME...
Page 30: Air-Cooling System
Pro, Nxt, & Max User Guide USE BUBLE START FRAME LEVEL TO SET INSTALLATION THE FRAME HORIZONTALLY THIS IS LCD SCREEN CENTER LEVEL, INSTALL IT AT EYE LEVEL ATTACH greenBOX, FIX IT BY THREE FINISH THE SCREWS INSIDE FRAME...
Page 31: Enclosure Cable Connections
Pro, Nxt, & Max User Guide Enclosure Cable Connections IEC POWER SOCKET COOLING AIR INLET ETHERNET LAN TERMINAL ICOTEK CABLE ENTRY (IP 65) TWO HOLES FOR CABLE CONDUIT...
Page 32: Power Master Vfd Installation
The greenBOX is compatible with Ecogate Power MASTER VFDs, both with ABB ACS880 and ACS580 drives. The VFD parameters must be set to values per Ecogate User guide by using simple setup Assistant (on ABB control panel press Menuà Assistants à Ecogate Setup Assistant). The Modbus terminating resistors must be switched ON at greenBOX Nxt and at end of the Modbus loop.
Page 33: How To Connect Gates To Ecogate Master Cable In Daisy-Chain
Pro, Nxt, & Max User Guide How to Connect Gates to Ecogate MASTER Cable in Daisy-chain ECOGATE MASTER CABLE (four wires + shielding) A= BLUE B= WHITE SHIELDING +24V = RED 0V = BLACK from to next greenBOX GATE...
Page 34: Connecting Gates - Alternatively Use Of Derivation Cables
Pro, Nxt, & Max User Guide Connecting Gates - Alternatively Use of Derivation Cables TO NEXT WORK MAXIMUM LENGTH OF SINGLE MAIN DUCT STATIONS DERIVATION CABLE CAN BE 60 ft/20 m TO DUST Max 60 ft COLLECTOR MODBUS (RS 485)
Page 35: The Gate Driver Board Overview
Pro, Nxt, & Max User Guide The Gate Driver Board Overview The GATE DRIVER V5 Board The workstation activity SENSOR input for Ecogate VOLT sensor output, or any normally open contact; The POWER SUPPLY terminal, connect the 24V same function like in previous gate model if input DC + and - jumper was set to “OpC”...
Page 36: Fan And Filter Pressure Tubing Connection
Pro, Nxt, & Max User Guide Fan and Filter Pressure Tubing Connection We recommend Polyconn Polyurethane Type 95A ⅜” outer diameter (OD) tubing because it is UV light (sunshine) resistant and recommended by Polyconn for barbed type connect fittings. The Ashcroft pressure transmitters we are using have ¼” outside diameter brass barbed fitting.
Page 37: Installation Of Hk Pressure Transmitter For Averaging Air Velocity Sensor, And For Temperature Sensors
Pro, Nxt, & Max User Guide Installation of HK Pressure Transmitter for Averaging Air Velocity Sensor, and for Temperature Sensors Set Top Jumpers J1 both for Input 1 (left) and Input 2 (right); leave J2, and J3 open Connect Ambient Temperature ...
Page 38: Averaging Air Velocity Sensor Installation
Pro, Nxt, & Max User Guide Use SEL, , and ¯ buttons to Set Top Jumpers J1 both for set Modbus address 220 Input 1 (left) and Input 2 (221 for 2 transmitter (right); leave J2, and J3 open etc.), and 19200 Bd speed...
Page 39 Pro, Nxt, & Max User Guide 4. The averaging sensor should be connected by plastic hoses 3/8" ID (see detail picture on next page) to barbed inlets at the HK Pressure transmitter. The total pressure outlet should be connected to + port of the transmitter, static port to the – port of the transmitter.
Page 40 Pro, Nxt, & Max User Guide...
Page 41: Hk Pressure Transmitter Installation Step By Step
2. Install the Ambient Air Temperature Sensor TEU PT 1000 in shaded area (generally to read lowest temperature outside). 3. Install the Duct Air Temperature Sensor TEK PT 1000 in clean air duct (about 3 duct diameters away from Ecogate Averaging Air Velocity sensor).
Page 42: Greenbox Dashboard
Pro, Nxt, & Max User Guide greenBOX Dashboard Filter Systems You Like to See Display/Hide Side Menu System Dashboard Information (All, Active, In Error, In Manual Short Name, Full Name, Mode, Status, Fan mode) Power, Savings (%), Workstation Utilization 9%, System Air Volume, Fan Pressure, Fan Power v.
Page 43: System Dashboard Information
Pro, Nxt, & Max User Guide System Dashboard Information The dashboard is greenBOX Nxt home page, after power on software will boot and display dashboard. As greenBOX Nxt can control multiple ventilation systems you will see here status of all defined systems (created by user in system setup).
Page 44: Greenbox Nxt Interface Board And Computer Monitoring And Control
Pro, Nxt, & Max User Guide greenBOX Nxt Interface Board and Computer Monitoring and Control Computer Monitoring View Ongoing Events Computer Control Restart & Shutdown greenBOX Virtual Private Network display Debug Information (VPN) is Connected Ethernet Port is Remote Access via...
Page 45 Pro, Nxt, & Max User Guide Use this page to monitor computer Networking utilization, CPU utilization, and Memory utilization. The MAC Address can be used to identify greenBOX on LAN, at Tailscale, and at Mender websites. On right side is three dot icon with these buttons to control the computer: Restart greenBOX, Shutdown greenBOX, and display Debug Information (Setup file).
Page 46: Greenbox Nxt Interface Board Monitoring
Pro, Nxt, & Max User Guide greenBOX Nxt Interface Board Monitoring Use this page to monitor Ecogate interface board and industrial computer monitoring and control. Interface Board Processor Temperature PC to Interface Communication Quality LED Status Lights 24V Supply Voltage...
Page 47 (OK1), Power Supply #2 is OK (OK2); Note: Power supply OK 1 & 2 are meaningful only for redundant power supplies as used with greenBOX Max; in future version of software for greenBOX Pro and Nxt the Power OK will be disabled (hidden).
Page 48: Interface Board Oled Display
Interface Board OLED Display You can monitor all critical data of Ecogate interface board data also on small 1” OLED display at interface board. Following data will be displayed in sequence (after a few seconds for each screen). Use button (capacitive button on interface board Version 7 and later) under the screen to scroll pages.
Page 49: Workstations And Gates
Pro, Nxt, & Max User Guide Workstations and Gates SYSTEM DESIGN AIR VOLUME USE + TO ADD GATES & WORKSTATION WORKSTATION S COUNT GATE IS CLOSED USE + ICON TO ADD GATE TO SAME WORKSTATION, USE MENU TO EDIT WORKSTATION...
Page 50: Gates Icons Explanation
Pro, Nxt, & Max User Guide Gates Icons Explanation GATE OPEN GATE IS OPEN AT LIMIT SWITCH DELAY GATE IS CLOSED GATE IS AT LIMIT SWITCH DISCONNECTED GATE CLOSE GATE IS DELAY DISABLED GATE IS OPEN FOR MINIMAL GATE ERROR...
Page 51 Pro, Nxt, & Max User Guide 4.Enabled 5. Controls After you enter Gate Driver ID number, velocity, and gate When gate is connected use these diameter, press ENABLED – greenBOX will find the gate controls to open, close gate.
Page 52: Adding Workstation And Gate Step By Step
Pro, Nxt, & Max User Guide Adding Workstation and Gate Step by Step 1. Press New workstation, fill the workstation name 2. Press Add Gate, fill Gate Driver ID number ID (yellow four or five-digit number on gate motor enclosure) 3.
Page 53: Gate Properties
Pro, Nxt, & Max User Guide For machines like CNCs or molders, where only one or a few heads operate at a time, it makes sense to install individual gates for each head. This reduces the air volume necessary for the machine, saving air volume and costs. In this scenario, you can switch the workstation to “One-To-One Sensor Mode,”...
Page 54 (seconds) before it will start system. 10. STOP ON LIMIT SWITCH: Ecogate gates are equipped by the open and close limit switches and preferable way is stop the gate motor by reaching open or close limit switches; when gate driver is used for third party gate without limit switches, this option can be switched off; also can be used if limit switch will fail, before it will be replaced.
Page 55: Gate Options
18. INVERT LIMIT SWITCHES: do not normally change this option, it is used only if the gate driver is used for third party gate with limit switches, that are connected to the gate driver board, but limit switches are not NO (as Ecogate limit switches), but they are NC (Normally closed).
Page 56: Customer Information
Pro, Nxt, & Max User Guide greenBOX Settings greenBOX Information greenBOX name, localization, time zone, interface PC port, hardware version Interface Board Version greenBOX Nxt Block #3 serial number 021…040 use Version 6023 Customer Information Customer name, Factory location,...
Page 57: Greenbox Settings (Name, Localization, Time Zone, Interface Port & Hw Version, Customer Name & Address)
2. Metric (EU) or Imperial (US) localization (for gate diameters, pressure, velocity, air volume units) 3. Time zone where greenBOX is installed (important) 4. Interface Port Com Port (the industrial computer port that is used to communicate to Ecogate interface processor, do not change it or interface board will stop working) 5.
Page 58: Greenbox System Setup
Pro, Nxt, & Max User Guide greenBOX System Setup System Mode Auto, Off, Bypass, Simulation, Test 01.Fan Settings Fan speed in percentage of max. RPM 02.Minimum Airflow In multiple duct zones 03.Cleaning In multiple duct zones...
Page 59: Safety And Warning
Pro, Nxt, & Max User Guide 04.Fan Pressure Total Fan Static Pressure 05.Filter Pressure Filter Differential Pressure 06.Safety & Warning Filter Differential Pressure...
Page 60: System Mode
Pro, Nxt, & Max User Guide 0. System Mode Use Off Mode during system installation, AUTO for automatic operation, Bypass to open all gates and run with full fan power, Test for manual operation by user, Simulation Mode to test the system (in Automatic Mode) without System Mode starting workstations, Sensor Test for Workstation Activity Sensors test.
Page 61: Minimum Airflow
Pro, Nxt, & Max User Guide If the Winter Mode is enabled, greenBOX will automatically triggered by temperature sensors (or triggered by Winter Mode user or digital input) run the fan at "Winter Mode Fan Speed" to avoid filter bag freezing by moist, low Fan Speed (%) temperature air to keep them in operating condition.
Page 62: Cleaning
Pro, Nxt, & Max User Guide 3. Cleaning Use "None" for fume collection where it is not necessary maintain minimum transport air velocity, use "Last Used" for most of the systems (most used workstations will be used for minimal airflow, i.e. when operator will use it Minimum again it will be already open), use "from end"...
Page 63: Fan Pressure
Pro, Nxt, & Max User Guide 4. Fan Pressure CHECK MINIMUM FAN PRESSURE Checking this box will enable evaluation of minimum fan pressure warnings and errors. FAN MIN. PRESSURE The system will stop if fan min. pressure error is enabled and will reach ERROR value; the pressure ERROR AT value evaluation is delayed by time set in “Time to Error”.
Page 64: Safety & Warnings
Pro, Nxt, & Max User Guide 6. Safety & Warnings If checked, greenBOX will open all gates at fan stop, this is recommended insurance policy: if technician will override greenBOX and run fan at full speed the duct system will collapse if gates will be not open; in...
Page 65: Greenbox Vfd Setup
Pro, Nxt, & Max User Guide greenBOX VFD Setup PRESS TO RESET ERROR PRESS TO STOP THE FAN (SECOND CONFIRMATION (SECOND CONFIRMATION WILL BE DISPLAYED) WILL BE DISPLAYED) Select Model of the VFD from the list box Modbus Address of the...
Page 66: Greenbox Vfd Status
Pro, Nxt, & Max User Guide greenBOX VFD Status GREENBOX ENABLE INPUT CALCULATED (DI6) IS ACTIVE SPEED VFD OUTPUT AUTOMATIC FREQUENCY MODE (DI2) VFD OUTPUT ADDITIONAL POWER, ENABLE INPUTS VOLTAGE, AND (DI3, DI4) CURRENT IMMEDIATE STOP (DI5) IS OPEN...
Page 67: Vfd (Variable Frequency Drive) Setup
Modbus Port This is the number of the Modbus port of the Ecogate interface where the VFD is connected (1 or 2 or 3). Modbus This is the Modbus Address set in the VFD (at ABB VFDs this address is set in parameter 58.03 "Node Address").
Page 68: Greenbox Modbus Devices
Pro, Nxt, & Max User Guide greenBOX Modbus Devices For selected system press Edit System (at Dashboard use pencil icon, or system shield) and Modbus Devices. Modbus Connected Devices: Adding HK Pressure Transmitter for Averaging Air Velocity Meter, and Temperature Sensors for...
Page 69: Modbus Device
Pro, Nxt, & Max User Guide 2. Name Device in a 1. Press ADD 5. Select ENABLED way you will MODBUS DEVICE recognize it in the list boxes below 6. Now you should 3. Select from the “Communication list box “HK Quality”...
Page 70: Setup À System À 02. Main Duct Measurement
Pro, Nxt, & Max User Guide Setup à System à 02. Main Duct Measurement 2. Select from the list box name of the sensor 1. Set Main Duct you set in previous step Diameter in millimeters 1. At the “02. Main Duct Air Measurement” set Main Duct Diameter in millimeters (conversion from inches = multiply by 25.4; i.e. 1 inch = 25.4 millimeters).
Page 71: Source Options Of Main Duct Air Volume And Air Velocity Measurements
Source Options of Main Duct Air Volume and Air Velocity Measurements 1. Disabled 2. By External Sensor (most precise, typically Ecogate Averaging Air Velocity Sensor connected via HK Pressure transmitter) 3. By Sum of Measured Gates Air Volumes 4. By Fan Power, Fan Pressure, and Fan Efficiency (as installed in the system)
Page 72: Measured And Required Air Volume At System Dashboard
Pro, Nxt, & Max User Guide Measured and Required Air Volume at System Dashboard After Air Velocity and air Volume Measurements are set up per previous steps the Air Volume is displayed at system dashboard. The Measured Air Volume is displayed...
Page 73: Air Velocity, Air Volume, And Pressure Measurements At The Gates
Pro, Nxt, & Max User Guide Air Velocity, Air volume, and Pressure Measurements at the Gates The Pressure, Air Velocity, and Air Volume as measured by gate are displayed at gate user interface. Values are visible only if measurements are enabled at gate Advanced settings, and only if system is running (i.e. fan is producing pressure and air movement).
Page 74 Pro, Nxt, & Max User Guide Enable Pressure, Air Velocity, and Air Volume measurement Air Velocity Calibration Constant is calculated by entering air velocity measured by air velocity meter...
Page 75: Conversions Between Metric And Imperial (Us) Ventilation Values
Pro, Nxt, & Max User Guide Conversions Between Metric and Imperial (US) Ventilation Values Preferably use online calculator at https://www.ecogate.info/unit-conversions.html Air Velocity (FPM) and Air Velocity (m/s)
Page 76: Air Volume (Cfm) And Air Volume (M 3 /H)
Pro, Nxt, & Max User Guide Air Volume (CFM) and Air Volume (m...
Page 77: Diameter (Inch) And Diameter (Mm)
Pro, Nxt, & Max User Guide Diameter (inch) and Diameter (mm)
Page 78: Pressure (Inch W.c.) And Pressure (Kpa)
Pro, Nxt, & Max User Guide Pressure (Inch w.c.) and Pressure (kPa) 1 kPa (kilopascal) = 1,000 Pa (Pascals)
Page 79: Datamining Data Collection And Monitoring
Pro, Nxt, & Max User Guide DataMining Data Collection and Monitoring greenBOX is collecting all data same as GBMbase to the Prometheus database on local disk, and displaying a few of them at greenBOX Monitoring page. Savings of all systems together, selectable last 30 minutes, last 6 hours, last 1 day, last 7 days, last 30 days, last 90 days of system savings in %, savings in kWh, and utilization of workstation.
Page 80: What Is Not Supported Yet
What is not supported yet? 1. Use only one Duct Zone #0, and “Last Used” (gates) for minimal air flow. 2. Data collection to Ecogate cloud servers not yet implemented. 3. Cascading fans, Fans in parallel, in series are not implemented yet.
Page 81: Remote Access To Greenbox Units On Local Network And Via Internet
Pro, Nxt, & Max User Guide Remote Access to greenBOX Units on Local Network and via Internet • If you are on same local network like greenBOX you can connect directly by typing greenBOX IP address (IPv4, for details see in greenBOX side menu Monitoring à...
Page 82: Dhcp Greenbox Ip Address Reservation
Pro, Nxt, & Max User Guide Workaround: press Advanced, and Proceed to “greenBOX Nxt Name” or access Nxt via Tailscale VPN. DHCP greenBOX IP Address Reservation We prefer to use DHCP reservations whenever possible at our client installations (Dynamic Host Configuration Protocol - DHCP is a client/server protocol that automatically provides an Internet Protocol - IP host with its IP address and other related configuration information such as the subnet mask and default gateway).
Page 83: Addendum A: Savings Page To Display Savings In Kwh, $, And Co 2 Emissions Reduction Equivalent
1. To Reset Savings, write “1” to the VFD parameter 45.21 after system commissioning 2. Write Ecogate Baseline Power to the VFD parameter 45.19 (kW) = baseline power is power with proper air velocities at all gates as indicated by the VFD while running in Bypass or Manual (if system is not designed to ventilate all gates at a same time the baseline power cannot be measured, must be calculated).
Page 84: Addendum B: Greenbox How To Guides
Pro, Nxt, & Max User Guide Addendum B: greenBOX How to Guides Note About greenBOX Software Update and Software Version The greenBOX software is updated by downloading a 3.5 GB hard disk image. After downloading greenBOX will switch images and reload new image.
Page 85: Greenbox Screen Sharing Via Mac Application "Screen Sharing
4. Kingston M.2 SSD: 75 C 5. Ecogate Interface processor 105 C, Ecogate Interface Modbus chip 85 C At the interface version 6, the PWM regulated output for cooling fan 24V DC, max. 0.3A was added. From interface version 7 it is possible to set temperature when cooling fan will start (user can set this temperature in greenBOX Service Mode).
Page 86: Addendum C: Greenbox Maintenance
Monitor à VBAT: Ecogate recommends to change the 3V battery every five years to avoid any surprises if greenBOX power supply is lost: incorrect time & date means internet communication will not work, lost CMOS configuration means many BIOS function will be reset to default values and system will stop functioning properly unless BIOS setting is set again.
Page 87: Motherboard Cooling Fan
Pro, Nxt, & Max User Guide Motherboard Cooling Fan As a part of greenBOX maintenance check if motherboard heatsink and fan is clean and functional; clean by compressed air as necessary. The cooling fan of NUC-J6412 & NUC-N97 motherboards is WHEE WSA05010F05H, and the life expectance is 40,000 hours @40C ambient temperature.
Page 88: 10" Touch Screen Menu (Used For Greenbox Nxt)
10” Touch Screen Menu (used for greenBOX Nxt) There is RESET function available – Ecogate is not changing any touch screen settings for greenBOX Nxt. The buttons on the back of display are from top: POWER, MENU, UP, DOWN, EXIT (you need a pencil to press them).
Page 89 Pro, Nxt, & Max User Guide #2: Aspect Ratio #3: Color Temperature...
Page 90 Pro, Nxt, & Max User Guide #4: OSD (On-Screen Display) #5: Reset...
Page 91 Pro, Nxt, & Max User Guide #6: Auto Power...
Page 92: Addendum D - Greenbox Known Software Issues & Workarounds
Pro, Nxt, & Max User Guide Addendum D – greenBOX Known Software Issues & Workarounds 1. While connecting to the greenBOX user interface warning “Your connection is not private” will appear. Workaround: press “Show Advanced” button, and then “Proceed to “IP address”.
Page 93: Connecting To Greenbox On Local Network
Pro, Nxt, & Max User Guide Connecting to greenBOX on Local Network If your device is on the same LAN network like greenBOX you can connect to it by just entering greenBOX IP address to your browser. The IP address is available from greenBOX menu MONITORINGà COMPUTER:...
Page 94: Addendum E: System Events (Info, Warning, Error) Description, Explanation, And Troubleshooting
Pro, Nxt, & Max User Guide Addendum E: System Events (Info, Warning, Error) Description, Explanation, and Troubleshooting YOU CAN FILTER EVENTS 1. YOU CAN FILTER EVENTS BY SEVERITY (ANY, WARNING, ERROR) 2. YOU CAN FILTER EVENTS BY DEVICE TYPE...
Page 95: Event (Info, Warning, Error)
2. Adjust Airflow and Fan Speed: Increase the 'Minimum Airflow' setting in the system setup. Also, make sure the 'Minimum' and 'Maximum Fan Speed' settings are correct. If you're unsure, check with your system administrator, refer to the manual, or contact support@ecogate.com for assistance.
Page 96: Fan Pressure Below Limit
3. Note: the pressure value evaluation is delayed by time set in “Time to Error” (usually 10 seconds, it is used to eliminate short fluctuations in the pressure readings). Not sure what to do? Contact your system administrator, refer to the manual, or email support@ecogate.com for guidance.
Page 97: Fan Pressure Sensor Is Not Properly Setup
Pro, Nxt, & Max User Guide Error: Fan Pressure Sensor Setup Issue. This error means the greenBOX control unit isn't correctly interpreting Fan Pressure Sensor Is the sensor's setup values. Here's how to fix it: Not Properly Setup Check Sensor Connection: Ensure the fan pressure sensor is connected to Analog Input #2 on the Power MASTER VFD.
Page 98: Check Fan Sensor Communication (Modbus)
3. Note: the pressure value evaluation is delayed by time set in “Time to Error” (usually 10 seconds, it is used to eliminate short peaks in the pressure readings). If you're unsure, check with your system administrator, refer to the manual, or contact support@ecogate.com for assistance.
Page 99: Fan Pressure Low
3. Note: the pressure value evaluation is delayed by time set in “Time to Error” (usually 10 seconds, it is used to eliminate short fluctuations in the pressure readings). Not sure what to do? Contact your system administrator, refer to the manual, or email support@ecogate.com for guidance."...
Page 100: Filter Pressure Below Limit
3. Note: the pressure value evaluation is delayed by time set in “Time to Error” (usually 10 seconds, it is used to eliminate short peaks in the pressure readings). Not sure what to do? Contact your system administrator, refer to the manual, or email support@ecogate.com for guidance.
Page 101: Filter Pressure Sensor Is Not Properly Setup
Pro, Nxt, & Max User Guide Error: Filter Pressure Sensor Setup Issue. This error means the greenBOX control unit isn't correctly Filter Pressure Sensor Is interpreting the filter sensor's setup values. Here's how to fix it: Not Properly Setup Check Sensor Connection: Ensure the fan pressure sensor is connected to Analog Input #1 on the Power MASTER VFD.
Page 102: Check Filter Sensor Communication (Modbus)
4. Note: the pressure value evaluation is delayed by time set in “Time to Error” (usually 10 seconds, it is used to eliminate short peaks in the pressure readings). Not sure how to proceed or need further guidance? Consult with your dust collector manufacturer, your system administrator, refer to the manual, or email support@ecogate.com for assistance.
Page 103: Filter Pressure Low
Not sure how to proceed or need further guidance? Consult with your dust collector manufacturer, your system administrator, refer to the manual, or email support@ecogate.com for assistance. Error: VFD Issue Detected. This error occurs when the Power MASTER VFD, which drives the ventilation fan, VFD Error - Reset it from stops operating due to an external or internal issue.
Page 104: Reset Immediate Stop At Vfd
VFD's LCD screen. You can also reset error remotely from the greenBOX on the VFD page. If you're unsure about these steps or need further assistance, please contact your system administrator, consult the manual, email support@ecogate.com, or call 888-ECOGATE for guidance.
Page 105: Vfd Enable Missing - Dust Collector Not Running
(Adecom data is missing). Follow these steps to troubleshoot: (Configuration Error) 1. Restart greenBOX: On the dashboard, click the three dots icon in the top right corner, select 'Restart', and confirm. 2. If same error persist contact support@ecogate.com or 888-ECOGATE for assistance.
Page 106: Check Vfd Communication (Modbus)
Pro, Nxt, & Max User Guide Error: VFD Modbus Data Missing. This error occurs when the system can't communicate with the Power Check VFD MASTER VFD. Follow these steps to troubleshoot: Communication 1. Check Power MASTER VFD: Ensure that the Power MASTER VFD is turned on.
Page 107: Vfd Is Not Ready To Operate, Check Vfd Panel
AUTO-STOP-MANUAL is set by user to MANUAL Mode. The speed of the fan is set by the VFD parameter 47.07. Running @ Constant The speed can be also set by using Ecogate Setup Assistant step #11 (use right Menu button of the VFD control panel, select Assistants, Ecogate setup).
Page 108: Check Vfd Panel Alarm, & Reset It
4. Contact Support: Have the VFD model number and serial number ready and call ABB support at 800-435-7365 to arrange a service technician visit. Still unsure or need additional help? Contact your system administrator, refer to the ABB ACS880 primary control program, Firmware manual, email support@ecogate.com, or call 888-ECOGATE for guidance.
Page 109: Vfd/Fan Enable Missing - Dust Collector Not Running
Branch 1, 2, and 3 (Enabled, Voltage OK, Current OK, and Current value). As default current limit is set to 3,200 mA (3.2 A) for each branch. 3. Inspect Ecogate Modbus Cable: the issue might be with the Modbus communication cable connecting the greenBOX MASTER and gates in daisy-chain. Check if it's disconnected, shorted, or not properly plugged in.
Page 110: Some Gates Not Operating Correctly
Branch 1, 2, and 3 (Enabled, Voltage OK, Current OK, and Current value). As default current limit is set to 3,200 mA (3.2 A) for each branch. 3. Inspect Ecogate Modbus Cable: the issue might be with the Modbus communication cable connecting the greenBOX MASTER and gates in daisy-chain. Check if it's disconnected, shorted, or not properly plugged in.
Page 111: Check Communication (Modbus Data Missing)
Pro, Nxt, & Max User Guide Error: VFD Modbus Data Missing. This error occurs when the system can't communicate with the Power Check Communication MASTER VFD. Follow these steps to troubleshoot: (Modbus Data missing) 1. Check Power MASTER VFD: Ensure that the Power MASTER VFD is turned on.
Page 112: Reset Immediate Stop At Vfd Panel
4. Contact Support: Have the VFD model number and serial number ready and call ABB support at 800-435-7365 to arrange a service technician visit. Still unsure or need additional help? Contact your system administrator, refer to the ABB ACS880 primary control program, Firmware manual, email support@ecogate.com, or call 888-ECOGATE for guidance.
Page 113: Vfd/Fan Not Enabled - Dust Collector Is Not Running
AUTO-STOP-MANUAL is set by user to MANUAL Mode. The speed of the fan is set by the VFD parameter 47.07. To Manual (Constant The speed can be also set by using Ecogate Setup Assistant step #11 (use right Menu button of the VFD control panel, select Assistants, Ecogate setup).
Page 114: Vfd In Stop - Select Automatic Mode
2. Status of the Remote/Local control is indicated at top left of the VFD LCD panel by "Remote" or "Local". If you're unsure about how to proceed or need additional help, please contact your system administrator, refer to the ABB ACS880 manual, or email support@ecogate.com for guidance. greenBOX Computer Errors & Warnings From version 8.0.14 (March 29, 2024) greenBOX software is monitoring lot of possible computer hardware warnings: Heavy Memory...
Page 115 Pro, Nxt, & Max User Guide...
Page 116: Addendum F: Greenbox Max Overview
Pro, Nxt, & Max User Guide Addendum F: greenBOX Max Overview Two redundant power supplies OLED 15.6” touch screen 4k resolution 2nd IEC-60320 Type First IEC-60320 Type C14 Power Inputs 120–240 VAC, 50-60 Hz C14 Power Inputs Current 5A @115V AC, 2.5A @ 230V AC; use IEC-60320 C13 cables.
Page 117 Pro, Nxt, & Max User Guide Industrial NUC PC Cooling Air Outlet (Next Unit of Computing) Cooling Air Outlet with Filter #2 with Filter #2 Wall Mount Screw Wall Mount Screw Industrial 24V DC Industrial 24V DC Power Supply 20A,...
Page 118: Greenbox Max Wall Mounting Plate
Pro, Nxt, & Max User Guide greenBOX Max Wall Mounting Plate USE BUBLE LEVEL TO SET THE FRAME HORIZONTALLY THIS IS LCD SCREEN CENTER LEVEL, INSTALL IT AT EYE LEVEL INSTALL THE FRAME TO THE WALL BY FOUR SCREWS...
Page 119: Appendix G: Conditions For Automatic System Start
Pro, Nxt, & Max User Guide Appendix G: Conditions for Automatic System Start Condition Description Corrective Action Press RESET ERROR on greenBOX SCREEN; if error Error is displayed as will not reset clear condition that is causing error greenBOX is NOT in ERROR...
Page 120: Appendix H: What Will Stop The Ventilation System
Pro, Nxt, & Max User Guide Appendix H: What Will Stop the Ventilation System? 1. Emergency Stop from greenBOX User Interface 2. Pressure Fan and Filter Errors (error pressure levels are user adjustable) 3. Missing VFD Enable Signals (DI3, DI4, DI6) the VFD itself will stop (if VFD Enable signal is missing it means dust collector has some error, some trouble) 4.
Page 121: Appendix I: Minimum Transport Air Velocities Per Industrial Ventilation, By Acgih, 17Th Edition
Pro, Nxt, & Max User Guide Appendix I: Minimum Transport Air Velocities per Industrial Ventilation, by ACGIH, 17th Edition Lower end range: simple horizontal ducting, smooth-bore duct system, obstruction-free interior Higher end range: elevation change, lot of direction changes (elbows)
Page 122: Greenbox Pro, Nxt, Max Specifications
Volt or current sensors for all workstations, Power Master Variable Frequency Drive, Ecogate NEED Master Cable to connect the gates to the greenBOX, and Ecogate Sensor Cable to connect sensors to the gates. Model: greenBOX Pro, product Model: greenBOX Nxt, product Model: greenBOX Max, product EG.155...
Page 123 Schaffner EMI input filter. EMI input filter. Modbus Ports: three (Pro, Nxt), six (Max) Modbus over RS485 for Ecogate Smart gates, and for Ecogate Power MASTER Variable Frequency Drives; and for other Modbus devices (air velocity sensors, pressure transmitters, temperature sensors etc.), the 24V DC is provided for Ecogate gates and other Modbus devices, each 24V DC...
Page 124 Ecogate Compatibility: Ecogate Smart gates 2” to 26” (+ metric 120, 140, 160 mm), Ecogate VOLT or current sensors, Ecogate Power Master variable frequency drives for 10 to 400 HP fan motors, Ecogate Master and Sensor cables.

This manual is also suitable for:

Greenbox nxt Greenbox max