Your dust collector is a crucial investment, and the control panel is one of the key elements that helps it deliver consistent performance. Imperial Systems’ Keystone Controller, standard on our CMAXX and Shadow dust collectors, give you the power to maximize efficiency, minimize downtime, and take full command of your air filtration equipment.
At the heart of every Keystone system is an Allen-Bradley® Micro820 PLC paired with a PanelView® 800 HMI touchscreen. Together, they form the intelligent brain of your dust collection system—delivering precision control, automation, and insight you can rely on.
The VFD Advantage: Smart Efficiency in Action
Upgrading to a Variable Frequency Drive (VFD) transforms how your dust collector performs. Instead of running full-speed all the time, the VFD adjusts the fan speed automatically to match demand—saving energy, extending equipment life, and improving consistency.
Here’s how Keystone’s VFD-enabled controls deliver measurable value:
- Consistent Suction, Automatically – As filters load with dust, static pressure rises and airflow can drop. The Keystone Controller monitors this in real time and automatically speeds up the fan to maintain constant suction throughout the filter’s life.
- Significant Energy Savings – Running the fan at only the speed required—rather than 100% all the time—can drastically cut power usage. In many cases, the energy savings alone allow the VFD upgrade to pay for itself.
- Cleaner Downtime Cleaning – Instead of shutting off completely, the Keystone Controller’s downtime cleaning slows the fan to create a light backpressure. This gentle airflow keeps fine dust from backtracking through ductwork and creating messy dust clouds.
- Weekend Mode for Cold Climates – For facilities in freezing conditions, the Keystone Controller offers a low-speed “weekend mode.” It runs the fan just enough to prevent condensation and freezing in ducts—protecting your equipment even while idle.
Smarter Control Comes Standard
Every Keystone panel comes preloaded with intelligent automation that adapts to your workflow.
- Flexible Operation Modes
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- Local Control: Start and stop manually at the touchscreen.
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- Remote Control: Automatically runs when connected machines power up, and shuts down after the final cleaning cycle.
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- Scheduled Operation: Set start/stop times by day to match your plant’s production schedule.
- Automatic Downtime Cleaning – Whenever the fan stops, Keystone Controller runs a deep-clean pulse cycle—extending filter life and maintaining airflow efficiency.
- Password-Protected Settings – A secure maintenance screen allows authorized users to adjust pulse limits, alarm thresholds, cleaning durations, and VFD parameters—keeping untrained personnel from accidentally altering key functions.
Proactive Intelligence to Prevent Downtime
Keystone Controller doesn’t just control your dust collector—it helps prevent costly interruptions.
- Predictive Maintenance Alerts – The system counts every pulse valve cycle and notifies you when components approach their expected lifespan, helping you schedule maintenance before failures occur.
- Smart Self-Diagnostics – If a sensor or connection fails, the HMI immediately displays a detailed trouble code to guide technicians directly to the issue.
- Comprehensive Data Logging – All alarms and key system metrics are automatically recorded for quick reference and trend analysis, including alarm history, differential pressure trending, and data export.
- Track Filter Life Accurately – A resettable hour meter records how long each set of filters has been in use, allowing you to predict replacement cycles and budget with precision.
- Optional Remote Monitoring – With an Ethernet-based PLC, the Keystone Controller supports VPN-enabled remote access. View live data, monitor system pressures, and even allow Imperial Systems technicians to assist remotely—reducing downtime and service costs.
Future-Ready Design
Your operation evolves, and your controls should evolve with it. The Keystone Controller system is designed for seamless expansion and advanced integration.
- Safety Ready – Preprogrammed logic allows simple integration of smoke detection or fire suppression sensors.
- Combustible Dust Ready – Built-in logic supports explosion vents and isolation valves on CMAXX collectors, ensuring compliance and safety without complex programming.
- Monitoring & IIoT Integration – Keystone supports IO-Link communication, enabling real-time digital data exchange between sensors, actuators, and the control system over standard wiring. This opens the door to advanced diagnostics, smart sensor monitoring, and full IIoT connectivity.
Smarter Control Means Cleaner Air
Imperial Systems’ Keystone Controller transform your dust collector from a simple machine into a truly intelligent clean-air system. With energy-saving automation, predictive maintenance, and future-ready expandability, Keystone helps you get the most from your investment—day after day. Discover the Keystone Controller from Imperial
