Troubleshooting CO2 Removal System Issues
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Troubleshooting CO2 Removal System Issues

You’re running a factory shelter drill, everything’s humming along, then suddenly the air feels off—guys complaining of stuffiness, alarms beeping weird. Panic sets in. Turns out your CO2 removal system hit a snag: clogged filter, dead sensor, or bed not regenerating. Happened to us at Sigma Power Tech during a Mumbai plant test—fixed in 20 minutes, drill saved. No drama if you know the fixes. Here’s the straight talk on troubleshooting CO2 removal system problems before they bite—pointers from 10+ years installing these lifesavers.​

Spotting When Your CO2 Removal System Needs Attention

First sign: Air feels heavy, CO2 readings creep above 1% on gauges, or fans hum funny. Workers yawn more, headaches pop up—classic CO2 creep. Dashboard lights blink (yellow for warning, red for fail). Noisy blowers or weak flow? Unit’s crying for help. Log everything—when it started, occupancy, recent use. Quick checks save hours: power on? Doors sealed?.​

Common Issue #1: Poor Airflow and Clogged Filters

Fans spin but air barely moves—dust from factory ops clogs pre-filters fast. Pointers to fix:

  • Power off unit, pop cover, inspect filters (visual dust buildup?).
  • Vacuum or rinse non-chemical filters (HEPA/carbon)—tap gently.
  • Replace if torn (₹5k spares stock up).
  • Test flow: Hand near intake feels pull? Good. Weak? Fan motor suspect.​

Our tip: Dusty sites get monthly wipes—extends life double.

Common Issue #2: High CO2 Readings Despite Running

Scrubber beds saturated or sensors lying. Walkthrough:

  • Check bed indicators (color change? Saturated).
  • Bypass test: Run fresh air through—readings drop? Beds bad.
  • Regen cycle: Heat to 150°C 30 mins (or moisture vent)—resets 80%.
  • Sensor cal: Expose to known air (₹10k annual pro job).​

One client: False high from dirty sensor—clean fixed, saved ₹50k bed swap.

Common Issue #3: Noisy or Failing Fans/Blowers

Grinding or weak whir—bearings shot or blades dirty. Hands-on:

  • Unplug, open panel, spin blades by hand (smooth?).
  • Clean dust/vibration debris.
  • Oil bearings if access (light machine oil).
  • Test run: 100-500 CFM spec? Multimeter voltage.​

Battery fans? Charge check—DC 12V holds 48hrs.​

Common Issue #4: Regeneration Failures

Beds won’t reset—heat/moisture cycle stuck. Step-by-step:

  • Verify heat element (multimeter resistance).
  • Check moisture drain (clogged? Flush).
  • Manual override regen (SCS menu).
  • Pro swap if fried (₹20k beds).​

Pro trick: Weekly dry run prevents buildup.

Common Issue #5: Power and Control Glitches

No start, random shuts—wiring or Shelter Control System fault. Debug:

  • Battery voltage (12.5V min).
  • Fuse check (blower/control circuits).
  • SCS reboot (power cycle 5 mins).
  • Ground faults (continuity test).​

Backup gen tie-in essential—blackouts kill most.

Common Issue #6: Leaks and Overpressure Loss

Air escaping, contaminants sneaking. Hunt:

  • Feel doors/vents for whistles.
  • Soap test seals (bubbles = leak).
  • Tighten fittings, silicone gaps.
  • SCS overpressure set 5-10Pa.​

NBC shelters? Double gasket check.

Quick Daily Walkthrough Checklist

Keep handy:

  • Lights normal? (Green running).
  • Flow strong both ends.
  • Readings <0.8% CO2 steady.
  • No odd smells/noise.
  • Logs print weekly.​

When to Call Pros for CO2 Removal System

DIY 80%, but:

  • Bed chemistry off.
  • Sensor dead.
  • Full rebuild.
  • Warranty work.

Sigma hotline: 24hr response.​

Prevention Beats Fixes Every Time

  • Dusty factories: Bi-weekly filters.
  • Humid areas: Dehumid tie-in.
  • Train 2 staff deep.
  • Annual audit (₹25k).​

Factory/ Shelter Real Fixes We’ve Done

Welding shop: Clogged regen—cleaned, back online 15 mins. Chem plant: Sensor drift—calibrated, false alarms gone. Bunker owner: Fan seize—oiled, drill passed.

Can CO2 cause headaches?

Carbon dioxide Co2 exposure, particularly in sealed environments where human respiration causes rapid accumulation, is known to induce headaches along with various other physical symptoms.

What system removes CO2?

The respiratory system is the biological system responsible for removing unwanted carbon dioxide CO2 from the body and taking up oxygen. The primary organ in this system is the lungs, supported by other components like the nose, trachea, and the breathing muscles (diaphragm and intercostal muscles).