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What air compressor should I use with my Duplicator 2?

Most air compressors are factory set to automatically cycle on at 90 PSI and automatically cycle off at 120 PSI. Conwin's automatic sizers must have a steady supply of air or gas to produce equal sized balloons. For accurate sizing, it is essential to work within the limits of the cubic-foot-per-minute capacity of the air compressor.

Air Compressor Required Specifications
• Primary Moisture Filter
• 20-Gallon Storage Tank
• Cycle Pressure: 90 PSI on - 120 PSI off
• Compressed Air Availability: 6.5 cubic feet/minute at 90 PSI

Important Guidelines When Using an Air Compressor
• Compressor must build up tank pressure before inflating balloons.
• The output setting on the air compressor should not exceed 80 PSI. If the compressor is set higher than 80 PSI, the automatic sizer will outperform the compressor's storage tank capacity.
• After each job, blow down the compressor to remove water collected in the tank during compression. The automatic sizer will require factory rework and re-calibration if moisture enters its system.
• Power surges will affect the accuracy of the Duplicator 2 - line voltage must be steady at 120 volts.

Air Compressor Hook-Up Instructions
1. Verify the air compressor has a primary dirt and moisture filter prior to attaching the hose. Attach the quick disconnect socket to the air compressor. Plug-in the air line into the socket on the compressor and into the back of the inflator.

2. The color of the filter on the end of the Air Compressor Hook-Up line will change from black to clear if moisture is present in the line. If this occurs, change the primary moisture filter on the air compressor and replace the filter on the end of the air line.

How do I tune up my Duplicator 2?

Seven-Point Tune Up for Automatic Inflators

Give your Duplicator 2 a Seven-Point Tune Up.

1. Set your inflator to 9.0 seconds at 90 PSI. Tap the foot pedal or press the inflation button 3 times to cycle the unit. This will blow out any foreign particles that may have entered the system.

2. Remove the filling outlets and gas supply line from the unit.

3. Spray silicone lubricant into gas supply port (located in the back of the unit) and into the latex inflating port(s) on the top of the unit. IMPORTANT: Only use spray food grade silicone lubricant. Do NOT lubricate the unit with an oil-based lubricant. Spray silicone lubricant is available at your local hardware or automotive store.

4. Tilt the inflator to the right and hold for a few seconds. Then, tilt the inflator to the left and hold for a few seconds. This will allow the silicone lubricant to fully enter the unit.

5. Attach the gas supply line and pressure the unit. Do not attach filling outlets.

6. Set your unit to 0.3 seconds at 80 PSI. Cover the inflating ports on the top of the unit with a rag and tap the foot pedal or press the inflation button 10 times to fully lubricate the unit.

7. Before using your inflator, it is important to blow out all excess lubricant. Place a clean paper towel over the outlets and tap the foot pedal or press the inflation button to cycle the unit. If the paper towel shows any lubricant, it is necessary to continue cycling the unit. When the towel shows no signs of lubricant, replace filling outlets. Now your inflator is ready for use!

What troubleshooting recommendations would you make for my Duplicator 2?

1. Confirm that the cylinder valve is fully open. If you're using one of our older, non-digital models make sure that you're using a 110-volt transformer. Note: If a 110 volt unit is exposed to 220 volts it will be damaged beyond repair.

2. Make sure that you are following the instruction sheet with size-setting chart. If you've lost your instructions, you can download the PDF by visiting our Instruction sheet page.

3. To adjust the 2nd stage regulator, unlock the black knob by pulling up. Turn the knob clockwise to increase the pressure and increase the speed of inflation. Turn the knob counter clockwise to decrease the pressure and speed of the inflator. Press the knob down to lock in place. Recommended settings: 5-Inch balloons set at 50 PSI, 11-Inch+ balloons set at 80 PSI.

4. If you're using an air compressor, confirm that the air compressor meets the requirements listed on the instruction sheet. If the storage tank is too small, the sizer will outperform the compressor and 9-inch and larger balloons will vary in size between cycles. The compressor must have a moisture trap. If moisture enters the sizer the timers will be damaged.

5. When inflating 9" and larger balloons, adjust the size setting every 1/3 of a cylinder. This assures that the size of balloons is consistent as the cylinder pressure decreases.

6. After reviewing the above, if you are unable to correct the problem, do a 7-Point Tune Up on your inflator.

What general troubleshooting recommendations would you make for my inflator?

Problem: The inflator makes a loud, high-pitched noise when inflating balloons.

Solution: This happens when the balloon is not properly placed over the filling outlet. If you hold the neck of the balloon with two hands over the filling outlet, the helium flow entering the balloon will cause vibrations and make a loud noise. The balloon should be held in one hand between your thumb and index finger.

Problem: Push valve sticks or leaks.

Solution: It is possible that Hi-Float is in the outlet. If you believe that Hi-Float is in the outlet, you should replace the outlet. If the unit was exposed to moisture, we recommend spraying silicone lubricant on the push valve.

Problem: Tilt valve leaks.

Solution: It is possible that Hi-Float is in the outlet. If you believe that Hi-Float is in the outlet, you should replace the outlet. When gas leaks from the tip of the outlet, it is necessary to replace the tilt valve.

Problem: Inflator leaks.

Solution: Conduct a leak-check test to confirm the exact location of the leak. If the inflator leaks at the cylinder connection, close the cylinder valve, bleed the pressure out of the inflator, and firmly tighten the cylinder connection. Repeat the leak test.

If the inflator continues to leak, remove the inflator from the cylinder and try it on another cylinder. Repeat the leak-check test. If the inflator does not leak on the new cylinder, we recommend returning the original helium cylinder to the supplier for credit. (In some cases, the cylinder valve will have bad threads that cause the inflator to leak.) If it is not the cylinder valve, replace the O-ring for the cylinder connection.

If the inflator leaks somewhere other than the cylinder connection, return the inflator for service.

Problem: Pressure gauge concerns

Solution: If the pressure gauge goes up and down every time a balloon is inflated, this is an indication that the cylinder valve is not fully open. Make sure that the valve is open completely to correct the problem.

If the pressure reading on the gauge is inaccurate, it is more than likely that the inflator has been dropped or bumped during transit. The gauge cannot be re-calibrated and must be replaced

Problem: Foil balloon inflation is too slow.

Solution: If the automatic foil balloon inflator seems to operate too slowly, confirm that the balloon is pointing downward during the inflation process. If the internal valve on the foil balloon is folded over, the flow will be restricted and inflation will be very slow. Please note that Conwin's automatic shutoff foil balloon inflators are designed to inflate foil balloons at a slower flow rate than latex balloons to insure that the foil valve is not damaged during the inflation process.

Problem: Inflator makes a loud popping noise when inflating balloons.

Solution: This is caused by the pressure alert valve being activated by a sudden change in pressure. We recommend trying the inflator on a cylinder that has less than 2400 PSI. First, close the cylinder valve and release the pressure from the inflator, then slowly reopen the cylinder valve -- this will avoid the extreme pressure spike from opening the valve too quickly. If the problem persists, return the inflator for service.

Problem: How do I test my inflator for a leak?

Solution: Use a spray bottle filled with soapy water and spray around the area where you suspect the leak is located. If large bubbles appear in one area, then you may have a leak. Be sure to thoroughly clean your inflator immediately after testing to avoid water damage. Please call the Service & Repair Department.

If your question is still unanswered, please contact the Service & Repair Department at (818) 246-9233 ext. 207