Azuradisc Dual Disc II Operating instructions

© 2010 AzuradiscR. All rights reserved. Printed in the U.S.A.
Dual Disc II • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
OPERATION & TROUBLESHOOTING
Ver 4.0 07-08-2010

Ver 4.0 07-08-2010
2
SAFETY
When using the Azuradisc Dual Disc II disc repair machine, the following basic safety precautions should always be
followed to reduce the risk of fire, electric shock, or injury to persons:
• Read this manual before assembling or using the machine.
• Use this machine only for its intended use as described in this manual.
• Use only with Azuradisc-recommended accessories and repair materials. (The use of repair materi-
als not approved by Azuradisc may damage discs permanently or cause injuries.)
• Pay close attention when the machine is used near children. The machine is not intended for use by
children.
• Do not operate the machine if the cord or plug is damaged, is not working properly, has been dam-
aged, or immersed in water. If these conditions are present, return the machine to Azuradisc for
examination, repair, or adjustment.
• Do not drop or insert objects into any openings.
• To disconnect, turn off the machine, then remove plug from the electrical outlet.
• Use a grounded plug when using an extension cord.
• Keep fingers and all body parts away from moving parts and openings.
• Disconnect electrical supply before cleaning.
© 2008 AzuradiscRAll rights reserved. Printed in the U.S.A.
This manual may not be copied, in whole or in part, without written consent of Azuradisc. Use of the Azuradisc
logo without the prior written consent of Azuradisc may constitute trademark infringement and unfair competition
in violation of federal and state laws.
Every effort has been made to ensure that the information in this manual is accurate. Azuradisc is not responsi-
ble for printing or clerical errors.
Azuradisc Inc.
7307 South 89th Place
Mesa, Arizona 85212
480.827.8786
www.azuradisc.com
Azuradisc Inc. is not responsible or liable for damage, of any type, to discs inserted into an Azuradisc machine.
If you believe that an Azuradisc machine is malfunctioning, discontinue use and contact Azuradisc or an author-
ized representative.

Ver 4.0 07-08-2010
3
TABLE OF CONTENTS
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
OUT OF THE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
PART IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
SET UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
BASIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
WALKTHROUGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
SELECT TO START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
ABOUT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
POLICOOL LOW & LID OPEN SCREEN: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
INFO MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
EDUCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
HOW DISCS ARE MADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
HOW A DVD IS MADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Single Layer DVDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Double Layered DVDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Double Sided DVDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Double Sided/Double Layered DVDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
IDENTIFYING SCRATCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Reading Side Scratches - CDs, CD-ROMs & DVDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Top Side Scratches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Top Side Foil Dents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
AZURADISC ONE-YEAR/100,000 DISC LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . .21
WARRANTY COVERAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
EXCLUSIONS AND LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
OBTAINING WARRANTY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

PART IDENTIFICATION AAccess Door:
• PolicoolTM Cartridge
• Easy access to PoliCoolTM pump
• Easy access to PoliCoolTM radiator
BSafety Lid:
• Automatic shut-off when open
CFiberglass Casing
• Will not conduct electricity
• Waterproof
• Easy to clean
DRear mounted cooling fans
EAC recepticle
• Industrial Strength
• Fused
• On/Off Switch
F Electronic Controller
CAUTION!
Make sure there is adequate room
for air flow behind and under-
neath the machine AT ALL TIMES!
E
A
B
E
F
C
D
D
D
C
C
D
Ver 4.0 07-08-2010
4
OUT OF THE BOX
After unpacking the Dual Disc 2, verify the following items, in the quantities shown, are included. Contact
Azuradisc, or the local representative if any items are missing. Place the machine on sturdy surface. Ensure there
are no obstructions of air circulation around the bottom and rear of the machine. Ensure that unused cartridges are not stored
directly behind the Dual Disc.
1 ea. - Base Head Assy - 1/8 inch fiberglass
Used with the black 1/4 inch Polishing Pad.
Item # ph_02577_6
1 ea. - PoliCoolTM v3.0 Cartridge Kit
Includes 64oz of PoliCool, and 1 Pad.
Item # dd_02557_8 (Sold as a Kit)
(Combo Item)
1 ea. - Micro-Fiber Wiping Cloths 6x6 - Hand washable and reusable super soft
material to clean optical surfaces.
1 ea. - Optical SprayCleaner 2oz.- Laser clear anti-static formula spray cleaner.
Item # CK 00262 3
1 ea. - Maintenance Kit - Small Brush and white lithium grease.
Item # CK 00262 3
1 ea. - Power Cord
1 ea. Scratch Removal Poster
Item # adv_00222_7
1/8 inch
fiberglass

5
Important Information
About PoliCoolTM & Smart Chip Technology
What is PoliCoolTM ?
PoliCoolTM is an advanced formula of micro-abrasives particles, along with a cooling solution and other
proprietary ingredients mixed together in a single liquid to provide maximum scratch removal and pol-
ishing properties.
Performance
PoliCoolTM outperforms polish compounds in cut rate & finish. PoliCoolTM lasts longer than most fixed
abrasives. One of the greatest benefits of PoliCoolTM is that it can be recycled over and over (with fil-
tering) until it has reached the end of its useable life. This creates the benefits of cooling a disc during
repair without creating wastewater, or having a complex recirculation system. There is no need to add
water, or clean up messy polish compound splatter or dust from the machine similar to those used in
"water based" or "dry process" machines. PoliCoolTM is automatically recycled back into the cartridge at
the end of the cycle.
Usable Life
The performance and life of this product is measured in seconds run time. Different size containers and
mixtures contain a smart chip with the information containing the maximum "seconds of run time" per
cartridge. If PoliCoolTM were used beyond this life, poor performance would result, and disc damage
could occur. Since product life is critical to performance, PolicoolTM is only sold in containers called car-
tridges that contains a smart chip.
About the Smart Chip IMPORTANT MUST READ INFORMATION
Each PoliCoolTM cartridge is outfitted with a smart chip that carries the information about the maximum
useable life (run time) of each individual cartridge. Azuradisc disc repair machines that use PoliCoolTM
technology are outfitted with a smart chip reader that reads and transfers the "run time" information
from the cartridge to the disc repair machine. Once transferred, the runtime information cannot be
transferred back to the PoliCoolTM cartridge, nor can it be transferred to a different machine. To get
maximum life out of each PoliCoolTM cartridge, it must be completely used before replacement. Once a
cartridge has been mated with a machine, only that machine (not the cartridge) keeps track of the
credits of repair seconds and assumes that the same cartridge stays in place to be used until that
repair time is used-up. The cartridge itself is no longer able to identify itself or to provide left-over
credits to this or any other machine.
While it is possible to remove a partially used cartridge from the machine (for transportation or to
shake and mix the liquid) it is important that the same cartridge is reinserted in the same machine to
be able to use-up the remaining credits.
PLEASE NOTE:
- Inserting a new cartridge in a machine that still has credits left from a previous cartridge
will ERASE the original credits left from the previous cartridge and replace them with the credit for the
new cartridge.
- Inserting a partially used cartridge in another machine will not transfer any credit.
Azuradisc does not provide refunds or credits for losses due to premature replacement of PoliCoolTM
cartridges or the improper exchange of cartridges between machines.
Ver 4.0 07-08-2010

6
SET UP - SUPPLIES - CARTRIDGE & PAD PLACEMENT
12
4
3
To be performed initially and each time you replace the consumables.
IMPORTANT! Always change the abrasive pad when starting a new cartridge.
Align holes and press the velcro
side of the pad on to the base-
head.
Be sure to REMOVE OLD OR EXISTING BLACK PAD
from base spindle before installing a new one.
Information
Scroll Forward
Enter
Scroll Back
Pump Prime
f: Start Sec: 00
5
Verify the base-head has been
installed on the unit’s turntable hook
side up.
Installing a new Pad
Ver 4.0 07-08-2010
Shake PoliCoolTM every hour of use!
PoliCool Time
Sec: 12,000 AD:On
Turn PoliCool upside down..Shake vigorously
making sure all sediment is mixed. Store lid
for re-shaking.
Turn power on. Wait for PoilCool Time
12,000 seconds to appear on the screen.
Prime lines until PoliCool is flowing and no air
bubbles are present. It may take more than
one 60 second priming sequence.
Press the “i” button, use the arrow
buttons to scroll to the prime pump screen.
Pressing the enter button turns on the
PoliCool pump for 60 seconds.
Press “i” to stop and return to main screen.
With machine turned off, and lid closed,
remove PoliCool Cap and
insert Perma Filter & tube making sure filter
is fully sub-merged. Align bottle opening
under drain with color label side facing
Smart Chip Reader.

7
BASIC OPERATION
Place a CD or DVD on
the left spindle
Place a CD or DVD on
the right spindle
Close the lid, press and turn latch
clockwise until it moves passed
resistence.
Incorrect
Correct
Ver 4.0 07-08-2010
For the lid to be sealed the edge
must be flush with the interior bevel
of the cabinet as shown above.
(Figure 2.1) (Figure 2.2)
For the lid to be closed the top latch has to be in
the configuration shown in Figure 2.1
Select Repair Cycle
Number = Length of time in seconds
After pressing selected amount the screen will
show time remaining
PoliCool Time
Sec: 1858 AD:On
Time Remaining
Sec: 59 AD:On
After repair cycle is finished remove
CD’s or DVD’s from spindles.

8
Ver 4.0 07-08-2010
ABOUT THE REPAIR / POLISHING PROCESS - The Dual Disc II uses a single polishing pad &
PoliCoolTM to remove scratches. Choose the desired level of repair using the indicator buttons. This
will vary the total amount of time used in the repair /polishing process.
Select the length of repair and
press the corresponding button.
Near the end of the cycle, your
discs will be dried by the
AutoDry process if activated.
The cartridge count begins
when you press the Start
button and counts off time
with every repair.
Inserting a new cartridge
will reset the counter.
Once it reaches 1500 sec-
onds the screen will indi-
cate a warning. Once it
reaches 0 seconds, the
machine will no longer
start. Install new car-
tridge as shown in steps 1
through 5 - SET UP -
SUPPLIES - CARTRIDGE &
PAD PLACEMENT.
PoliCool Low Screen
Select to start
Number = Length of time in seconds
After pressing selected amount the
screen will show time remaining
Press enter to stop process
& return to main screen
Lid Open Screen
PoliCool Time
Sec: 1858 AD:On
Time Remaining
Sec: 27 AD:On
PoliCool Low !
f:Reset Warning
Dual Disc II
Lid Open

9
TROUBLESHOOTING
No power • Verify the power cord is properly inserted in a working outlet; test the outlet with another device.
• Check the fuse (by the power connector) on the machine. 110 -230V
machines: 15A (1 spare fuse can be found in the AC outlet)
• Check On/Off switch is in the “On” position.
Caution: To avoid electrical shock, ensure the outlet is properly equipped
with a ground connection.
Little or No water flow • Is the hose inserted into the PoliCoolTM container?
• Are there any kinks in the hose(s)?
• Is the pump turning? (try priming pump)
• Check and clean filter if needed.
Machine overheating • Verify the machine is on a flat sturdy surface. A carpeted surface may block the air outlet on
the bottom of the machine.
• Leave space behind the machine to allow air flow for the cooling fans.
• PoliCoolTM liquid is not flowing correctly. Verify proper flow of liquid with no air bubbles by using
the pump prime feature. Look for constant flow under the lid during the priming process.
Cartridge not reading • Remove cartridge and reinstall it behind the access door making sure to position cartridge label
side in. (step 2)
• Make sure that the cartridge is new and that it has not already been inserted in this or another
machine and has already transferred its credits.
• Test cartridge in test mode (Refer to smart tag test mode)
Not responding to
Control Panel
• Power machine down. Turn machine back on and check for display on the front control panel.
• Wait for the screen to be on.
Has power but will not
run
• Make sure there are no obstructions under the lid and reclose.
• Make sure the prime pump sequence has completed, and press the start button again.
• Check for indicators on the screen. A new PoliCoolTM cartridge may be required.
• Make sure controller is displaying main screen.
Preamature wear on
the pad
• Never run the machine with one disc. If this happens, the rubber pad from the handle will dam-
age the polish pad which will then have to be replaced. The PoliCoolTM will still be useable, but
the pad must be replaced with a new one. The handle pad may also need to be replaced if it has
been damaged.
Fuse Removal
Ver 4.0 07-08-2010

INFO MENU
• Prime Pump
Press the “i” button, use the arrow buttons to scroll to the prime pump screen. Pressing the enter button turns on the policool pump
for 60 seconds. Press “i” to stop and return to main screen.
• PoliCoolTM Loads
Press the “i” button, use the arrow buttons to scroll to the PoliCoolTM Loads screen to see the number of cartridges used.
Pressing the enter button activates the screen.
• Total Runtime Meter
Press the “i” button, use the arrow buttons to scroll to the Runtime Meter screen to see the total
amount of cycle run time. Pressing the enter button activates the screen.
• Auto Dry On/Off
Press the “i” button, use the arrow buttons to scroll to the auto dry screen. Pressing the Enter Button turns auto dry on or off.
• Dry Time 3 Seconds
Pressing the enter button activates (or deactivates) the 3 second Auto Dry cycle timer.
• Dry Time 5 Seconds- This is the default setting.
Pressing the enter button activates (or deactivates) the 5 second Auto Dry cycle timer.
• Dry Time 7 Seconds
Pressing the enter button activates (or deactivates) the 7 second Auto Dry cycle timer.
• Dry Time 10 Seconds
Pressing the enter button activates (or deactivates) the 10 second Auto Dry cycle timer.
• Pump Tube Runtime
Press the “i” button, use the arrow buttons to scroll to the pump tube runtime screen. Pressing the enter button resets the runtime to “0”.
Info
Button
Enter
Button
Forward Scroll
Button
Reverse Scroll
Button
Press “i” from the
main screen to get to
main info shown at
right.
Press “i” at any time
to return to the main
screen
Info>:NextScreen
f:Smart Tag Test
Pump Prime
f:Start Sec:00
Ver 4.0 07-08-2010
10
PoliCool Loads
Total: 9
Total Runtime
Minutes: 33
Auto Dry On.Off
Auto Dry = Off
Dry Time 3 sec
f= On/Off On
Dry Time 5 sec
f= On/Off On
Dry Time 7 sec
f= On/Off On
Dry Time 10 sec
f= On/Off On
PumpTube Runtime
f:Reset : 23