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.

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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
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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.
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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
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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
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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
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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
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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

INFO MENU
• 180 Second Cycle Count
Press the “i” button, use the arrow buttons to scroll to the count screen. Displays recipe tracking.
• 120 Second Cycle Count
Press the “i” button, use the arrow buttons to scroll to the count screen. Displays recipe tracking.
• 90 Second Cycle Count
Press the “i” button, use the arrow buttons to scroll to the count screen. Displays recipe tracking.
• 60 Second Cycle Count
Press the “i” button, use the arrow buttons to scroll to the count screen. Displays recipe tracking.
• 30 Second Cycle Count
Press the “i” button, use the arrow buttons to scroll to the count screen. Displays recipe tracking.
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
90 Second Recipe
Count: 2
120 Second Recipe
Count: 2
Info>:NextScreen
f:Smart Tag Test
180 Second Recipe
Count: 3
30 Second Recipe
Count: 18
60 Second Recipe
Count: 4
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INFO MENU
• PoliCool Load Screen
Press the “i” button, use the arrow buttons to scroll to the count screen. Displays reload totals.
• Recipe Count Screen
Press the “i” button, use the arrow buttons to scroll to the count screen. Displays recipe totals.
• Total Runtime in Minutes
Press the “i” button, use the arrow buttons to scroll to the count screen. Displays total in minutes.
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
Total Runtime
Minutes: 33
Recipe Count
Total: 3
Info>:NextScreen
f:Smart Tag Test
PoliCool Loads
Total: 9
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12

INFO MENU
• PoliCool Time Clear WARNING! This permanently erases PoliCool Credits.
Press the “i” button, use the arrow buttons to scroll to the PoliCoolTM Time Clear screen. Press enter to proceed to confirmation screen.
• Are You Sure?
Press the “enter” (yes) to confirm or “i” to cancel.
• PoliCool Count Clearance
Hold the “Enter” button down for 5 seconds to zero out PoliCoolTM credits. Use the “i” button to cancel.
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
Are You Sure?
f: Yes i:Cancel
Press f5Sec=Clr
i:Cancel 03.45
Info>:NextScreen
f:Smart Tag Test
Are You Sure?
f: Yes i:Cancel
Press f5Sec=Clr
i:Cancel 05.00
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INFO MENU
• Test Screen
Press the “i” button, to return to the main screen.
• Test Screen Smart Tag Loaded
• Test Screen Smart Tag Depleted
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
Test Reset: 00.00
Sec Loaded: 0
Test Reset: 01.38
Sec Loaded: 12000
Smart Tag Reset
Depleted 02.46
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14

Step 4: If the PoliCoolTM has been
depleted you will be taken to a different
screen showing you that it is depleted
and you will also see a timer counting
down. When the timer has expired you
will automatically return to the Main Test
Screen. ( Figure 6.1 )
Step 5: If the PoliCoolTM Chip is Corrupt
( BAD ) you will remain on the Test Screen and
nothing will occur. The timer will not count down
and the Seconds will continue to display zero.
( Figure 7.1 ) Remember if you need to return to
the Main Test Screen you can do this by pushing
the “i” button.
( Figure 6.1 ) ( Figure 7.1 )
Smart Chip Reset
Depleted 02.46
Test Reset: 00.00
Sec Loaded: 0
Step 1: To start testing, press the
enter button. (Figure 3.1 ) This will
take you to the testing screen. To
return to the main screen press the “i”
button. ( Figure 3.2 )
When you are at the testing screen
you will see a time value.
( Figure 3.2 )
Step 2: Place
the PoliCoolTM
next to the
Smart Chip
Reader.
( Figure 4.1 )
Step 3: If the
PoliCoolTM is valid you
will see the amount of
credits in seconds.
The timer will begin to
count down and auto-
matically return you to
the Main Test Screen
after the timer has
expired.
( Figure 5.1 )
( Figure 3.1 ) ( Figure 3.2 )
( Figure 4.1 )
( Figure 5.1 )
Info>:NextScreen
f:Smart Tag Test
Test Reset: 00.00
Sec Loaded: 0
Test Reset: 01.38
Sec Loaded:12000
Ver 4.0 07-08-2010
15

16
Ver 4.0 07-08-2010
Step 1:
Turn pump assembly
counter clockwise to
remove outer cover.
MAINTENANCE
Step 2:
Remove and replace hose.
Step 3:
Align pins and turn pump
clockwise to replace outer
cover.
CHANGE PUMP TUBE
LUBE SQUEAKY HINGES
Step 1:
Clean, lubricate or Adjust
hinges
Step 2:
Open lid approximately 45
Degrees - Spray Silicone
Lubricant on hinge pin.
Step 3:
Tighten center adjustment
screws to desired resistance.
NOTE:
Only loosen or tighten the rear center
adjustment screw -
Removing the hinge is irreversible.
LUBE QUICK LOAD SLIDERS VERSION 2
Step 1:
Remove set screw by turning
counter clockwise.
Step 2:
Separate and lubricate rings
Step 3:
Assembly is reverse, HOLES MUST
ALIGN or damage will result.
Do NOT over tighten set screw or
damage will result.

17
Ver 4.0 07-08-2010
Step 1:
Note: Remove only one
side at a time.
Remove the 3 screws that
attach the handle to the lid.
MAINTENANCE
Step 2:
Spray Silicone Lubricant on
the slide mechanism.
Step 3:
Reinstall the handle mechanism.
LUBE QUICK LOAD SLIDERS VERSION 1
REPLACE BEARINGS IN QUICK LOAD SPINNERS VERSION 1
Step 2:
Remove disc plate by
extracting the 4 attached
screws.
Step 3:
Separate bearing case
from “T” block.
Step 1:
Note: Remove only one
side at a time.
Remove the 3 screws that
attach the handle to the lid.
Step 5:
Remove set screw and
bearings
Step 4:
Remove slide screws and
extract slide from bearing
case.
Step 6:
To re-Install simply follow
steps 5 through 1
(Reverse the instructions)
Use pin to re-align

EDUCATION
HOW DISCS ARE MADE
CDs consist of 99% clear polycarbonate plastic. The reflective layer, protective layer and screen print comprise
the remaining 1% of the disc.
1. A disc is created from molten polycarbonate and digital information
is stamped on the top of the disc, while it is still near melting point,
using a die with microscopic bumps. These bumps are known as
“pits and lands”.
2. After the information is molded into the polycarbonate, a reflective
foil layer is applied using a process called sputtering or wet silver-
ing. This layer reflects the laser back to the player, so it’s integrity
is extremely important. The layer is usually silver, but can be made
of gold or platinum.
3. A clear lacquer coating is applied to seal the reflective layer and
prevent oxidation. This layer is very thin and offers little protection
from top side scratches.
4. Finally the artwork is screen-printed on the top of the disc.
Pits and Lands are imprinted into the disc to indicate a one or a zero. A laser beam is sent from the player to the
disc and the reflective layer reflects it back to the reader and the ones and zeros are translated by the player.
Recordable discs have a photosensitive dye type layer instead of the stamped information layer. This layer, when
exposed to a certain light, will make an impression of a pit into the layer.
Re-recordable discs use a layer that allows the laser to polarize the photosensitive layer back and forth between
a visible pit to an invisible pit.
HOW A DVD IS MADE
DVDs are made in different ways depending on the amount of information that is recorded on the disc. DVDs may
be single or double layered and single or double layered double sided.
NOTE: DVDs cannot be repaired as many times as CDs because the read side polycarbonate layer is thinner.
Single Layer DVDs (DVD-5 - 4.7GB)
These DVDs are made the same way as a CD with one additional polycarbonate layer added between the label
and the pits and lands.
4
3
2
1
Label
Polycarbonate
Reflective Layer
Polycarbonate Laser
Thickness: 1.2mm
0.6mm
0.6mm
Label
Pit
Land
Reflective Layer
Polycarbonate Laser
Ver 4.0 07-08-2010
18

Double Layered DVDs (DVD-9 - 8.5GB)
Double layered DVDs have a semi reflective layer and a reflective layer giving two layers to store information.
Double Sided DVDs (DVD-10 - 9.4GB)
Double sided DVDs consist of two discs bonded back to back with the reflective layers in the middle and both
sides are repairable. Double sided DVDs require the use of smaller of micro-abrasive polishing papers to prevent
the manufacturer’s label area from being removed during the repair process.
Double Sided/Double Layered DVDs (DVD-18 - 17.1GB)
Double sided/double layered DVDs are simply two double layered discs bonded back to back.
IDENTIFYING SCRATCHES
The three basic types of scratches on CDs are: topside, reading side, and top side foil dents. DVDs are not sub-
ject to top side scratches and foil dents as the manufacturing process is different from CDs.
Reading Side Scratches - CDs, CD-ROMs & DVDs
Reading side scratches are the most common type, the easiest to identify, and the
only type of scratch that can be repaired.
If the scratch has a double Image, as shown in the figure to the right, it is a reading
side scratch and can be repaired by using an Azuradisc scratch repair machine. The
double image is the result of the actual scratch and a reflection made by the reflec-
tive foil layer.
Label
Polycarbonate
Reflective Layer
Bonding Layer
Semi Reflective Layer
Polycarbonate
Laser
Thickness: 1.2mm
0.6mm
0.6mm
Polycarbonate
Reflective Layer
Bonding Layer
Reflective Layer
Polycarbonate
Laser
Thickness: 1.2mm
0.6mm
0.6mm
Laser
Polycarbonate
Semi Reflective Layer
Reflective Layer
Bonding Layer
Reflective Layer
Semi Reflective Layer
Polycarbonate
Thickness: 1.2mm
0.6mm
0.6mm
Laser
Laser
Scratch
Reflection
Ver 4.0 07-08-2010
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Top Side Scratches
Note: The scratches shown below are not found on DVDs
Top side scratches are caused by a sharp object damaging the top or label side of a disc.
In this case, the information just below the printed label area is damaged and causes a
skip. Top side scratches cannot be repaired, however they can be prevented by using an
Azuradisc Scratch Guard.
The easiest way to identify a top side scratch is to hold the suspected scratch up to a light
source and verify that light will pass through the disc in that area.
Note: If light does not pass through, check the reading or bottom side of the disc for a scratch without a “double
image”. If a double image is not visible, it is a topside foil dent or a top side scratch that did not damage any
of the label.
Top Side Foil Dents
Top side foil dents are not scratches but look like a scratch on the reading side of the disc.
The dent is made by a large amount of pressure put on the label side of the disc, causing
the foil layer to dent. This dent will cause skips and cannot be repaired, however they can
be prevented using an Azuradisc Scratch Guard.
The easiest way to identify the top side foil dent is to see if there is a “double image” pro-
duced. There should not be a second image because the damage is to the inner foil layer.
There may not be any evidence on the label side of the disc because the pressure did not
cause any of the label to be removed.
Light passes
through the disc.
No double image
Reinforced plastic spindles
for in-plant handling and storage of
compact discs
Item # spn_01677_4
ACCESSORIES
Polishing Pad
Double Sided DVD
with velcro
Replacement pad
(Do NOT install until old pad
has been removed)
Item # st2_02579_0
Base Head Assy.
with velcro
Used with the Polishing Pad
Item # ph_02577_6
Ver 4.0 07-08-2010
20
Game Cube Adapter Ring
Fits Dual Disc II & Uno
Item # gca_02508_0