For business or home users who need to make multiple copies of CDs and DVDs, having a dedicated CD DVD duplicator is a powerful solution. A dedicated CD and DVD duplicator is reliable, fast, easy to use, and easy to maintain. It also produces more universally readable media than other methods.

Copying one CD or DVD at a time is no problem for today’s fast machines and reliable burners. But if, for example, a user needs to get a parts list on CD to their top 10 wholesalers every month, or needs to distribute 50 copies of a sales-training video on DVD, then one-at-a-time is not the way to go. Besides being tedious, it can tie up one or more PCs–something many businesses cannot afford.

Two Types of Duplicator Towers

Duplicator towers are typically built using one of two methods: Either as a PC-based system, or using a specially built piece of hardware called a duplication controller.

Here’s a quick view of their relative benefits:

PC-Based:

• Can be used for other tasks (though not when duplicating)
• Easily expandable
• Good use for an older PC
• Wide choice of duplication software

Duplication Controller-Based:

• Fewer parts: no motherboard, memory, or OS needed!
• Simplicity of construction and operation
• Designed for optimal data throughput for fewer copy errors
• Compact size

While I’ll discuss both options, this article will focus on the more flexible PC-based approach. I’ll show you how to build a PC with multiple burners that is optimized for channelized data transfer between the disk and burners to avoid buffer underrun–the most common cause of copying failure. Before we start building, let’s examine this important issue.

Why Bad Things Happen to Good Copies

The process of burning CDs and DVDs is not without problems. At the top of the trouble list is compatibility, or a lack thereof. The industry has adopted a large and growing number of disk formats and media types. This means that a disc that plays just fine on one machine may not work at all on another.

Also, problems inherent with the burning process can render a disk unreadable on some players. Anyone who has burned copies of their favorite music CD has probably had the experience of seeing “disc not found” or a similar error message when later trying to play the disc in their car or portable CD player. These defective disc are also known as “frisbees” - good only for throwing or possibly skeet shooting to vent some frustration.

Here’s a breakdown of the current leading CD and DVD formats. Including non-recordable formats, I count a total of 10 that you need to at least consider:

There are other reasons why burning can fail, too. The most notorious is a condition called “buffer underrun.” It occurs when the buffer supplying data to the burner is emptied before all the data requested can be written. It happens either when data is interrupted or can’t be supplied fast enough to the writing device. If the PC’s software and hardware fail to prevent this situation, the disc is rendered useless. The good news is that there are several ways–using both hardware and software–to avoid buffer underrun.

Now let’s start building our duplication tower. As I mentioned earlier, there are two main ways to go: PC-based, or duplication controller-based. Let’s look at the PC solution first.

PC plus Software Solution

In general, I recommend IDE devices. If you have been building PCs for a while, SCSI might seem like an obvious choice for attaching multiple media devices. In fact, SCSI is used in building monster duplicating systems where data-bus control is critical. (For example, Nero software has built and tested duplication towers connecting 32 burners via SCSI.)

But IDE devices offer several advantages over SCSI. While SCSI may provide better control of more peripheral devices, IDE invariably wins out in price, availability, and ease in configuration. One serious limitation of IDE for this application is the limit of two devices sharing one channel with a Master/Slave relationship. To build a system with multiple IDE burners, you must use multiple IDE controllers, which use up valuable PCI slot real estate. Still, since IDE parts are so widely available and proven, I prefer IDE for systems with six or fewer burners. I only use SCSI for larger systems where cost is less of an issue.

Here’s my parts list and considerations for a PC-based duplication tower:

• Motherboard: I recommend Pentium III / 400 MHz or better with at least 128 MB of RAM. (With requirements this modest, consider retooling an older PC as a duplication tower.) Remember that the number of IDE devices you can add depends on the number of IDE ports that are available. For example, many popular IDE controller cards support only two IDE ports. Depending on how many burners will be installed, you may need to obtain additional PCI slots.
• Hard Disk Drive: You’ll need a 40 GB hard disk if the system will be used for copying CDs only, but a 120 GB drive for duplicating DVDs. Either way, partition at least OS and data partitions. Then, for the most expedient transfer to your line of burners, keep individual files or disc images on a data partition. The newer 7200-RPM drives are best for copying DVDs and achieving higher write speeds, though they’re not necessary for CD duplication. Also, remember to defrag your disk often; it’s one way to avoid burning errors (and see more tips below).
• IDE Controllers: As already mentioned, you’ll need additional IDE controller cards to attach IDE burners. Each card supports two channels, and each channel will support one master device and one slave. I prefer adding additional controllers when possible, then configuring all burners as master devices; this achieves top speeds while still avoiding buffer underrun. SIIG’s IDE controllers, such as the model SC-PE4B12 are know to work well for duplicating applications. Sadly, Promise IDE cards have had issues with duplication software, so I’d avoid them for this application. A word about cables: For best performance, use 80-wire IDE cables for all primary connections between the IDE controller and the DVD/CD burners or ROMs. These newer IDE cables have 80 wires–twice as many as the older cables–but still connect to 40-pin headers. Also, 80-wire cables produce faster, more accurate data transfers, which, in turn, support faster devices. Plus, the cost difference between 40- and 80-wire cables is minimal.
• Case: Look for a sturdy case with ample bays on the front. If you are building for four or more burners, choose a full tower for space. Some case manufacturers offer a “duplication tower” case that’s ideal for this application; these cases include front-accessible bays with good airflow. Also, consider adding extra cooling if your duplication tower will be used in a production setting. Remember, these boxes are called “burners” because they actually use a laser to burn the disk. That creates a lot more heat than a normal PC. Finally, avoid running the system “open” or with case covers or sides off, even when testing. With the covers removed, air will not flow through the case as designed, and the system could overheat. Burners generate a good deal of heat, and they depend on fresh air being pulled through and around them to keep them cool. Proper air circulation is critical.
• Power Supply: You’ll need a high-quality power supply to meet the demands of your system. A minimal system with a couple of burners will require at least 250 watts. Larger systems with additional fans would be safer with at least 300 watts, even more.
• Monitor, keyboard, and mouse: Standard equipment is adequate, as there are no special requirements here.
• CD/DVD ROM: As your source, this should be reliable and at least as fast as your target burner’s speed. That way, it will help to avoid buffer underrun on occasions where you might copy directly from CD/DVD ROM to CD/DVD Burners. It is more efficient to burn from a disk image, so–other than to make the occasional one-to-one copy–CD/DVD ROMs are typically used only to load data onto a drive partition. For my tower, I chose Lite-On IT’s Model SOHD-1673S 16x DVD ROM drive for both price and reliability.
• CD/DVD Burners: I recommend that, whenever possible, you use drives of the same make and model number. While a burner is not strictly necessary, you will enjoy a distinct advantage by using drives of just one type. This will guarantee the same buffer sizes and buffering strategy. All the burners I’ve seen from major manufacturers perform well and are reliable, and I’ve seen little difference among them. Also, some burners, including the Lite-On SOHW-812S Dual DVD+RW Writer, have a 2 MB cache and employ buffer handling to prevent a buffer underrun condition. (Lite-On calls its buffer-handling feature Smart Burn.)
• Application Software: My pick is Nero’s latest, Nero 6 Reloaded, which is available as part of Nero’s Ultra Edition. Like most commercial copy software, Nero creates a hard-disk image of the CD or DVD you will be copying. It then buffers the data while it initiates the writing process to your line of burners. This is carefully orchestrated so the data arrives at the burner on time to avoid buffer underrun. Nero also recognizes the various buffering strategies of the burners and configures itself accordingly. Nero is an obvious choice for software; the vendor has a long-standing reputation as the leader in the field, and it performs significant testing with multiple burners. Also, with Nero 6, users get support for up to four target burners and can purchase a software key to turn on support for more.
• Operating System: I chose Windows XP Home Edition since no special features or networking are required. For optimal performance on the duplication software, configure Windows for the maximum size for PageFile under System Performance. Also, avoid using WinME and Win95 to run your duplication towers, as these two OSes are known to have difficulty handling the duplication processes, buffering, and multiple controllers required for making disc copies.

Assembly Tips

In most respects, assembling your duplication tower will be the same as a standard desktop solution–just with more burners. But you will need to do some careful planning regarding your additional IDE controller cards, burners, and cabling. After all, you’ll have more devices and more cables than usual.

Once you’ve gathered together your parts and you have removed the cover from the case, plan the location of your IDE controllers, burners and cabling before configuring and installing any drives. Make sure all cables are long enough and that they can be dressed to promote good airflow.

Next, configure the motherboard, but install the processor, fan, and memory before installing the motherboard in the case. Install all additional IDE controllers and cables to the CD/DVD burners and ROM. Minimize cable clutter by keeping data cables flat along flat surfaces, gently folding and securing them to allow plenty of airflow through the case.

If, after a thorough visual inspection, you are satisfied with your system, it’s time to connect your peripherals, power up the system, and do a BIOS setup. Create OS and data partitions on the hard disk, and your assembly is complete. You are now ready to move on to loading the OS and application software onto your duplication tower.

Once again, airflow is critical. So make sure the case has all its covers on before you do any significant or prolonged testing of the burners. Prolonged testing without the covers on is likely to overheat the system.

Duplication Controller Solution

While the PC approach offers flexibility and uses familiar components, a system built around a duplication controller offers one major benefit: All the hardware and software needed for the system reside on just one card! With multiple IDE controllers, memory, and firmware dedicated to the task of duplicating CDs and DVDs, all the builder has to do is install a duplication controller card in a case with a suitable power supply and compatible burners. Presto! It’s ready to start copying.

With a duplication controller-based system, there is no need for commercial copying software, since all the rudimentary functions like selecting source and targets, copy speed, testing, etc., are programmed into the firmware. Some controller cards support a hard disk for creating and storing disk images, as well as USB ports for connecting to a PC.

For some users, this type of system could represent the ultimate trouble-free solution. It’s compact and simple to build, use and maintain. Once set-up, the system is essentially a “one button” operation.

Choosing a Controller Card

To build a duplication tower built around a duplication controller, the first step is to choose a controller. Commonly available duplication controllers can support from as many as nine target burners; some are dedicated CD or DVD burners; and others can copy both CDs and DVDs. There are only a few recognized names in the industry: Wytron and Acard are the best known.

There are only a few choices for duplication controller cards. Acard and Wytron are both respected names. I considered both Acard’s DVD-2033 and Wytron’s DVD-399, and opted for Wytron’s solution after talking to them about compatibility and support. The Wytron DVD-399 controller supports 10 IDE channels and the following media types: DVD-ROM, DVD-video, DVD-R, DVD-RW, DVD+R, DVD+R DL, DVD+RW, DVD-audio, DVD-RAM, CD-R & CD-RW. Wytron has compatibility tested with all the popular burner manufacturers and provide firmware updates.

Assembly Tips

Systems built around a duplication controller are almost as simple to build as they are to operate. All the parts and assembly recommendations for a duplication controller box are the same as our PC-based solution, except that you’ll save the expense and complication of a motherboard, memory, additional IDE controllers, monitor, keyboard and mouse.

As you would with a PC-based solution, carefully plan the location of components in the case. For larger towers–those with more than four burners–locate your duplication controller in a bay half-way down the box to minimize cable clutter and to easily reach all the CD/DVD burners. Also, remember that airflow through the case is critical. Pay special attention to dressing cables so they do not restrict airflow. Also, before doing any significant or prolonged testing, be sure all the sides are back on the case. Testing with an open case can overheat the system.