3D IN-LINE INSPECTION SYSTEMS

Operation Manual

Koh Young Technology Inc.

14F, Halla Sigma Valley, 53 Gasan digital 2-ro, Geumcheon-gu, Seoul 08588 Korea
Tel: +82.2.6343.6000 / Fax: +82.2.6343.6001
Homepage: www.kohyoung.com / Email: kohyoung@kohyoung.com

C-Platform_All Models
 2

No part of this manual may be copied, reproduced, translated, or published in any form or by
any means (electronic, mechanical, photocopying, or otherwise) without the express written
permission of Koh Young Technology, Inc. (“Koh Young”).

This manual may include the website links to companies other than Koh Young. Koh Young is
not responsible for any of these links. Each respective author owns the copyrights of the
materials mentioned herein.

Although Koh Young made every effort to ensure the accuracy of this document, it assumes no
responsibility for errors or omissions that may appear herein. The figures in this manual may
differ depending on the version of the product or operating system, or the way it runs.
Information in this manual is subject to change without notice.

Revision History
Date Version Remark
June 2018 1.0 Renewal of Operation Manual
November 2018 1.1 Regular Update
February 2019 1.2 Updated Safety Labels

Koh Young Technology Inc.

 3

Table of Contents
Safety Precautions .................................................................................................................5
Caution/Danger/Warning....................................................................................................5
Lock-out & Tag-out Procedures..........................................................................................6
Operating Switch ...............................................................................................................7
Interlock System Signal and Action ....................................................................................9
Safety Labels and Signs ..................................................................................................10
Location of Safety Labels.................................................................................................13
Before Operation .............................................................................................................17
During Operation .............................................................................................................18

SPI Operation........................................................................................................................19
Powering On the System .................................................................................................19
Starting Inspection ...........................................................................................................20
Defect Viewer ...........................................................................................................22
Changing JOB file.....................................................................................................22
Shutting Down the System...............................................................................................23
S/W Bypass Mode ...........................................................................................................23
H/W Bypass Mode ...........................................................................................................23

AOI Operation .......................................................................................................................24

Powering on the System ..................................................................................................24
Running the Program.......................................................................................................25
Starting Inspection ...........................................................................................................25
Determining Defect Results on the Defect Viewer............................................................28
Judgement................................................................................................................28
The Explanation of the Defect Viewer .......................................................................28
Determining Defect Result on the Review Station. ...........................................................29
Judgement................................................................................................................29
Screen Layout ..........................................................................................................29
Stopping Inspections........................................................................................................30
Bypass Modes .................................................................................................................30
Minimizing Programs .......................................................................................................30
AOIGUI.....................................................................................................................30
Review Station & AOI SPC .......................................................................................30
Closing Programs ............................................................................................................30
AOIGUI.....................................................................................................................30
Review Station & AOI SPC .......................................................................................30
When appearing Fiducial Error window.....................................................................31
When deactivating START button .............................................................................31
Shortcut Keys ..................................................................................................................32

Koh Young Technology Inc.

 4

Trademarks
© Copyright 2013 Koh Young Technology Inc. All rights reserved.

The product names used in this manual are the registered trademarks of their respective
companies and protected by relevant patent and copyright laws.

It is prohibited to duplicate all or part of this manual without the express written consent of Koh
Young Technology Inc.

Product specifications may change without prior notice.

Koh Young Technology Inc.

 5

Safety Precautions
Incorrect operation may cause a safety accident or system malfunction. Please follow the
following precautions.

Caution/Danger/Warning
Read and familiarize yourself with the following precautions before operating the
system.
Read and familiarize yourself with the precautions in safety labels placed on the system.
Make sure to comply with these precautions to prevent any unexpected safety hazard
or damage that may occur during system operation
Safety labels are classified as Danger, Warning, Caution, Prohibition, and Mandatory
as follows.

Danger – An immediately hazardous situation that may result in death

or major injury, or damage to the system.
Danger

Warning – A potentially hazardous situation that may result in major or

minor injury, or damage to the system.
Warning

Caution – A potentially hazardous situation that may result in major or

minor injury, or damage to the system.
Caution

Prohibition – Prohibitive Actions.

Prohibition

Mandatory – A required action to be taken to avoid the danger.

Mandatory

Koh Young Technology Inc.

 6

Lock-out & Tag-out Procedures

For safe maintenance and repair work of the machine, a lockable Main Switch is installed on
the machine. This is a safety device that prevents other workers from turning on power or Air
On/Off and Release Valve when the operator is performing maintenance and repair work.
Lock-out & Tag-out is the required safety procedures which must be followed when carrying out
Type 1 Task or other safety-related works.

For Lock-out & Tag-out, follow the steps below.

Main Switch
Lock-out Air On/Off &
Release Valve
Lock-out

1. Turn off the Main Switch and the Air On/Off and Release Valve and lock them out, and
then perform Tag-out indicating the maintenance is in progress (Lock-out & Tag-out).
The operator should carry the key to the lock.
2. Proceed with the required work.
3. After completing the work, unlock the Main Switch and the Air On/Off and Release
Valve and turn on the power.
4. Turn ON the computer power switch and then operate the control programs.

Koh Young Technology Inc.

 7

Operating Switch

A switch to turn ON or OFF the main power of the

Main Switch
system

A switch to use when an emergency or safety hazard

occurs during system operation.
How to operate: 3 Tower lamps will flash when
(EMS/EMO) switch is pressed. The system will
Emergency Stop/
stop immediately, and the main power will be
Emergency Off
turned off.
How to repair: Pull the (EMS/EMO) switch after the
problem is fixed. Then press the start button or
click the start button on the screen.

A button to activate the PCB inspection. When the

Start Button green button is pressed or the start button on the main
program is clicked, PCB inspection will be activated.

A button to pause the system momentarily. When the

Stop Button red button is pressed or the stop button on the main
program is clicked, the system will be paused.

Control Power Supplies power to the sensors and control boards of

Switch the system.

Control Power
Displays whether the control power is on or not.
Lamp

Koh Young Technology Inc.

 8

Main Power Lamp Displays whether the main power is on or not.

How to operate: When the cover of the device is

opened the safety interlock switch will
Safety Interlock automatically stop the system.
Switch How to repair: Close the cover of the device and
press the start button or click the start button on
the left side of the monitor.

Koh Young Technology Inc.

 9

Interlock System Signal and Action

EMO

Air On/Off &

Release Valve
Safety Interlock Switch
Safety Interlock Switch
(Option)

Action 2
Tower Action 1 Power State of
Related Delay H/W Machine-
Interlock System Lamp Actuator
Switch Time S/W Safety circuits
Color Power
and computer
systems excluded
Servo Motor
If EMO is Activated EMO 0 sec Red H/W Turn Off Machine
Power Off
Servo Motor
If EMO is Inactivated EMO 0 sec Green H/W Turn On Machine
Power On
If Door Interlock Switch is
Door
Activated Servo Motor
Interlock 0 sec Red H/W Turn Off Machine
(Lockable Type Safety Power Off
Switch1
Interlock Switch)
If Door Interlock Switch is
Door
Inactivated Servo Motor
Interlock 0 sec Green H/W Turn On Machine
(Lockable Type Safety Power On
Switch1
Interlock Switch)
If Door Interlock Switch is
Door
Activated Servo Motor
Interlock 0 sec Red H/W Turn Off Machine
(Magnetic Type Safety Power Off
Switch2
Interlock Switch)
If Door Interlock Switch is
Door
Inactivated Servo Motor
Interlock 0 sec Green H/W Turn On Machine
(Magnetic Type Safety Power On
Switch2
Interlock Switch)
Air
Air On/Off and Release On/Off
Servo Motor
Valve is Activated and 0 sec Red S/W Turn On Machine
Control Stop
(at Low Pressure) Release
Valve
Air
Air On/Off and Release On/Off
Servo Motor
Valve Activated and 0 sec Red S/W Turn On Machine
Control Stop
(at High Pressure) Release
Valve

Koh Young Technology Inc.

 10

Safety Labels and Signs

General Safety Rules

Only authorized personnel who have completed the training can use the machine, while others
cannot use the machine.
If the machine is to be turned off for a long period of time, disconnect the power cable and the
Air On/Off and Release Valve, and perform Lock-out & Tag-out.
When installing the machine, make sure to connect PE wire (Green and Yellow stripe).
Be careful not to contaminate the machine with foreign objects.
Perform maintenance activities according to the safety procedures specified in this document.
Do not insert your hands into the board inlet/outlet on the left and right sides of the machine
when the machine is switched on.

Electrical Danger

DANGER As a general rule, electrical work must be performed after

turning off the Main Switch and performing Lock-out & Tag-out.
DANGER When the Main Switch is turned on, electrical work must be
carried out according to the specified operating procedures in this
document.

WARNING Electrical power could still be in flow after the main power is
cut.
WARNING Authorized person only.

DANGER As a general rule, electrical work must be performed after

turning off the Main Switch and performing Lock-out & Tag-out.
DANGER When the Main Switch is turned on, electrical work must be
carried out according to the specified operating procedures in this
document.
WARNING Improper grounding may lead to electric shock or
malfunction of the machine.
WARNING Establish and maintain protective earth grounding according
to the operator’s manual

Koh Young Technology Inc.

 11

Mechanical Danger

WARNING When opening the Fixed Cover, make sure to turn off the
Main Switch or turn off the Control Power Switch to stop the machine.
WARNING Do not insert your hands into the PCB inlet/outlet on the
left and right sides of the machine.

WARNING Do not spray compressed air on skin or eyes.

WARNING When repairing pneumatic device, perform Lock-out & Tag-
out on the pneumatic valves of the machine.

DANGER Do not put your head into the machine while power is
supplied.
DANGER Before putting any part of your body into the machine, make
sure to turn OFF the Main Switch and perform Lock-out, or turn OFF
the Control Power Switch.
DANGER Indicate “Danger” sign on moving parts of the device.

WARNING Do not touch the device while running.

WARNING Before putting any part of your body into the machine,
make sure to turn OFF the Main Switch and perform Lock-out, or turn
OFF the Control Power Switch

WARNING Do not open the door of the device while running.

WARNING Before putting any part of your body into the machine,
make sure to turn OFF the Main Switch and perform Lock-out, or turn
OFF the Control Power Switch
WARNING Before conducting maintenance, make sure to turn OFF
the Main Switch and perform Lock-out, or turn OFF the Control Power
Switch
WARNING Before conducting maintenance, make sure to cut off the
main air and release the air.
DANGER Do not put your head into the machine while power is
supplied.
DANGER Before putting any part of your body into the machine, make
sure to turn OFF the Main Switch and perform Lock-out, or turn OFF
the Control Power Switch.
DANGER Indicate “Danger” sign on moving parts of the device.

WARNING When opening the Fixed Cover, make sure to turn off the
Main Switch or turn off the Control Power Switch to stop the machine.
WARNING Do not insert your hands into the PCB inlet/outlet on the
left and right sides of the machine.

Koh Young Technology Inc.

 12

WARNING Do not touch the device while running.

WARNING Before putting any part of your body into the machine,
make sure to turn OFF the Main Switch and perform Lock-out, or turn
OFF the Control Power Switch.

Prohibition

CAUTION Do not disassemble or modify the machine. Doing so

may damage the machine.

WARNING Do not remove or dissemble Door Interlock Switch

Mandatory

Please read this manual thoroughly before using the machine.

Please observe the procedure of Lock-out & Tag-out during

maintenance work.

Stop the device when it is saving data.

Not stopping the device may lead to malfunctioning.

Use designated grease only.

For LM of NSK, it is recommended to use GREASE PS2.
For LM of THK, it is recommended to use GREASE AFB.

Separate the PC when moving the device.

Moving with the PC attached my lead to hard disk damage.

Koh Young Technology Inc.

 13

Location of Safety Labels

Note: The location of the safety labels and the appearance of the machine may vary depending
on the model.

Koh Young Technology Inc.

 14

Note: The location of the safety labels and the appearance of the machine may vary depending
on the model.

Koh Young Technology Inc.

 15

Note: The location of the safety labels and the appearance of the machine may vary depending
on the model.

Koh Young Technology Inc.

 16

<Single Lane>

<Dual Lane>

Note: The location of the safety labels and the appearance of the machine may vary depending
on the model.

Koh Young Technology Inc.

 17

Before Operation
DANGER: Ground the GND terminal using a copper wire with a cross-section area
greater than 2.0 before using the system. Otherwise, there may be an electric shock
or noise.
DANGER: Avoid contact between the system's moving mechanical parts and your body,
clothing or other objects. Make sure to check if it is safe before supplying power to the
system.
CAUTION: Make sure that the system is turned off before slowly supplying compressed
air to the system for normal system operation.
CAUTION: Make sure to check the system before connecting its power cable to the
power supply.
WARNING: Restrict use or maintenance of the system to persons trained for system
operation and maintenance.
CAUTION: If a natural disaster such as an earthquake, flood or fire occurs, stop system
operation immediately and remove the power cable.
CAUTION: Do not locate flammable materials or gas near the system. This may lead to
explosion or fire.

Koh Young Technology Inc.

 18

During Operation
DANGER: If a hazardous situation occurs during system operation, press the
Emergency OFF Switch (EMO) immediately and set the Main Switch to OFF.
DANGER: When more than one person is engaged in system operation, ensure proper
communication to prevent any unforeseen accidents.
DANGER: Do not open the Fixed Cover during system operation. This may lead to
personal injury or damage.
DANGER: If abnormal conditions occur during system operation, make sure to shut
down power to the system before taking necessary actions.
DANGER: When the green tower lamp is ON, handle the system with care as the
system is in automatic operation even though it appears to have stopped.
DANGER: If users notice anything unusual in the operation of the system, stop the
system first and then shut down the power.
DANGER: Do not attempt to stop the operation of safety interlock. Also, periodically
check that interlocks are working properly. Malfunctioning of the safety interlock may
lead to system errors or personal injury or damage.
DANGER: Do not operate the system when the Fixed Cover is open. Ignoring this
safety instruction can lead to operator wounds / injuries.
WARNING: Turn the system off during part replacement or system calibration. When
the system has completely stopped, remove the power cable from the power supply
and then follow the required steps for replacement or calibration.
WARNING: Make sure to keep hands and other objects out of the buffer conveyor on
either side. Ignoring safety instructions can lead to operator wounds / injuries.
WARNING: No person other than an operator should be allowed into the system
operation area.
CAUTION: Do not attempt to manipulate the various sensors attached to the conveyors
on the left and right sides of the system by yourself. This may lead to system errors or
other problems.

Koh Young Technology Inc.

 19

SPI Operation
Powering On the System
1. Open the back door and set the Main Power Circuit Breaker (MCCB) to ON.

2. Turn on the Main Switch on the left front of the machine clockwise to supply the power
and wait for about 40 seconds.

3. Once the computer is turned on, turn on the Main Switch.

4. Once the computer booting process is completed, turn on the Control Power Switch
and wait for about 10 seconds.
5. When running the GUI( ) by clicking its icon on desktop, wait until the GUI window is
opened after GUI initialization.
6. Return to the desktop and click the WinMCS( ) icon to run the program. Then, the
system starts homing in about 20 secs.
7. When the Homing message box disappears from GUI, start PCB inspection.

Koh Young Technology Inc.

 20

Starting Inspection
1. Once the computer booting process is completed, double-click KY3030.exe on the
desktop to run the program.
2. The JOB file recently used will be loaded and Input Production Quantity dialog box
will pop up.

3. Specify the information properly and click OK. Then, the screen below will be displayed.

Note: When the Program Status Bar indicates OFF-Line, nothing is activated on the Inspection
Execution Tool Bar.

Koh Young Technology Inc.

 21

4. Once the home-checking process for the system is completed, the status of machine
will change into IDLE. It takes about 3 minutes.
5. Click the Start button on the Inspection Execution Tool Bar.
6. PCB inspection will be started.
7. If you select either 'NG' or 'Pass', the corresponding board will be ejected, and the next
board will be ready for inspection.

Koh Young Technology Inc.

 22

Defect Viewer

Item Description
Defect List ( ) Selects the defect pad in this list, then PCB view moves to the
selected pad
Pad ID ( ) Displays the pad’s location and Pad ID
Condition Info/ Result Info ( ) Displays the inspection results
Defect image and result ( ) Displays the selected component in PCB view
Double-click the defect list to display the pads
Comment ( ) Inputs comments to the selected pad

Changing JOB file

1. Click Import in main UI.
2. Once Select JOB File window appears, select a JOB file and click OK.
3. The selected JOB file will be automatically loaded.

Koh Young Technology Inc.

 23

Shutting Down the System

1. Close all programs.
2. In Windows, click the Start button and choose Turn Off Computer. Then, the Turn off
computer dialog box will appear.
3. Choose Turn Off and click the OK button.
4. When the computer is turned off, turn the Control Power Switch counter-clockwise.
Then, the Control Power Lamp (Green) will turn off.
5. Turn the Main Switch counter-clockwise. Then, the Main Power lamp (Red) will turn
off.
6. Set the MCCB switch to OFF.

S/W Bypass Mode

1. Make sure that the status of the machine is IDLE.
2. Click BYPASS on the Left Button Bar.
3. The status of the machine will be changed to BYPASS.
4. The machine will let boards through without any inspection.

H/W Bypass Mode

WARNING: You must use this mode only in the EMERGENCY situation where the computer
does not work.

1. Control Power should be turned off.

2. Open the bottom side door of the machine and turn the conveyor S/W clockwise.
3. Turn control power S/W clockwise, then the conveyor switch lamp will be turned on.
The Conveyor Only Mode is started to work.
4. The machine will be used as a conveyor.
5. In order to go back to the normal mode, take the reverse order.

Koh Young Technology Inc.

 24

AOI Operation
Powering on the System
1. Switch the Main Power Circuit Breaker on the back of the machine to ON.

2. Change the Main Switch on the left side of the machine to ON.

3. Check that the MAIN LED lamp is lit.

4. Press the Vision PC Power button.

5. When the OS of the computer is completely booted, change the Control Power
Switch located on the left side of the front to ON.

6. Check that the Control Power Lamp is ON.

Koh Young Technology Inc.

 25

Running the Program

1. Run AOIGUI.exe and WinMCS by clicking and on the desktop.

2. After approximately 20 seconds, the system starts homing.

3. When the Homing message box disappears on the GUI, start PCB inspection.

Starting Inspection
1. Click the button in the AOIGUI menu to load a new JOB file. Or click the next
button to select the JOB file you recently loaded.

Koh Young Technology Inc.

 26

2. The PCB Settings & Info window appears when loading a JOB file.

3. Click ‘Adjust conveyor width’ in Conveyor Width.

Koh Young Technology Inc.

 27

4. Set Angle Direction either ‘Clockwise’ or ‘Counter Clockwise’.

5. Click Apply.

6. After the conveyor width adjusts automatically, click Production menu.

7. Begin inspection by clicking or by pressing START on the switch panel.

8. The Defect Viewer appears after the machine detects defects. After selecting detected
defects, displaying either ‘NG’ or ‘OK’, the inspected board is extracted from the
machine. The machine rests in standby status, ready to inspect the next board.

Koh Young Technology Inc.

 28

Determining Defect Results on the Defect Viewer

Judgement
NG: PCB is determined for defective boards. Operators must eliminate the inspected
board.
OK: PCB is determined for good boards. Proceed with the next PCB inspection.

The Explanation of the Defect Viewer

3D Viewer: Color 3D and PCB tab.

Good Image & OCV Image: Display good images. Add / delete OCV Images.
Result Info: Display info about inspection results.
Inspection Condition: Modify Inspection conditions.
Inspection Result: Display inspection results.

Koh Young Technology Inc.

 29

Determining Defect Result on the Review Station.

In the Review Station, reconfirm the inspection results(NG or PASS) of PCBs.

Judgment
If Defect Viewer does not judge NG or Pass, judge it in Review Station.
NG: The PCB is determined for a defective board.
PASS: The PCB is determined for a good board.

Screen Layout

Navigation Map: Displays the location of an item selected in Failure Item List.
3D Viewer: Display 3D images.
2D Viewer: Display 2D images.
Failure Item List: Display defective items.
Buttons to judge whether the board is defective or not. Select either Pass or NG based
on the Failure Item List.
Buttons to reconfirm the defective item selected in the Failure Item List. Select Defect
if it is defective, or Defect Pass if it is not defective.

Koh Young Technology Inc.

 30

Stopping Inspections
Click on the Main Menu to stop inspection. Or, press STOP on the front panel to stop
inspections in progress.

Bypass Modes
There might be an occasion when you need to suspend the inspection of a PCB as it is
necessary to adjust to the speed of processes or due to other circumstances. In this case,
Bypass Modes are recommended.
- SW Bypass: Select the Inspection tab and click the button to stop inspection.
- HW Bypass: Change the HW Bypass Switch to ON.

Minimizing Programs
AOIGUI
Click to minimize AOIGUI.

Review Station & AOI SPC

Click to minimize Review Station.

Closing Programs
AOIGUI
Click to close SPC.

Review Station & AOI SPC

Click to close Review Station.

Koh Young Technology Inc.

 31

When appearing Fiducial Error window

1. Click Teaching.

2. Select one fiducial to modify on the fiducial list.

3. After checking detailed information about the selected fiducial, modify its information if
it is necessary.

4. Test the modified fiducial by clicking Test.

5. If there is no problem, click Apply to save modified information.

When deactivating START button

When deactivating , click .

Koh Young Technology Inc.

 32

Shortcut Keys

Key Description Additional Actions

F2 Re-inspection
F3 Re-inspection (Single component)
F4 ‘Color 3D’ tab & ‘PCB’ tab Modification Button
F5 View Mode Modification Button
F6 3D & 2D Image Modification Button
F7 Display Cad information Window
F9 ‘Result Info’ tab & ‘PkgEdit’ tab Modification Button
A: Apply
Ctrl + D Cad Information Modification Button
C: Cancel
R: Apply CCW Rotation
Ctrl + R Display Rotation Application Window A: Apply
C: Cancel
Tab ‘Result Info’ tab & ‘Property’ tab Modification Button

Shortcut keys can be modified.

Koh Young Technology Inc.