eqss Genie GEN-5 Series User manual

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Genie GEN-5 Series
Installation Manual
REV 2.0
24/09/2020
Model6253 OverWatch™Installation Manual
Document # DO001235
EQSS Model6253 –OverWatch™
Genie GEN-5
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** Failure to follow this installation manual will void warranty **

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Genie GEN-5 Series
Installation Manual
REV 2.0
24/09/2020
Model6253 OverWatch™Installation Manual
Document # DO001235
|2 of 24|
AUTHORS:
Kieren Grogan, Jay Nandakumar, Truong
Bui
AUTHORISED BY:
Kieren Grogan
CHECKED BY:
Kieren Grogan
DOCUMENT ABSTRACT:
This Installation Manual details the manufacturer’s installation instructions for installing the Model6253 OverWatch™ on a
Genie GEN-5 scissor lift.
PRODUCT NAME:
Model6253 OverWatch™ Operator Detection System
REFERENCE DOCUMENTS:
DO0001195 Model6253 OverWatch™ User Manual
CURRENT DOCUMENT REVISION:
2.0
REVISION INFORMATION:
•1.0 Initial Document Creation for installation on a Genie Gen5
•1.1 Changed layout of installation manual and corrected wiring colours
•1.2 Updated to include wire harness images
•2.0 Updated location of drive and elevate signal

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Genie GEN-5 Series
Installation Manual
REV 2.0
24/09/2020
Model6253 OverWatch™Installation Manual
Document # DO001235
|3 of 24|
Important Information
Information contained in this publication regarding this device’s applications and the like, is provided only for your
convenience and may be superseded by updates. It is your responsibility to ensure that the application or our
equipment meets with your specifications.
EQUIPMENT SAFETY SYSTEMS MAKE NO REPRESENTATIONS OR WARRANTIES OF ANY KIND, WHETHER EXPRESSED OR
IMPLIED, WRITTEN OR ORAL, STATUTORY OR OTHERWISE, RELATED TO THE INFORMATION, INCLUDING, BUT NOT
LIMITED TO, IT’S CONDITION, QUALITY, PERFORMANCE, MERCHANTABILITY OR FITNESS FOR PURPOSE.
Equipment Safety Systems disclaims all liability arising from this information and its use. Use of Equipment Safety
Systems’ products as critical components in life support systems is not authorised except with express written
approval by Equipment Safety Systems. No licenses are conveyed, implicitly or otherwise, under any Equipment Safety
Systems intellectual property rights.
This is a class A product certified to AS/NZS CISPR 22:2006. In a domestic environment this product may
cause radio interference in which case the user may be required to take adequate measures.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Genie GEN-5 Series
Installation Manual
REV 2.0
24/09/2020
Model6253 OverWatch™Installation Manual
Document # DO001235
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Table of Contents
Preparation ...........................................................................................................................................5
Required Tools.................................................................................................................................5
Installation Time..............................................................................................................................5
Installation Instructions........................................................................................................................6
Operator Sensor................................................................................................................................6
Control Module................................................................................................................................9
Post Installation Configuration ..........................................................................................................17
Overview........................................................................................................................................17
Minimum system requirements......................................................................................................17
Wi-Fi Connection & Web Page Access.........................................................................................17
Machine Model Selection ..............................................................................................................18
Installation Test..............................................................................................................................19
Change Model Configuration.........................................................................................................20
System Settings..................................................................................................................................21
Default Settings..............................................................................................................................21
Polarity and Input Style..................................................................................................................23
Bypass............................................................................................................................................23
Connection Schematics –Typical Application..................................................................................24

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Genie GEN-5 Series
Installation Manual
REV 2.0
24/09/2020
Model6253 OverWatch™Installation Manual
Document # DO001235
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Preparation
Required Tools
The OverWatch™ has been designed to be fitted using basic workshop tools. Shown below is a list of tools required
to complete the installation
Item
Tool / Description
1
Electric Drill
2
Centre punch
3
Hammer
4
Side Cutters
5
Drill 3.2mm
6
Drill 5.0mm
7
Metric sockets or spanners
8
Needle nose pliers
9
Screw drivers
Installation Time
The suggested time required to install the OverWatch™ is as detailed below
Task
Estimated Time (Minutes)
Open the operator control box
1
Drilling of all mounting holes for the various components
13
Mechanical assembly
10
Electrical assembly
30
Post installation system tests
10
Close the operator control box
1
Total
65

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Genie GEN-5 Series
Installation Manual
REV 2.0
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Model6253 OverWatch™Installation Manual
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Installation Instructions
Operator Sensor
Step
Description
Diagram
1.
Drill two 5.0mm holes to
mount the operator sensor in
the position shown in the
diagram.
The sensor should be
mounted at an angle of 40
degrees.
Drill a 4.0mm hole for the P-
Clip installation.
2.
Mount the Operator Sensor in
the located position using the
supplied angled wedges,
sensor guard, M4 washers,
nuts and bolts.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
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Genie GEN-5 Series
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3.
Remove the bottom cover of
the joystick enclosure.
4.
Install the Operator Sensor
cable gland in the location
shown by drilling a 20mm
hole.
50.00mm

EQUIPMENT SAFETY SYSTEMS
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Genie GEN-5 Series
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5.
Route the operator sensor
cable as shown in the
diagram.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
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Genie GEN-5 Series
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Model6253 OverWatch™Installation Manual
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Control Module
Step
Description
Diagram
1.
To mount the ECU
module, drill the holes
shown in the diagram.
Use the supplied bolts and
nuts to mount the ECU
module to the inside of
the control box.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
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Genie GEN-5 Series
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2.
Wiring connections are
made by the OverWatch™
Harness AS001955.

EQUIPMENT SAFETY SYSTEMS
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3.
Ground Connection:
Solder the Black Ground
wire from the
OverWatch™ECU Harness
to the White wire
(Ground) from the main
connector.
4.
Power Connection:
Install the Red wire from
the OverWatch™ECU
harness to the E-stop
switch connector terminal
1.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Genie GEN-5 Series
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5.
Trigger Connection:
Locate the Orange wire
from the harness coming
from the joystick (14 pin
connector) and cut it in
half.
Solder the Green wire
from the OverWatch™
ECU harness to the
Orange wire on the side
that is coming from the
joystick.
Solder the Blue wire from
the OverWatch™ECU
harness onto the
connector side of the wire
that was cut.
6.
Joystick Connection:
Solder the Grey wire from
the OverWatch™ECU
harness onto the Yellow
wire coming from the
joystick.
7.
Remove the buzzer and
the E-Stop button to have
better access to the main
circuit board.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Genie GEN-5 Series
Installation Manual
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8.
Identify the pin locations
on the circuit board
shown in the image.
Detailed instructions on
soldering locations will be
displayed in the following
steps.
Carefully remove the
protective coating on the
circuit board to expose
the through hole push
button switch pads as
shown in the image. The
protective coating can be
removed by using a small
pick.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Genie GEN-5 Series
Installation Manual
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9.
Drive Select Connection:
Solder the Purple wire
from the OverWatch™
ECU harness to the pin
behind the Drive Select
button as shown in the
image.
10.
Elevate Select
Connection:
Solder the Orange wire
from the OverWatch™
ECU harness, to the pin
behind the Elevate Select
button as shown in the
image.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
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Genie GEN-5 Series
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11.
Horn Connection:
Solder the white horn
wires from the
OverWatch™ECU harness
to the pins shown in the
photo.

EQUIPMENT SAFETY SYSTEMS
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Genie GEN-5 Series
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12.
Use hot glue to cover the
soldered locations.
Use the 6.3mm P-clip
provided to secure the
wires as shown in photo.
13.
Connect the 8-Pin
connector from the
Operator Sensor and the
12-Pin connector from the
machine harness to the
control module.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Genie GEN-5 Series
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Model6253 OverWatch™Installation Manual
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Post Installation Configuration
Overview
After the OverWatch™ has been installed it must be configured with the parameters to suit the machine. Follow
the instructions below to configure the OverWatch™.
Minimum system requirements
Any smart phone, tablet or laptop that meets the following requirements:
•The device can connect to a Wi-Fi access point supporting 802.11 b/g/n (2.4GHz) protocol
•The device has an up to date web browser installed (2019 onwards). Firefox or Chrome are
recommended. Note: Microsoft Internet Explorer is not supported.
Wi-Fi Connection & Web Page Access
To enable the Wi-Fi connection on the OverWatch™ to complete the configuration follow the steps below.
1. Power down the platform control box with the ESTOP
2. Wait 10 seconds
3. Power up the platform control box with the ESTOP
4. While standing in the operator position, switch on the OverWatch™
5. As the welcome chime starts to play, cover the sensor. The LED will flash white then black to acknowledge.
6. Remove your hand from the sensor. The LED will flash white then black to acknowledge.
7. After covering then uncovering the sensor this way 2 more times, "Wi-Fi On" will be announced
8. On your Wi-Fi enabled device (laptop, tablet, smartphone, etc), show the available wireless networks
9. Select the wireless network (starts with “overwatch”) to connect to the OverWatch™
10. When prompted, enter the password “12345678”
11. Open your preferred web browser (Chrome, Firefox)
12. Enter the following into the address bar http://192.168.4.1 to open the OverWatch™ main page

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Genie GEN-5 Series
Installation Manual
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Model6253 OverWatch™Installation Manual
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Machine Model Selection
Follow the instructions below to configure the OverWatch™.
1. Select the Setup option
2. If there is a password field at the bottom of the page, follow the instructions in Change Model Configuration
to obtain the password and enter the password field
3. Select the EWP Model from the drop-down list and click Set
4. Click on Proceed to Test to begin the installation test
Genie Gen 5
Genie Gen 5
Genie Gen 5

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
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Genie GEN-5 Series
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Model6253 OverWatch™Installation Manual
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Installation Test
After the model configuration has been set or updated an Installation Test must be performed. This will ensure the
installation has been correctly performed and the OverWatch™is functioning correctly.
Follow the instructions on the web page to complete the Installation Test.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
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Genie GEN-5 Series
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Model6253 OverWatch™Installation Manual
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Change Model Configuration
To reconfigure the OverWatch™for a different model requires an authorisation password to be supplied by a
service manager. The authorisation password is generated from the EQSS website. The EQSS website requires a
login username and password. If you are a service manager and do not have a username and password, contact
EQSS to register. Follow the instructions below to obtain an authorisation password.
1. Open your preferred web and enter the following into the address bar http://www.eqss.com.au/overwatch
to open the Login page
2. Select Customer
3. Enter your username and password
4. Ask the service technician for the serial number shown on the Setup page or on the ECU module along with
the owner details of the EWP and complete the details form then click Generate Hash
5. Provide the 5-digit hash password to the service technician
Genie Gen 5