eqss OverWatch 6253 User manual

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Skyjack Mid-Size RT Scissors
Silver Control Box
Installation Manual
REV 1.4
18/01/2024
Model6253 OverWatch™Installation Manual
Document # DO001300
|1 of 22|
EQSS Model6253 –OverWatch™
Mid-Size RT Scissors, Silver Control Box,
Installation Manual
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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]
Skyjack Mid-Size RT Scissors
Silver Control Box
Installation Manual
REV 1.4
18/01/2024
Model6253 OverWatch™Installation Manual
Document # DO001300
|2 of 22|
AUTHORS:
Kieren Grogan
AUTHORISED BY:
Kieren Grogan
CHECKED BY:
Andrew Donegan
DOCUMENT ABSTRACT:
This Installation Manual details the manufacturer’s installation instructions for installing the Model6253 OverWatch on a
Skyjack Mid-Size Rough Terrain Scissor Lift with a Sliver control box
PRODUCT NAME:
Model6253 OverWatch Operator Detection System
REFERENCE DOCUMENTS:
DO0001195 Model6253 OverWatch User Manual
CURRENT DOCUMENT REVISION:
1.4
REVISION INFORMATION:
•1.1 Initial Document Creation for installation on a Skyjack SJIII RT
•1.2 Update of wiring installation procedures
•1.3 Update of document name to define RT scissors with a sliver control box
•1.4 Inclusion of sensor guard V2 and update of machine configuration instructions

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Skyjack Mid-Size RT Scissors
Silver Control Box
Installation Manual
REV 1.4
18/01/2024
Model6253 OverWatch™Installation Manual
Document # DO001300
|3 of 22|
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convenience and may be superseded by updates.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]
Skyjack Mid-Size RT Scissors
Silver Control Box
Installation Manual
REV 1.4
18/01/2024
Model6253 OverWatch™Installation Manual
Document # DO001300
|4 of 22|
Table of Contents
Preparation.........................................................................................................................................................................5
Required Tools ............................................................................................................................................................... 5
Installation Time ............................................................................................................................................................ 5
Installation Instructions...................................................................................................................................................... 6
Operator Sensor............................................................................................................................................................. 6
Control Module..............................................................................................................................................................9
Post Installation Configuration .........................................................................................................................................15
Overview...................................................................................................................................................................... 15
Minimum system requirements .................................................................................................................................. 15
Wi-Fi Connection & Web Page Access .........................................................................................................................15
Machine Model Selection ............................................................................................................................................16
Installation Test............................................................................................................................................................ 17
Change Model Configuration....................................................................................................................................... 18
System Settings.................................................................................................................................................................19
Default Parameters......................................................................................................................................................19
Polarity and Input Style................................................................................................................................................20
Harness Drawing AS001987.............................................................................................................................................. 21
Replacement Parts............................................................................................................................................................ 22

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Skyjack Mid-Size RT Scissors
Silver Control Box
Installation Manual
REV 1.4
18/01/2024
Model6253 OverWatch™Installation Manual
Document # DO001300
|5 of 22|
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 5.0mm
6
Metric sockets or spanners
7
Needle nose pliers
8
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
10
Post installation system tests
10
Close the operator control box
1
Total
45

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Skyjack Mid-Size RT Scissors
Silver Control Box
Installation Manual
REV 1.4
18/01/2024
Model6253 OverWatch™Installation Manual
Document # DO001300
|6 of 22|
Installation Instructions
If any decals are damaged during the installation process or if any decals are obstructed following the installation,
they should be replaced accordingly.
Operator Sensor
Step
Description
Diagram
1.
Separate the joystick from
the enclosure and drill
two 5.2mm holes to
mount the operator
sensor in the position
shown in the diagram.
The distance between the
two holes is 61mm.
The angle between the
two holes is 45-degrees
measured from the
vertical of the metal
enclosure.
2.
Sensor Mounting Guard
V1 (ME001794)
Mount the module in the
located position using the
wedges, sensor guard,
bolts, and washers.
The 7.5-degree angled
wedge blocks must be
positioned in the correct
orientation such that the
sensor is twisting
outwards from the
joystick.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Skyjack Mid-Size RT Scissors
Silver Control Box
Installation Manual
REV 1.4
18/01/2024
Model6253 OverWatch™Installation Manual
Document # DO001300
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3.
Sensor Mounting Guard
V2 (AS002326)
This bracket (AS002326)
supersedes the original V1
design. Attach the bracket
in position using the M5
nuts and washers. Make
sure that the sensor is on
the 7.5-degree angle,
such that it is twisted
outwards from the
joystick controller.
The 7.5-degree twist is
achieved by rotating the
sensor inside the
assembly and using the
bolt hole as show in the
image.
4.
If the operator control box
does not have metal side
cover use the supplied
bracket ME001813 and
M4 nuts and bolts to
create a support structure
for the operator sensor.
Such that the operator is
mounted at an angle of 40
degrees.
Use an existing hole 1 on
the control box and drill
hole 2 to mount the
bracket as shown in the
image.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Skyjack Mid-Size RT Scissors
Silver Control Box
Installation Manual
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Document # DO001300
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5.
Make sure the operator
sensor cable runs clear to
the joystick enclosure and
tighten the M20 gland to
seal the cable entry point
as shown in the image.
6.
Drill a 20mm hole to run
the operator sensor M20
cable gland and drill two
5.2mm holes for the cable
gland guard.
7.
Install the cable gland in
the location by using the
M4 screws, nuts and
washers as shown in the
image.
Use two P-clips to secure
the operator sensor cable.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Skyjack Mid-Size RT Scissors
Silver Control Box
Installation Manual
REV 1.4
18/01/2024
Model6253 OverWatch™Installation Manual
Document # DO001300
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Control Module
Step
Description
Diagram
1.
Drill two 5.2mm holes to
mount the ECU as shown
in the image.
2.
Mount the ECU module by
using the bolts, and
washers.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Skyjack Mid-Size RT Scissors
Silver Control Box
Installation Manual
REV 1.4
18/01/2024
Model6253 OverWatch™Installation Manual
Document # DO001300
|10 of 22|
3.
Wiring connections are
made with the AS001987
harness.
4.
Joystick Connection:
Disconnect the 9-Pin
connector from the
joystick and install the
OverWatch harness in
series.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Skyjack Mid-Size RT Scissors
Silver Control Box
Installation Manual
REV 1.4
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Model6253 OverWatch™Installation Manual
Document # DO001300
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5.
Horn Connection:
At the back of the horn
push button, install the
OverWatch white wires to
the terminals 3 and 4 as
shown in the image.
6.
Elevate Connection:
At the back of the
Drive/Elevate switch:
1. Identify the switch
block with the power wire
ID 08.
2. Install the orange wire
from the OverWatch
harness to the switch
block terminal as shown in
image.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Skyjack Mid-Size RT Scissors
Silver Control Box
Installation Manual
REV 1.4
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Model6253 OverWatch™Installation Manual
Document # DO001300
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7.
Drive Connection:
At the back of the
Drive/Elevate switch:
On the same switch block
with the power wire ID 08,
install the purple wire
from the OverWatch
harness to the switch
block terminal as shown in
image.
8.
Ground Connection:
Install the black wire from
the OverWatch harness
with the wire ID 02 on the
switch block as shown in
the image.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Skyjack Mid-Size RT Scissors
Silver Control Box
Installation Manual
REV 1.4
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Model6253 OverWatch™Installation Manual
Document # DO001300
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9.
Remove the screws on the
front plate which secure
the joystick block in place.
10.
Trigger Connection:
Cut the white/yellow wire
from the joystick.
Solder the green wire
from the OverWatch
harness to the
white/yellow wire from
the joystick side.
Solder the other end of
the white/yellow wire
from the circuit side to the
blue wire from the
OverWatch harness.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Skyjack Mid-Size RT Scissors
Silver Control Box
Installation Manual
REV 1.4
18/01/2024
Model6253 OverWatch™Installation Manual
Document # DO001300
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11.
Connect the 8-Pin
connector from the
operator sensor and the
12-Pin connector from the
OverWatch harness, into
the ECU.
Re-assemble the joystick
back into the enclosure.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Skyjack Mid-Size RT Scissors
Silver Control Box
Installation Manual
REV 1.4
18/01/2024
Model6253 OverWatch™Installation Manual
Document # DO001300
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Post Installation Configuration
Overview
After the system 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
•The device has an up to date web browser installed. Firefox, Chrome or Safari are recommended.
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 5 seconds
3. Power up the platform control box with the ESTOP
4. While standing in front of the operator sensor, 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, Safari)
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]
Skyjack Mid-Size RT Scissors
Silver Control Box
Installation Manual
REV 1.4
18/01/2024
Model6253 OverWatch™Installation Manual
Document # DO001300
|16 of 22|
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

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Skyjack Mid-Size RT Scissors
Silver Control Box
Installation Manual
REV 1.4
18/01/2024
Model6253 OverWatch™Installation Manual
Document # DO001300
|17 of 22|
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
P: [phone] E: [e-mail]
Skyjack Mid-Size RT Scissors
Silver Control Box
Installation Manual
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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. The authorisation
password is generated from the EQSS website. The EQSS website requires a login username and password, contact
EQSS for these details.
Follow the instructions below to obtain an authorisation password. It is important to note that each ECU has a
unique serial number and a unique password.
1. Open your web and enter the following into the address bar http://www.eqss.com.au/overwatch to open the
Login page
2. Enter your username and password
3. Enter the EUC serial number which is shown on the setup page or on the ECU serial number sticker, also
enter the owner and model details of the EWP and then click Generate Hash
4. The generated Hash code or password can be used to change the model configuration.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Skyjack Mid-Size RT Scissors
Silver Control Box
Installation Manual
REV 1.4
18/01/2024
Model6253 OverWatch™Installation Manual
Document # DO001300
|19 of 22|
System Settings
Default Parameters
The OverWatch is configurated with the following default parameters.
Setting Name
Description
Default
max_safe_velocity
This is the velocity threshold for the cutout in cm/s for drive
mode.
95
max_safe_displacement
This is the maximum permitted distance in cm the operator
may be away from the calibration position in drive mode.
50
max_safe_velocity_elevate
This is the velocity threshold for the cutout in cm/s for elevate
mode.
75
max_safe_displacement_elevate
This is the maximum permitted distance in cm the operator
may be away from the calibration position in elevate mode.
50
fwddispadj
The proportion of the calibration distance toward the sensor
permitted to the operator.
0.7
fwdveloadj
The coefficient to apply to the maximum allowable velocity
when the movement of the operator is toward the sensor.
1.0
zone_obstruction
If the lidar sensor reading is below this, the lidar is considered
to be obstructed (with paint or thick coat of dust) and the
system is cutout until the obstruction is cleared.
5
zone_minimum
The minimum calibration distance. If the operator is closer to
the sensor than this “operator zone” will be announced.
17
zone_maximum
The maximum calibration distance. If the operator is further
from the sensor than this “operator zone” will be announced.
120
adc_elevate_threshold
Threshold value for the elevate ADC input.
900
adc_drive_threshold
Threshold value for the drive ADC input.
900
adc_trigger_threshold
Threshold value for the trigger ADC input.
900
adc_joystick_fwd_threshold
Forward threshold value for the joystick ADC input.
100
adc_joystick_bwd_threshold
Backward threshold value for the joystick ADC input.
200
throttle_time
Period after the trigger is pressed (ms) during which initial
velocity reading is computed.
500
driving_state_timeout
Mode selection switch timeout (ms)
7000

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Skyjack Mid-Size RT Scissors
Silver Control Box
Installation Manual
REV 1.4
18/01/2024
Model6253 OverWatch™Installation Manual
Document # DO001300
|20 of 22|
Polarity and Input Style
The table below describes each setting
Setting Name
Description
Default
joystick_drive_forward
Direction of joystick to move machine forward
forward
joystick_elevate_upward
Direction of joystick to move machine upwards
forward
elevate_polarity
Direction of signal logic
high
drive_polarity
Direction of signal logic
high
tigger_polarity
Direction of signal logic
high
joystick_polarity
Direction of signal logic
low
driving_state_input
Direct or timer based
direct