eqss OverWatch Dingli S03-ACE Series User manual

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Dingli S03-ACE
Installation Manual
REV 1.1
01/08/2023
Model6253 OverWatch™Installation Manual
Document # DO001616
EQSS Model6253 –OverWatch™
Dingli S03-ACE Series
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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]
Dingli S03-ACE
Installation Manual
REV1.1
01/08/2023
Model6253 OverWatch™Installation Manual
Document # DO001616
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AUTHORS:
Kieren Grogan, Bhavani Kacharapu
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
Dingli S03-ACE series scissor lift.
PRODUCT NAME:
Model6253 OverWatch™Operator Detection System
REFERENCE DOCUMENTS:
DO0001195 Model6253 OverWatch™User Manual
CURRENT DOCUMENT REVISION:
1.1
REVISION INFORMATION:
•1.0 Initial document creation for installation on a Dingli S03-ACE series
•1.1 Update of installation manual and instructions for plug and play installation.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Dingli S03-ACE
Installation Manual
REV1.1
01/08/2023
Model6253 OverWatch™Installation Manual
Document # DO001616
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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convenience and may be superseded by updates.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]
Dingli S03-ACE
Installation Manual
REV1.1
01/08/2023
Model6253 OverWatch™Installation Manual
Document # DO001616
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Table of Contents
Preparation.........................................................................................................................................................................5
Required Tools ...............................................................................................................................................................5
Installation Time ............................................................................................................................................................ 5
Installation Instructions......................................................................................................................................................6
Operator Sensor............................................................................................................................................................. 6
Control Module............................................................................................................................................................ 10
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
Set Date and Time........................................................................................................................................................ 19
System Settings.................................................................................................................................................................20
Polarity and Input Style................................................................................................................................................ 22
Tilt detection................................................................................................................................................................22
AS002208 Plug and Play Harness Drawing .......................................................................................................................23

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Dingli S03-ACE
Installation Manual
REV1.1
01/08/2023
Model6253 OverWatch™Installation Manual
Document # DO001616
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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
Step Drill –up to 20mm
8
Metric sockets or spanners
9
Needle nose pliers
10
Screw drivers
Installation Time
The suggested time required to install the OverWatch™is as detailed below.
Task
Estimated Time (Minutes)
Drilling of all mounting holes for the various components
10
Mechanical assembly
10
Electrical assembly
15
Post installation system tests
10
Total
45

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Dingli S03-ACE
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Model6253 OverWatch™Installation Manual
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Installation Instructions
Operator Sensor
Step
Description
Diagram
1. 1
.
Remove the Joystick
controller from the metal
housing.
Note: If the control box has
an existing Dingli Ultrasonic
Sensor fitted. This needs to
be removed, and the scissor
lift (Dingli ECU) must be
configured to disable the
ultrasonic sensor option.
Please consult Dingli support
for this procedure.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
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2. 2
.
Drill two 5mm holes to mount
the operator sensor in the
position as shown in the
image.
The sensor should be
mounted at an angle of 40
degrees from the vertical axis.
Distance is measured from
the vertical and horizontal
edge of the metal cover.
Hole #1- 123mm from the
bottom vertical edge and
60mm from the horizontal
edge.
Hole #2- 71mm from the top
vertical flat edge and 22mm
from the horizontal edge.
The distance between two
holes is 61mm.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
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3. 3
.
Drill one 5mm hole to mount
a P-clip on the metal housing
as shown in the image.
4. 4
.
Mount the operator sensor to
the metal enclosure by using
the sensor guard, positioning
wedges, M4 washers, and
bolts.
The orientation of the wedge
blocks is critical for the
correct positioning of the
operator sensor, make sure
that the sensor is angled,
such that it is twisted
outwards from the joystick
controller.

EQUIPMENT SAFETY SYSTEMS
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5.
Route the operator sensor
cable as shown in the
diagram. Use a P-Clip to
secure the cable to the metal
box.

EQUIPMENT SAFETY SYSTEMS
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Control Module
Step
Description
Diagram
1.
Remove the bottom
plastic cover from the
Joystick to expose the
inside wiring and
electronics.
2.
Remove the Buzzer, E-
Stop, Ultrasonic sensor
connector, and the
controller circuit board
from the joystick
enclosure.
3.
Drill a 20mm hole to run
the operator sensor M20
gland into the plastic
joystick enclosure. The
position of the hole is
detailed as in the image. It
is recommended to use a
step drill for this hole, as it
is running through plastic
material.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Dingli S03-ACE
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4.
Use a fine metal pick to
clean the area shown in
the red circles on the
adjacent image to allow
access to the pins. This
process removes the
conformal coating on the
PCB and allows electrical
access to the drive,
elevate and horn
connections on the circuit
board.
5.
Use a fine pair of side
cutters to trim down the
signal pins. These
connections must be
trimmed to be as flat as
possible so that the spring
pin from the plug and play
board can make suitable
contact with the terminal.
6.
Trim down the Elevate
signal pin. This pin is
located as displayed in the
image. Using a fine pair of
side cutters make sure
that the pin is trimmed
flat.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Dingli S03-ACE
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7.
Trim down the Drive
signal pin. This pin is
located as displayed in the
adjacent image. Using a
fine pair of side cutters
make sure that the pin is
trimmed flat.
8.
Trim down the two Horn
signal pins. These pins are
located as displayed in the
adjacent image. Using a
fine pair of side cutters
make sure that the pins
are trimmed flat.
9.
Wiring connections are
made by the AS002208
Plug and Play Loom.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
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Dingli S03-ACE
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10.
Mount the Overwatch
circuit board on top of
joystick circuit board by
using the provided screws
and spacers in the kit.
Make sure that the board
is sitting in the correct
position and the spring
pins are contacting the
joystick circuit board
signal pins.
11.
Install the Overwatch
joystick connectors in
between the joystick and
the control box circuit
board.
Visually check that all pins
from the original joystick
connector have a
corresponding cable on
the Overwatch harness.
Reconnect the other
connectors, which were
disconnected in step 1 to
the control box circuit
board.
12.
At the back of the E-stop,
install the OverWatch red
power cable to terminal 1
of the E-Stop.
Note: This red power wire
might need to be changed
to terminal 2 if the
Overwatch is powered
with the E-stop pushed in.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
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13.
Mount the OverWatch
ECU inside the joystick
control box, by using the
adhesive velcro tape.
Run the operator sensor
cable through the
predrilled 20mm hole and
secure the cable gland.
Connect the 8-pin
connector from the
operator sensor and the
12-pin connector from the
overwatch loom to the
ECU.
14.
Re-assemble the joystick
control box and mount to
the metal shroud.
Make sure the operator
sensor cable runs clear to
the joystick enclosure and
tighten the M20 gland to
seal the cable entry point.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Dingli S03-ACE
Installation Manual
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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
•The device has an up to date web browser installed (2019 onwards). Firefox or Chrome 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 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, Safari, Edge)
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]
Dingli S03-ACE
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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

EQUIPMENT SAFETY SYSTEMS
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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
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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 don’t 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

EQUIPMENT SAFETY SYSTEMS
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Set Date and Time
Date and time should be set accordingly. The date and time can be set on the log page. This page allows
adjustment of the system’s real time clock and calendar if required. Please note, any time or date change is logged
and recorded.

EQUIPMENT SAFETY SYSTEMS
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System Settings
See the sections below for details on each of the Dingli S03-ACE Series OverWatch™system default settings.
Setting Name
Description
Value
Deltaseek
This specifies which of the previous lidar reading to
compare against the current one to calculate the
speed.
20
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. in
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
max_safe_velocity_neutral
This is the velocity threshold for the cutout in cm/s. in
neutral mode.
60
max_safe_displacement_neutral
This is the maximum permitted distance in cm the
operator may be away from the calibration position in
neutral mode.
40
Fwddispadj
The coefficient to apply to the displacement when the
displacement is toward the sensor.
-0.55
Fwdveloadj
The coefficient to apply to the velocity when the
displacement is toward the sensor.
-1
zone_obstruction
The lidar is considered obstructed if the lidar sensor
reading is below this.
5
zone_minimum
Any lidar reading below this will trigger a cutout with
the message: “Operator Zone”
15
zone_maximum
Any lidar reading above this will trigger a cutout with
the message: “Operator Zone”
120
horn_count_max
The number of times the horn will sound when
alerting the operator if the trigger remains pressed
during the cutout.
2
horn_time_ms
The amount of time in milliseconds each individual
horn should play.
200
adc_elevate_threshold
For the elevate ADC input, a reading below this
indicates the EWP is in elevate mode.
500
adc_drive_threshold
For the drive ADC input, a reading below this indicates
the EWP is in drive mode.
500
adc_trigger_threshold
For the trigger ADC input, a reading below this
indicates the trigger is pressed.
100