eqss OverWatch Genie GR-12 User manual

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Genie GR-12/15/20
Installation Manual
REV 1.1
14/08/2023
Model6253 OverWatch™Installation Manual
Document # DO001620
EQSS Model6253 –OverWatch™
Genie GR-12/15/20
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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 GR-12/15/20
Installation Manual
REV 1.1
14/08/2023
Model6253 OverWatch™Installation Manual
Document # DO001620
|2 of 24|
AUTHORS:
Kieren Grogan, Bhavani Kacharapu
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
Genie GR-12/15/20 Series vertical mast with mode selection.
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 Genie GR-12/15/20 Series control box with mode selection
functionality. Mode selection refers to the indoor and outdoor mode.
•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]
Genie GR-12/15/20
Installation Manual
REV 1.1
14/08/2023
Model6253 OverWatch™Installation Manual
Document # DO001620
|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convenience and may be superseded by updates.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 GR-12/15/20
Installation Manual
REV 1.1
14/08/2023
Model6253 OverWatch™Installation Manual
Document # DO001620
|4 of 24|
Table of Contents
Preparation.........................................................................................................................................................................5
Required Tools ...............................................................................................................................................................5
Installation Time ............................................................................................................................................................ 5
Installation Instructions......................................................................................................................................................6
Operator Sensor............................................................................................................................................................. 6
Control Module..............................................................................................................................................................9
Post Installation Configuration .........................................................................................................................................16
Overview...................................................................................................................................................................... 16
Minimum system requirements .................................................................................................................................. 16
Wi-Fi Connection & Web Page Access .........................................................................................................................16
Machine Model Selection ............................................................................................................................................17
Installation Test............................................................................................................................................................ 18
Change Model Configuration.......................................................................................................................................19
Set Date and Time........................................................................................................................................................ 20
System Settings.................................................................................................................................................................21
Polarity and Input Style................................................................................................................................................ 23
AS002240 Harness Drawing..............................................................................................................................................24

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Genie GR-12/15/20
Installation Manual
REV 1.1
14/08/2023
Model6253 OverWatch™Installation Manual
Document # DO001620
|5 of 24|
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
Step Drill (5 –30mm)
7
Metric sockets or spanners
8
Needle nose pliers
9
Screw drivers
Installation Time
The suggested time required to install the OverWatch™on the Genie GR12/15/20 is as detailed below.
Task
Estimated Time (Minutes)
Drilling of all mounting holes for the various components
10
Mechanical assembly
5
Electrical assembly
20
Post installation system tests
10
Total
45

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Genie GR-12/15/20
Installation Manual
REV 1.1
14/08/2023
Model6253 OverWatch™Installation Manual
Document # DO001620
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Installation Instructions
Operator Sensor
Step
Description
Diagram
1.
Remove the Joystick
controller from the metal
housing.
2.
Drill two 5mm holes to
mount the operator sensor
in the position as shown in
the image.
Distance is measured from
the vertical and horizontal
curve edge of the metal
enclosure.
Hole #1- 25mm from the
vertical curve edge and
32mm from the horizontal
curve edge.
Hole #2- 68mm from the
vertical curve edge and
77mm from the horizontal
curve edge.
The sensor should be
mounted at an angle of 40
degrees from the vertical
when the control box is
mounted on the machine.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Genie GR-12/15/20
Installation Manual
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Model6253 OverWatch™Installation Manual
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3.
Drill two 5mm holes for the
P-clip installation at the rear
and side of the controller
box as shown in the image.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Genie GR-12/15/20
Installation Manual
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Model6253 OverWatch™Installation Manual
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4.
Mount the operator sensor
in the 40-degree position by
using the positioning
wedges, sensor guard, M4
washers, nuts, 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.
5.
Route the operator sensor
cable as shown in the image.
Use P-clips to secure the
cable to the metal
enclosure.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Genie GR-12/15/20
Installation Manual
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Model6253 OverWatch™Installation Manual
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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.
Remove the buzzer, E-
stop, and the circuit
board from the joystick
enclosure.
2.
Drill a 20mm hole to run
the operator sensor M20
gland into the joystick
enclosure. The position
of the hole is detailed as
in the image. It is
recommended to use a
step drill for this hole.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Genie GR-12/15/20
Installation Manual
REV 1.1
14/08/2023
Model6253 OverWatch™Installation Manual
Document # DO001620
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3.
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, horn and
mode selection
connections on the
joystick circuit board.
4.
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 pins from the
Overwatch plug and play
board can make suitable
contact.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Genie GR-12/15/20
Installation Manual
REV 1.1
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Model6253 OverWatch™Installation Manual
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5.
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.
6. 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.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Genie GR-12/15/20
Installation Manual
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Model6253 OverWatch™Installation Manual
Document # DO001620
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7.
Trim down the Mode
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.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Genie GR-12/15/20
Installation Manual
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Model6253 OverWatch™Installation Manual
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9.
Wiring connections are
made by the AS002240
harness.
Use the following
hardware:
4 x 6.4mm spacers
4 x G4x19mm screws
These hardware
components are critical
and must be used to
space the daughter
board above the Genie
joystick circuit board.
10.
Mount the daughter
board on top of joystick
circuit board by using
the provided screws and
spacers in the kit. It is
critical that the white
plastic spacers are used
in each location.
These spacers position
the board at the correct
vertical height so that
the spring pins make
correct electrical
contact.
Make sure that the
board is sitting in the
correct position and the
spring pins are
contacting the joystick
circuit board signal pins.
Use the cut-outs next to
each spring pin to
inspect that the contact
is aligned with the
joystick board contact
points.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Genie GR-12/15/20
Installation Manual
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Model6253 OverWatch™Installation Manual
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11.
Install the harness
joystick connectors in
between the joystick and
the 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 2 of
the E-stop.
Note: This cable might
need to be changed to
terminal 1 if the
Overwatch is powered
with the E-stop pushed
in.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Genie GR-12/15/20
Installation Manual
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Model6253 OverWatch™Installation Manual
Document # DO001620
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13.
Mount the OverWatch
ECU inside control box,
the ECU is mounted on
the right hand inside
wall 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 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]
Genie GR-12/15/20
Installation Manual
REV 1.1
14/08/2023
Model6253 OverWatch™Installation Manual
Document # DO001620
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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 (2021 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]
Genie GR-12/15/20
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

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Genie GR-12/15/20
Installation Manual
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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
P: [phone] E: [e-mail]
Genie GR-12/15/20
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 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
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Genie GR-12/15/20
Installation Manual
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14/08/2023
Model6253 OverWatch™Installation Manual
Document # DO001620
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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.