eqss OverWatch Skyjack SJ12 User manual

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Skyjack SJ12/16/20 Black Box
Installation Manual
REV 1.5
18/01/2024
Model6253 OverWatch™Installation Manual
Document # DO001484
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EQSS Model6253 –OverWatch™
Skyjack SJ12 / SJ16 / SJ20 Black Box
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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 SJ12/16/20 Black Box
Installation Manual
REV 1.5
18/01/2024
Model6253 OverWatch™Installation Manual
Document # DO001484
|2 of 21|
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
Skyjack SJ12/16/20 Black Box Vertical Mast
PRODUCT NAME:
Model6253 OverWatch Operator Detection System
REFERENCE DOCUMENTS:
DO0001195 Model6253 OverWatch User Manual
CURRENT DOCUMENT REVISION:
1.5
REVISION INFORMATION:
•1.1 Initial Document Creation for installation on a JS12/16/20 Vertical Mast (Black Box)
•1.2 Update of images and revision of wire harness to use new relay connectors
•1.3 Update of tables with part numbers
•1.4 Update on rapid harness assembly number
•1.5 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 SJ12/16/20 Black Box
Installation Manual
REV 1.5
18/01/2024
Model6253 OverWatch™Installation Manual
Document # DO001484
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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convenience and may be superseded by updates.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]
Skyjack SJ12/16/20 Black Box
Installation Manual
REV 1.5
18/01/2024
Model6253 OverWatch™Installation Manual
Document # DO001484
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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 .........................................................................................................................................14
Overview...................................................................................................................................................................... 14
Minimum system requirements .................................................................................................................................. 14
Wi-Fi Connection & Web Page Access .........................................................................................................................14
Machine Model Selection ............................................................................................................................................15
Installation Test............................................................................................................................................................ 16
Change Model Configuration....................................................................................................................................... 17
System Settings.................................................................................................................................................................18
Default Parameters......................................................................................................................................................18
Polarity and Input Style................................................................................................................................................19
Harness Drawing AS001924.............................................................................................................................................. 20
Replacement Parts............................................................................................................................................................ 21

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Skyjack SJ12/16/20 Black Box
Installation Manual
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Model6253 OverWatch™Installation Manual
Document # DO001484
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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 5.2mm
6
Drill 6.5mm
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
10
Post installation system tests
10
Close the operator control box
1
Total
45

EQUIPMENT SAFETY SYSTEMS
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P: [phone] E: [e-mail]
Skyjack SJ12/16/20 Black Box
Installation Manual
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Model6253 OverWatch™Installation Manual
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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.
Remove the 6 bolts located at the
bottom of the joystick enclosure.
2.
Drill five X 5.2mm holes in the
locations as shown in the image.

EQUIPMENT SAFETY SYSTEMS
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3.
Sensor Mounting Guard V1
(ME001794)
Install the Operator Sensor onto the
supplied mounting plate as shown in
the diagram.
The wedge block must be orientated
such that the sensor twists away from
the joystick / control box. So that
when the operator is standing in
position the sensor is pointing towards
the centreline of the operator’s body.
4.
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, so
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.

EQUIPMENT SAFETY SYSTEMS
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Skyjack SJ12/16/20 Black Box
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5.
Drill two 6.5mm holes through the
plastic controller housing to make
room for the M5 nuts on the back of
the ME001080 operator sensor
mounting plate.
These holes are required when using
the Sensor Guard V2.
6.
Mount the operator sensor mounting
plate to the side of the control box
using the nuts, bolts, and washes, as
shown in the image.

EQUIPMENT SAFETY SYSTEMS
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7.
Install the cable gland and run the
operator sensor cable as shown in the
image.
Use a P-clip to secure the operator
sensor cable.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Skyjack SJ12/16/20 Black Box
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Control Module
Step
Description
Diagram
1.
Drill two 4.2mm holes to mount the ECU as
shown in the image.
2.
Mount the ECU module using the bolts,
nuts, and washers.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Skyjack SJ12/16/20 Black Box
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3.
Wiring connections are made with the
AS001924 harness.
4.
Joystick Connection:
Disconnect the 9-Pin connector from the
joystick and install the OverWatch harness
in series with the connectors.
5.
Elevate & Drive Connection:
At the back of the Drive/Elevate switch,
locate the three terminals that are not
used.
1.Using the M3 screw
provided, install the violet wire from the
OverWatch harness to position 10 on the
switch block.
2. Using the M3 screw
provided, install the install the red wire
from the OverWatch to position 11 on the
switch block.
3. Using the M3 screw
provided, install the install the orange wire
to position 12 on the switch block.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Skyjack SJ12/16/20 Black Box
Installation Manual
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6.
Horn Connection:
At the back of the horn push button, install
one of the OverWatch white wires to the
terminal 3. Install the other white wire to
the terminal 2 on the E-Stop switch.
7.
Connect the 8-pin connector from the
operator sensor, and the 12-pin connector
from the harness into the ECU.

EQUIPMENT SAFETY SYSTEMS
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8.
Reassemble the control box by suing the 6
bolts taken out earlier and secure the
operator sensor cable by using a cable tie.

EQUIPMENT SAFETY SYSTEMS
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P: [phone] E: [e-mail]
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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 SJ12/16/20 Black Box
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]
Skyjack SJ12/16/20 Black Box
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]
Skyjack SJ12/16/20 Black Box
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]
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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.
2200
adc_drive_threshold
Threshold value for the drive ADC input.
2200
adc_trigger_threshold
Threshold value for the trigger ADC input.
2000
adc_joystick_fwd_threshold
Forward threshold value for the joystick ADC input.
1400
adc_joystick_bwd_threshold
Backward threshold value for the joystick ADC input.
1500
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
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Skyjack SJ12/16/20 Black Box
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Polarity and Input Style
The table below describes each setting
Setting Name
Description
Default
joystick_drive_forward
Direction of joystick to move EWP forward
forward
joystick_elevate_upward
Direction of joystick to move EWP upward
forward
elevate_polarity
Direction of signal logic
high
drive_polarity
Direction of signal logic
high
trigger_polarity
Direction of signal logic
high
joystick_polarity
Direction of signal logic
low
driving_state_input
Direct, timer based or separate joysticks
direct

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Skyjack SJ12/16/20 Black Box
Installation Manual
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Harness Drawing AS001924