eqss JLG ES Series User manual

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
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JLG ES Series
Installation Manual
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Model6253 OverWatch™Installation Manual
Document # DO001203
EQSS Model6253 –OverWatch™
JLG ES 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]
JLG ES Series
Installation Manual
REV 1.4
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Model6253 OverWatch™Installation Manual
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AUTHORS:
Kieren Grogan, Truong Bui
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 JLG
ES Series Scissor Lift using the plug and play loom.
PRODUCT NAME:
Model6253 OverWatch™ Operator Detection System
REFERENCE DOCUMENTS:
DO0001195 Model6253 OverWatch™ User Manual
CURRENT DOCUMENT REVISION:
1.4
REVISION INFORMATION:
•1.0 Initial Document Creation for system installation on a JLG ES Series Scissor Lift
•1.1 Update of wire connection and sensor mounting instructions
•1.2 Update of schematic
•1.3 Update to be suitable with quick connect harness installation.
•1.4 Update on installation procedures to use Plug and Play loom

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
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JLG ES Series
Installation Manual
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Model6253 OverWatch™Installation Manual
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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convenience and may be superseded by updates.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
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JLG ES Series
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Model6253 OverWatch™Installation Manual
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Table of Contents
Preparation.........................................................................................................................................................................5
Required Tools ...............................................................................................................................................................5
Installation Time ............................................................................................................................................................ 5
Installation Instructions......................................................................................................................................................6
Operator Sensor............................................................................................................................................................. 6
Control Module..............................................................................................................................................................8
Post Installation Configuration .........................................................................................................................................13
Overview...................................................................................................................................................................... 13
Minimum system requirements .................................................................................................................................. 13
Wi-Fi Connection & Web Page Access ......................................................................................................................... 13
Machine Model Selection ............................................................................................................................................14
Installation Test............................................................................................................................................................ 15
Change Model Configuration.......................................................................................................................................16
System Settings.................................................................................................................................................................17
Default Settings............................................................................................................................................................17
Polarity and Input Style................................................................................................................................................ 19
Bypass .......................................................................................................................................................................... 19
Date and Time..............................................................................................................................................................19
Connection Schematics.....................................................................................................................................................20

EQUIPMENT SAFETY SYSTEMS
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JLG ES Series
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Model6253 OverWatch™Installation Manual
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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
5
Drilling of all mounting holes for the various components
15
Mechanical assembly
10
Electrical assembly
5
Post installation system tests
10
Close the operator control box
5
Total
50

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Installation Instructions
Operator Sensor
Step
Description
Diagram
1.
Mount the operator
sensor to the supplied
bracket, using the
supplied M4 washers
and security bolts, and
position the bracket in
the location shown in
the image.
When the sensor is
mounted on narrow
deck machines the
sensor should twist
towards the joystick. The
idea is to make sure that
the sensor is pointing
towards the operators
body centreline.
2.
Mount the module in the
located position using
the supplied M4
washers, nuts and
security bolts.

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Step
Description
Diagram
3.
Remove the outer
enclosure.
Install the supplied M20
cable glands in the
location shown in the
image and feed the wire
from the operator
sensor into the
enclosure.

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Control Module
Step
Description
Diagram
1.
Wiring connections are
made by the Plug and Play
loom AS001937.
2.
The following connections
will need to be done in the
bottom module.

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Step
Description
Diagram
3.
Joystick and power:
Disconnect the 9-pin
connector from the JLG
joystick and install the
OverWatch™ Harness in
series.
4.
Buzzer:
At the back the buzzer,
disconnect the orange cable
on the Negative side and
install the OverWatch™
harness white cable.

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Step
Description
Diagram
5.
Install the OverWatch™ ECU
module in the location
shown in the image and
neatly manage the cables.
Making sure the joystick
connectors are positioned
as shown.
6.
The following connections
will need to be done in the
top module.

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Step
Description
Diagram
7.
Install the M20 cable gland
in the top unit of the control
box in the location shown.
8.
Run the 2-core upper panel
cable from the bottom unit
to the top unit, through the
two M20 glands installed.

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Step
Description
Diagram
9.
Drive Select and Elevate
Select piggyback:
At the back the
Drive/Elevate switch:
Disconnect the existing
black Molex 3 pin connector
and install the Drive/Elevate
Select piggyback cable in
between. Refer to the photo
shown on the right.

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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

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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

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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.

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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

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System Settings
Default Settings
See the sections below for details on each of the JLG ES Series OverWatch™default system settings.
Setting Name
Description
Default
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.
100
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.
80
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.
-0.8
fwdveladj
The coefficient to apply to the velocity when the
displacement 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
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 deadman 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 above this indicates
the EWP is in elevate mode.
300
adc_drive_threshold
For the drive ADC input, a reading above this indicates the
EWP is in drive mode.
300

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Setting Name
Description
Default
adc_trigger_threshold (not
applicable)
For the deadman ADC input, a reading above this indicates
the trigger is pressed.
2000
adc_joystick_fwd_threshold
For the joystick ADC input, a reading above this indicates
the joystick has been pushed forward.
1250
adc_joystick_bwd_threshold
For the joystick ADC input, a reading below this indicates
the joystick has been pulled backward.
1450
override_cooldown
The amount of time in milliseconds the system will wait
before accepting another override request.
20000
override_time
The amount of time in milliseconds the override will last
before it expires, and normal operation is resumed.
15000
override_listening_time
The amount of time in milliseconds the system will wait
while the deadman is held down before considering it not
to be part of the triple click override request.
300
override_reset_time
The amount of time in milliseconds the override system will
wait before resuming listening after the deadman has been
released at the end of an override period.
500
override_triple_click_time
The amount of time in milliseconds 3 clicks of the deadman
needs to occur in order to trigger the override.
2000
lidar_fault_timeout
The amount of time in milliseconds of silence from the
sensor module before a fault condition is triggered.
1000
cutout_fault_timeout
The amount of time in milliseconds a discrepancy between
the cutout and the cutout sensor is permitted before a fault
condition is triggered.
3000
throttle_time
Period after the trigger is pressed, the system does not
track velocity.
2000
stuck_time
Period, after cutout to determine if the operator is not
moving and is trapped
5000
time_before_welcome
Time after power on before welcome audio is played
250
stuck_time_long
After the stuck time this is the interval between horn alerts
10000
stuck_displacement
How much movement is considered to be non operator
movement / trapped
20
wifi_on_clicks_count
The number of times the deadman trigger is pressed to
enter Wi-Fi mode.
10
wifi_on_clicks_time
The amount of time in milliseconds after power on to enter
Wi-Fi mode.
10000
wifi_on_gesture_count
The number of times to cover and uncover the sensor to
enter Wi-Fi mode.
3
wifi_on_gesture_time
The timeout before OverWatch stops waiting for the next
part of the gesture in milliseconds
3000
wifi_on_gesture_initial_time
The timeout after startup before OverWatch stops waiting
for start of the gesture in milliseconds
10000

EQUIPMENT SAFETY SYSTEMS
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Setting Name
Description
Default
driving_state_timeout
Mode selection switch timeout
7000
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
backward
joystick_neutral_move
Which direction requires monitoring when in neutral
forward
elevate_polarity
Direction of signal logic
high
drive_polarity
Direction of signal logic
low
trigger_polarity
Direction of signal logic
high
joystick_polarity
Direction of signal logic
low
driving_state_input
Direct or timer based
direct
neutral_safe
Safe or not safe
yes
Bypass
Setting Name
Description
test_cutout_state
Test channel enabled for primary cutout
bypassed
Date and Time
Setting Name
Description
Date
Enter the current date to be saved into the OverWatch™
Time
Enter the current time to be saved into the OverWatch™
Set date and time
Press to store the displayed date and time into the OverWatch™
Read OverWatch date and time
Press to display the current date and time stored in the OverWatch™

EQUIPMENT SAFETY SYSTEMS
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Connection Schematics