eqss Skyjack SJIII OverWatch 6253 User manual

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone]
E: [e-mail]
Skyjack SJIII DC Scissor
Plug and Play
Installation Manual
REV 1.2
07/10/2020
Model6253 OverWatch™Installation Manual
Document # DO001246
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EQSS Model6253 – OverWatch™
Skyjack SJIII DC Scissor
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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 SJIII DC Scissor
Plug and Play
Installation Manual
REV 1.2
07/10/2020
Model6253 OverWatch™Installation Manual
Document # DO001246
|2 of 19|
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
Skyjack
SJIII DC scissor lift.
PRODUCT NAME:
Model6253
OverWatch™ Operator Detection System
REFERENCE DOCUMENTS:
DO000119
5 Model6253 OverWatch™ User Manual
CURRENT DOCUMENT REVISION:
1.2
REVISION INFORMATION:
•1.1 Initial Document Creation for installation on a Skyjack SJIII Series
•1.2 Update installation instructions with plug and play Loom AS001924 and Update Loom AS001924 drawing
description

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone]
E: [e-mail]
Skyjack SJIII DC Scissor
Plug and Play
Installation Manual
REV 1.2
07/10/2020
Model6253 OverWatch™Installation Manual
Document # DO001246
|3 of 19|
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convenience and may be superseded by updates.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 SJIII DC Scissor
Plug and Play
Installation Manual
REV 1.2
07/10/2020
Model6253 OverWatch™Installation Manual
Document # DO001246
|4 of 19|
Table of Contents
Installation Instructions ...................................................................................................................................................... 5
Operator Sensor............................................................................................................................................................. 5
Control Module.............................................................................................................................................................. 7
Post Installation Configuration ......................................................................................................................................... 11
Overview ...................................................................................................................................................................... 11
Minimum system requirements .................................................................................................................................. 11
Wi-Fi Connection & Web Page Access ......................................................................................................................... 11
Machine Model Selection ............................................................................................................................................ 12
Installation Test............................................................................................................................................................ 13
Set Date and Time........................................................................................................................................................ 14
Change Model Configuration ....................................................................................................................................... 15
System Settings................................................................................................................................................................. 16
Default Settings............................................................................................................................................................ 16
Polarity and Input Style................................................................................................................................................ 18
Bypass .......................................................................................................................................................................... 18
Date and Time.............................................................................................................................................................. 18
AS001924 Plug and Play Harness Drawing ....................................................................................................................... 19

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone]
E: [e-mail]
Skyjack SJIII DC Scissor
Plug and Play
Installation Manual
REV 1.2
07/10/2020
Model6253 OverWatch™Installation Manual
Document # DO001246
|5 of 19|
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.
Drill two 5.2mm holes to
mount the operator
sensor in the position
shown in the diagram.
2.
Mount the module in the
located position using the
supplied M4 nuts 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. This is so that the
sensor can focus on the
centreline of the operator
in the normal standing
position.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone]
E: [e-mail]
Skyjack SJIII DC Scissor
Plug and Play
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3.
Drill the holes specified to
mount the operator
sensor gland and gland
guard.
4.
Install the supplied cable
gland in the location
shown in the image and
feed the wire from the
operator sensor into the
enclosure.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone]
E: [e-mail]
Skyjack SJIII DC Scissor
Plug and Play
Installation Manual
REV 1.2
07/10/2020
Model6253 OverWatch™Installation Manual
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Control Module
Step
Description
Diagram
1.
Drill the holes specified to
mount the ECU.
2.
Mount the ECU module
using the supplied nuts
bolts, and washers.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone]
E: [e-mail]
Skyjack SJIII DC Scissor
Plug and Play
Installation Manual
REV 1.2
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Model6253 OverWatch™Installation Manual
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3.
Wiring connections are
made by the plug and play
Harness AS001924.
4.
The connectors listed in
the table on the right, will
be connected inside the
machine control box.
EQSS Wiring Harness Connection
EQSS Harness Cable
Colour
Joystick and Power piggyback
Mixed
Horn piggyback
White
Drive Select piggyback
Purple
Elevate Select piggyback
Orange
Power
Red

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone]
E: [e-mail]
Skyjack SJIII DC Scissor
Plug and Play
Installation Manual
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Model6253 OverWatch™Installation Manual
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5.
Joystick Connection:
Disconnect the 9-Pin
connector from the
joystick and install the
OverWatch™ Harness in
series with the connector
connectors in the image.
6.
Horn Connection:
At the back the horn push
button, install the Horn
piggyback cables to the
terminal 3 and 4 as shown
in the photo.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone]
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Skyjack SJIII DC Scissor
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7.
Drive and Elevate
Connections:
On the back the
Drive/Elevate switch,
Locate the three terminals
that are not used.
2. Using the M3 screw
provided, install the Violet
wire from the
OverWatch™ Harness to
the switch block Top
terminal.
3. Using the M3 screw
provided, install the Red
cable from the
OverWatch™ Harness. to
the switch block Middle
terminal.
4. Using the M3 screw
provided, install the
Orange wire from the
OverWatch™ Harness to
the switch block Bottom
terminal.
8.
Connect the 8-Pin
connector from the
Operator Sensor and the
12-Pin connector from the
OverWatch™ Harness,
into the Control Module
and re-fit the joystick back
into the enclosure.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone]
E: [e-mail]
Skyjack SJIII DC Scissor
Plug and Play
Installation Manual
REV 1.2
07/10/2020
Model6253 OverWatch™Installation Manual
Document # DO001246
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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]
Skyjack SJIII DC Scissor
Plug and Play
Installation Manual
REV 1.2
07/10/2020
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]
Skyjack SJIII DC Scissor
Plug and Play
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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]
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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
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone]
E: [e-mail]
Skyjack SJIII DC Scissor
Plug and Play
Installation Manual
REV 1.2
07/10/2020
Model6253 OverWatch™Installation Manual
Document # DO001246
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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]
Skyjack SJIII DC Scissor
Plug and Play
Installation Manual
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Model6253 OverWatch™Installation Manual
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System Settings
Default Settings
See the sections below for details on each of the Skyjack SJIII OverWatch™ system default 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.
90
max_safe_displacement
This is the maximum permitted distance in cm the operator
may be away from the calibration position in drive mode.
40
max_safe_velocity_elevate
This is the velocity threshold for the cutout in cm/s. in
elevate mode.
70
max_safe_displacement_elevate
This is the maximum permitted distance in cm the operator
may be away from the calibration position in elevate mode.
40
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.
-0.6
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.
2200
adc_drive_threshold
For the drive ADC input, a reading above this indicates the
EWP is in drive mode.
2200

EQUIPMENT SAFETY SYSTEMS
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Setting Name
Description
Default
adc_deadman_threshold
For the deadman ADC input, a reading above this indicates
the deadman switch is pressed.
2000
adc_joystick_fwd_threshold
For the joystick ADC input, a reading above this indicates
the joystick has been pushed forward.
1500
adc_joystick_bwd_threshold
For the joystick ADC input, a reading below this indicates
the joystick has been pulled backward.
1400
override_cooldown
The amount of time in milliseconds the system will wait
before accepting another override request.
60000
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
deadman_fault_timeout
The amount of time in milliseconds a discrepancy between
the deadman and the deadman 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
driving_state_timeout
Mode selection switch timeout
7000

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone]
E: [e-mail]
Skyjack SJIII DC Scissor
Plug and Play
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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 machine forward
forward
joystick_elevate_upward
Direction of joystick to move machine upwards
forward
joystick_neutral_move
Which direction requires monitoring when in neutral
forward
elevate_polarity
Direction of signal logic
high
drive_polarity
Direction of signal logic
high
deadman_polarity
Direction of signal logic
high
joystick_polarity
Direction of signal logic
high
driving_state_input
Direct or timer based
direct
neutral_safe
Safe or not safe
yes
Bypass
Setting Name
Description
overwatch_state
Redundant
active
test_deadman_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
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone]
E: [e-mail]
Skyjack SJIII DC Scissor
Plug and Play
Installation Manual
REV 1.2
07/10/2020
Model6253 OverWatch™Installation Manual
Document # DO001246
|19 of 19|
AS001924 Plug and Play Harness Drawing