eqss OverWatch 6253 User manual

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Dingli S03-ACE
Installation Manual
REV 1.2
04/12/2023
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
REV1.2
04/12/2023
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 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:
1.2
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
•1.2 Update of sensor mounting guard V2 and update of machine configuration instructions

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Dingli S03-ACE
Installation Manual
REV1.2
04/12/2023
Model6253 OverWatch™Installation Manual
Document # DO001616
|3 of 22|
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convenience and may be superseded by updates.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
REV1.2
04/12/2023
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
System Settings.................................................................................................................................................................19
Default Parameters...................................................................................................................................................... 19
Polarity and Input Style................................................................................................................................................ 20
Harness Drawing AS002208..............................................................................................................................................21
Replacement Parts............................................................................................................................................................ 22

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Dingli S03-ACE
Installation Manual
REV1.2
04/12/2023
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 5.0mm
6
Drill 6.0mm
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
Installation Manual
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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 6mm 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.
Hole distances are 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 the
two holes is 61mm.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
Dingli S03-ACE
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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
.
Sensor Mounting Guard V1
(ME001794)
Mount the operator sensor in
the 40-degree position by
using the wedges, sensor
guard, bolts, and washers.
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. Mount the sensor
in position using the
positioning wedges, sensor
guard, M4 washers, and bolts.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
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5.
Sensor Mounting Guard V2
(AS002326)
This guard (AS002326)
supersedes the original V1
design. Attach the guard in
position using the M5 nuts
and washers. Make sure that
the sensor is on the 7.5-
degree angle, such 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.
6.
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
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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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
Installation Manual
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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]
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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 with the AS002208
harness

EQUIPMENT SAFETY SYSTEMS
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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
series.
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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Dingli S03-ACE
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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 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)
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]
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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.

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75 Naxos Way, Keysborough 3173 Victoria Australia
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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 browser 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
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Dingli S03-ACE
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System Settings
Default Parameters
The OverWatch is configured 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.
98
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.
0.55
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.
500
adc_drive_threshold
Threshold value for the drive ADC input.
500
adc_trigger_threshold
Threshold value for the trigger ADC input.
100
adc_joystick_fwd_threshold
Forward threshold value for the joystick ADC input.
900
adc_joystick_bwd_threshold
Backward threshold value for the joystick ADC input.
110
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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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
elevate_polarity
Direction of signal logic
low
drive_polarity
Direction of signal logic
low
trigger_polarity
Direction of signal logic
low
joystick_polarity
Direction of signal logic
low
driving_state_input
Direct or timer based
direct