eqss OverWatch JLG R-Series User manual

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
JLG R-Series
Installation Manual
REV 1.2
22/09/2020
Model6253 OverWatch™Installation Manual
Document # DO001237
EQSS Model6253 –OverWatch™
JLG R-Series
I
N
S
T
A
L
L
M
A
N
U
A
L
** 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 R-Series
Installation Manual
REV 1.2
22/09/2020
Model6253 OverWatch™Installation Manual
Document # DO001237
|2 of 20|
AUTHORS:
Kieren Grogan, Truong Bui, Jay
Nandakumar
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 JLG
3246R scissor lift.
PRODUCT NAME:
Model6253 OverWatch™ Operator Detection System
REFERENCE DOCUMENTS:
DO001195 Model6253 OverWatch - User Manual
CURRENT DOCUMENT REVISION:
1.2
REVISION INFORMATION:
•1.1 Initial Document Creation for installation on a JLG 3246R.
•1.2 Update to include installation steps for hard wire connections and more detailed installation graphics.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
JLG R-Series
Installation Manual
REV 1.2
22/09/2020
Model6253 OverWatch™Installation Manual
Document # DO001237
|3 of 20|
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convenience and may be superseded by updates.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]
JLG R-Series
Installation Manual
REV 1.2
22/09/2020
Model6253 OverWatch™Installation Manual
Document # DO001237
|4 of 20|
Table of Contents
Preparation.........................................................................................................................................................................5
Required Tools ...............................................................................................................................................................5
Installation Time ............................................................................................................................................................ 5
Installation Instructions......................................................................................................................................................6
Operator Sensor............................................................................................................................................................. 6
Control Module..............................................................................................................................................................9
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
Connection Schematics –Typical Application ..................................................................................................................20

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
JLG R-Series
Installation Manual
REV 1.2
22/09/2020
Model6253 OverWatch™Installation Manual
Document # DO001237
|5 of 20|
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
10
Soldering Iron
Installation Time
The suggested time required to install the OverWatch™ is as detailed below
Task
Estimated Time (Minutes)
Open the operator control box
2
Drilling of all mounting holes for the various components
15
Mechanical assembly
10
Electrical assembly
15
Post installation system tests
10
Close the operator control box
3
Total
55

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
JLG R-Series
Installation Manual
REV 1.2
22/09/2020
Model6253 OverWatch™Installation Manual
Document # DO001237
|6 of 20|
Installation Instructions
Operator Sensor
Step
Description
Diagram
1.
The operator sensor should
be positioned as shown in the
image to the right.
2.
Drill two holes for the
operator sensor bracket in
the location shown in the
diagram.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
JLG R-Series
Installation Manual
REV 1.2
22/09/2020
Model6253 OverWatch™Installation Manual
Document # DO001237
|7 of 20|
3.
Install the operator sensor as
shown in the diagram, using
the supplied bracket, nuts,
bolts, and washers. The
sensor should be positioned
so when it is mounted it is
twisting away from the
joystick, thus that it aligns
with the centreline of the
operator’s body when
standing in the normal
working position.
4.
Install the cable gland in the
location shown in the
diagram.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
JLG R-Series
Installation Manual
REV 1.2
22/09/2020
Model6253 OverWatch™Installation Manual
Document # DO001237
|8 of 20|
5.
Install the p-clip in the
location shown in the image.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
JLG R-Series
Installation Manual
REV 1.2
22/09/2020
Model6253 OverWatch™Installation Manual
Document # DO001237
|9 of 20|
Control Module
Step
Description
Diagram
1.
Using the supplied M4
bolts and washers, mount
the control module inside
the platform control
enclosure (mount on
bottom of metal
enclosure), in the location
shown in the image.
2.
The OverWatch™ is to be
installed by cutting and
crimping the connections
into the existing control
box wiring. The
connection instructions
will be explained in more
detail in the next few
steps.
PIN
Colour
Location
1
Red
+24V
2
Black
GND
3
Green
Enable/Deadman –Switch
Side (Yellow/White wire
from joystick circuit board)
5
White
Horn Splice (To Horn Relay)
8
Blue
Enable/Deadman –ECU Side
9
Orange
Elevate Switch Splice
10
Purple
Drive Switch Splice
12
Grey
Joystick 0-5V Splice

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
JLG R-Series
Installation Manual
REV 1.2
22/09/2020
Model6253 OverWatch™Installation Manual
Document # DO001237
|10 of 20|
3.
Trigger Switch
Connection:
Cut wire ID WHT 43-1
(TRIGGER) in half.
• Solder the Green wire
from the OverWatch™
Harness to the joystick
side of the 43-1 wire.
• Solder the Blue wire
from the OverWatch™
Harness to the ECU side of
the 43-1 wire.
4.
Joystick Connection:
Solder the Grey wire from
OverWatch™ Harness to
the wire with WHT 90 (JOY
SIG), making a splice
connection.
5.
Horn Connection:
Solder the Green from the
Relay of the ECU Harness
to wire ID WHT 85, which
is connected to SW299-1.
Solder the Green from the
Relay of the ECU Harness
to wire ID YEL PWR, which
is connected to SW299-2.
WHT 43-1
WHT 90
WHT 85
YEL PWR

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
JLG R-Series
Installation Manual
REV 1.2
22/09/2020
Model6253 OverWatch™Installation Manual
Document # DO001237
|11 of 20|
6.
Drive & Elevate
Connections:
• Connect the Violet wire
from the OverWatch™
Harness the wire with ID
WHT 82. Which is
attached the drive
selection switch in the
operator control box.
• Connect the Orange
wire from the
OverWatch™ Harness the
wire with ID WHT 83.
Which is attached the
elevate selection switch in
the operator control box.
7.
Power Connection:
Install the Red wire from
the OverWatch™ Harness
into Pin-1 (SW296-1) of
the E-Stop Switch.
WHT 83
WHT 82

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
JLG R-Series
Installation Manual
REV 1.2
22/09/2020
Model6253 OverWatch™Installation Manual
Document # DO001237
|12 of 20|
8.
Ground Connection:
Solder the Black wire from
the OverWatch™ Harness
to the wire BLK ID 1-41
(PLT GND)
9.
Connect the 8-pin
connector from the
Operator Sensor and the
12-pin connector from the
Solder the white wire
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]
JLG R-Series
Installation Manual
REV 1.2
22/09/2020
Model6253 OverWatch™Installation Manual
Document # DO001237
|13 of 20|
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]
JLG R-Series
Installation Manual
REV 1.2
22/09/2020
Model6253 OverWatch™Installation Manual
Document # DO001237
|14 of 20|
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
JLG R Series
JLG R Series
JLG R Series

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
JLG R-Series
Installation Manual
REV 1.2
22/09/2020
Model6253 OverWatch™Installation Manual
Document # DO001237
|15 of 20|
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]
JLG R-Series
Installation Manual
REV 1.2
22/09/2020
Model6253 OverWatch™Installation Manual
Document # DO001237
|16 of 20|
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 do not 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
JLG R Series

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
JLG R-Series
Installation Manual
REV 1.2
22/09/2020
Model6253 OverWatch™Installation Manual
Document # DO001237
|17 of 20|
System Settings
Default Settings
See the sections below for details on each of the JLG MRT 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.
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
fwdveloadj
The coefficient to apply to the velocity when the
displacement is toward the sensor.
-1
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 trigger 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.
2000

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
JLG R-Series
Installation Manual
REV 1.2
22/09/2020
Model6253 OverWatch™Installation Manual
Document # DO001237
|18 of 20|
Setting Name
Description
Default
adc_drive_threshold
For the drive ADC input, a reading above this indicates
the EWP is in drive mode.
2000
adc_trigger_threshold
For the trigger ADC input, a reading above this
indicates the trigger is pressed.
250
adc_joystick_fwd_threshold
For the joystick ADC input, a reading above this
indicates the joystick has been pushed forward.
1283
adc_joystick_bwd_threshold
For the joystick ADC input, a reading below this
indicates the joystick has been pulled backward.
1483
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
time_before_welcome
Time after power on before welcome audio is played
250
stuck_displacement
How much movement is considered to be non
operator movement / trapped
20
stuck_time
Period, after cutout to determine if the operator is
not moving and is trapped
5000
stuck_time_long
After the stuck time this is the interval between horn
alerts
10000
wifi_on_click_count
The number of times the trigger needs to be pressed
after startup to enter Wi-Fi mode.
10
wifi_on_click_time
The timeout after startup before OverWatch stops
listening to the trigger click method of turning on the
Wi-Fi
10000

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
JLG R-Series
Installation Manual
REV 1.2
22/09/2020
Model6253 OverWatch™Installation Manual
Document # DO001237
|19 of 20|
Setting Name
Description
Default
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
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 EWP forward
forward
joystick_elevate_upward
Direction of joystick to move EWP upward
backward
joystick_neutral_move
Direction of joystick that requires monitoring when in
neutral
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
neutral_safe
Monitor when no drive mode set
yes
driving_state_input
Direct, timer based or separate joysticks
direct
Bypass
Setting Name
Description
test_cutout_state
Test channel enabled for primary cutout
bypassed

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
JLG R-Series
Installation Manual
REV 1.2
22/09/2020
Model6253 OverWatch™Installation Manual
Document # DO001237
|20 of 20|
Connection Schematics –Typical Application



















           


























  
 




















  
 
 
 
  
  

























  
 