eqss OverWatch 6253 User manual

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EQSS Model6253 –OverWatch™
User Manual
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The OverWatch™ is an aid to the operator and this system should not in any way replace operator training.
The system relies on optical detection principles and may not work in all situations and environments.
The system must be properly maintained, and preoperational checks must be completed.

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AUTHORS:
Kieren Grogan, Greg Santucci, Jay
Nandakumar
AUTHORISED BY:
Kieren Grogan
CHECKED BY:
Andrew Donegan
DOCUMENT ABSTRACT:
This User Manual details the use and operation of the Model6253 OverWatch™
PRODUCT NAME:
Model6253 OverWatch™ Operator Detection System
CURRENT DOCUMENT REVISION:
1.7
REVISION INFORMATION:
•1.1 Initial Document Creation
•1.2 Inclusion of drill guides and update of electrical connection schematics
•1.3 Inclusion of Wi-Fi front end use cases and web pages
•1.4 Inclusion of detail images to add in explanation of functionality and addition of part ID
•1.5 Conformity changes and grammar check
•1.6 Addition of emergency lowering notices and WiFi access procedures
•1.7 Added additional detail to the operation of the motionless detection / horn event and added warning
for correct operator standing position

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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convenience and may be superseded by updates.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 of our
equipment meets with your specifications.
EQUIPMENT SAFETY SYSTEMS MAKE NO REPRESENTATIONS OR WARRANTIES OF ANY KIND WHETHER EXPRESS 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.

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Table of Contents
Principle of Operation.........................................................................................................................................................5
Preoperational Checks........................................................................................................................................................6
Operational Instructions.....................................................................................................................................................7
Standing Position ...........................................................................................................................................................7
Session Calibration......................................................................................................................................................... 8
Crush Event Cutout ........................................................................................................................................................9
Shear Event Cutout ......................................................................................................................................................10
System Override...........................................................................................................................................................11
Visual & Audio Notifications ........................................................................................................................................11
Obstructed Operator Sensor........................................................................................................................................12
Cutout Behaviour Processing............................................................................................................................................13
Elevate Mode ...............................................................................................................................................................13
Drive Mode ..................................................................................................................................................................14
Wi-Fi Access......................................................................................................................................................................15
General Use..................................................................................................................................................................15
Minimum system requirements ..................................................................................................................................15
Enable Wi-Fi Connection.............................................................................................................................................. 15
Accessing the Home Page ............................................................................................................................................16
Diagnostics........................................................................................................................................................................17
Retrieving Event logs ........................................................................................................................................................18
Inspection & Maintenance ............................................................................................................................................... 19
Periodic Maintenance ..................................................................................................................................................19
Periodic Testing............................................................................................................................................................20
Component Identification.................................................................................................................................................21
System Components ....................................................................................................................................................21

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Principle of Operation
The OverWatch™ is an innovative system designed as an aid to the operator. The system does not replace operator
training.
The system works on the premise of detecting the operator’s position and movements, with respect to the scissor
lift’s direction of movement in real time. This information is used to determine if a crushing or shearing event is about
to occur. This is determined by the physical movements and position of the operator’s body, with respect to the
platform control box.
When the operator pushes the dead-man trigger, the system calibrates the position of the operator relative to the
control box. The system senses the machine’s mode of operation (Drive or Elevate) and determines the position of the
joystick. This initial calibration is done each time the dead-man trigger is pushed; therefore, the system calibrates for
each use session with the specific operator and environmental conditions at that point in time.
The system constantly measures the operator’s position, acceleration and velocity. The system will trigger and cut the
machine operation if the system detects movements above the threshold limits. For example, if the machine is driving
forward and the operator moves forward to look over the front of the platform, the system will not trigger. If the
machine is driving backwards and the operator moves towards the platform controls quickly with a high acceleration,
this may indicate a dangerous shearing event, and therefore, the system will trigger.

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Preoperational Checks
The OverWatch™ is an electronic detection system and is an aid the operator. Before use make sure that the system is
in good working condition. Conduct the following pre-operation checks.
1. Make sure the sensor optics are clean, free of dust, water, paint, etc. Power up the system. Make sure you hear
the ‘welcome tone’and the green light is active
2. Select the drive mode. Stand in position. Make sure the light goes blue and you hear “Drive”
3. Drive the machine forward slowly. Duck down into the basket, then the system light will change to red and it
will say “Cutout” and the machine will stop.

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Operational Instructions
Standing Position
The OverWatch™ Sensor is mounted on the platform control box. This sensor is an infrared (invisible) LIDAR, which
is used to measure the operator’s position, acceleration and velocity. The OverWatch™ must always maintain a
visible line of sight to the operator. The operator must always remain in position and maintain normal movements
in order to control the machine functions.
The operator must stand in the following position for the OverWatch™ to function correctly and allow control of
the machine functions.
The OverWatch™ will not allow control of the machine functions if the operator is not in position. In most cases
the OverWatch™ stops operation of the machine in the conditions shown below.
Warning: Risk of Severe Injury or Death
* The OverWatch™ is an aid to the operator and this system should not in any way replace operator
training. The system relies on optical detection principals and may not work in all situations
and environments. The operator must use the machine while standing in front of the control box
at all times in the natural standing position.

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Session Calibration
The OverWatch™ starts sensing the operator from the time the platform’s dead-man trigger is pressed. When the
machine is powered, and the system is functional, the operator will see a green light on the OverWatch™ sensor.
This indicates that the OverWatch™ is ready for use.
When the operator pushes the joystick dead-man trigger, the system will calibrate to the operator’s current
position. If the calibration is successful, the light will change to blue and an audio announcement of either “Drive”
or “Elevate” will be made, depending on the platform’s mode of operation.
When the operator pushes the joystick dead-man trigger, and if the operator is not detected or is standing too
close or too far away from the sensor, the light will change to purple with an audio announcement of “Operator
Zone”. If the system is not able to calibrate, the operator must release the joystick dead-man trigger and move
into the correct working position.

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Crush Event Cutout
A normal crush event can occur when the platform is in elevate mode and the operator becomes pressed against
the platform handrail and an object above. With the OverWatch™ this event is detected based on the operator’s
acceleration, velocity and current position. An illustration of a crush event is shown below.
If a crush event is detected by the OverWatch™, the machine cutout will be applied, and the operator will be
disabled from elevating the machine and the system will announce “Cutout”. The operator can always descend the
platform or apply the system override to regain control and move out of the dangerous situation. Since the
OverWatch™only applies the cutout to the upper control panel, the lower panel can be used at any time to take
control of the machine and lower the platform.
In the situation where a crush event has been detected, and the OverWatch™ has sensed that the operator has not
moved position in 5 seconds since cutout, the OverWatch™ calculates that the operator may be pinned, stuck or
incapacitated. The OverWatch™ will sound the machine’s horn 3 times every 10 seconds. This is to alert
surrounding workers about the situation, so that they may assist where required. If the operator releases and then
presses the joystick trigger, the OverWatch™ determines that the operator is not incapacitated and is able to
control the machine and cancels the horn alert.
Warning: Risk of Severe Injury or Death
* The OverWatch™ is an aid to the operator and this system should not in any way replace operator
training. The system relies on optical detection principals and may not work in all situations
and environments.
* The OverWatch™only applies the cutout to the upper control panel, the lower panel can be used at
any time to take control of the machine and lower the platform.

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Shear Event Cutout
A shear event can occur when the platform is in drive mode and the operator is struck by a stationary object. This
event is detected based off the operator’s acceleration, velocity and current position. The direction of the
operator’s movement is opposite to the movement of the platform. For example, if driving forward the operator
can move forward to look over the front of the platform when driving, and when driving forward, if a shear event
occurs, the object would push the operator backwards. If the operator is driving backwards, a shear event would
push the operator forward towards the control box.
If a shear event is detected, the machine cutout will be applied, and the operator will be prevented from driving
the machine. The system will then announce “Cutout”. The operator can always regain control of the machine by
moving back into the correct working position or by applying the system override to move out of the dangerous
situation. Since the OverWatch™only applies the cutout to the upper control panel, the lower panel can be used
at any time to take control of the machine and lower the platform.
In the situation where a shear event has been detected, and the OverWatch™ has sensed that the operator has
not moved position within 5 seconds, the OverWatch™ calculates that the operator may be pinned, stuck or
incapacitated. As with a crush event and subsequent pinning of the operator, the OverWatch™ will sound the
machine’s horn 3 times every 10 seconds. This is to alert surrounding workers about the situation, so that they
may assist where required. If the operator releases and then presses the joystick trigger, the OverWatch™
determines that the operator is not incapacitated and is able to control the machine and cancels the horn alert.
Warning: Risk of Severe Injury or Death
* The OverWatch™ is an aid to the operator and this system should not in any way replace operator
training. The system relies on optical detection principals and may not work in all situations
and environments.
* The OverWatch™only applies the cutout to the upper control panel, the lower panel can be used at
any time to take control of the machine and lower the platform.

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System Override
The OverWatch™ has an override function. This function will allow free control of the machine for 15 seconds. This
function is only available for 15 seconds and can only be used every 60 seconds.
To activate the override, the operator must press and release the joystick dead-man trigger 3 times within 2
seconds. When this triple tap occurs, the system will announce “Override Active” and the light will change to
orange. When the override times-out, the system will announce “Override Expired”. If the operator tries to enable
the override again within 60 seconds, the system will announce “Override Unavailable”. This 60 second time-out is
referred to as the ‘override cool down period’.
Visual & Audio Notifications
Light –Colour
Audio Announcement
Description
Welcome chime at start up
System has started, is powered up
and is working with no errors
Drive / Elevate
Trigger pressed, movement
selection determined, system
calibrated to operator’s position.
System sensing
Sensor Obstruction
There is an object covering the
sensor (e.g. dust, water, paint, etc)
or the operator is too close to the
sensor
Operator Zone
The operator has moved out of
sight of the sensor
None
The sensor is pointing on a
reflective surface, such as the
reflective stripes on a safety vest
To Override:
3 quick presses of
the joystick trigger
“Triple Tap”

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Cutout
The EWP movements have been
cutout to prevent injury to the
operator
Override Active
The OverWatch™ is in override
mode to allow full control when
the operator is in a compromised
position
Override Expired
The override mode has timed out
and the OverWatch™ has returned
to normal operation
Override Unavailable
The override mode has been
disabled
Obstructed Operator Sensor
The OverWatch™ can detect if the operator sensor is obstructed. An obstruction may occur if the sensor is
physically covered with an object or a material such as dust, water or paint, etc. The OverWatch™ will announce
“Sensor Obstruction”. The operator must then clean the sensor in order to operate the machine. Alternatively, if
the sensor is damaged, the system override may be used to regain control and move the machine.

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Cutout Behaviour Processing
For the system to start functioning and release the machine’s cutout so that the operator can gain control of the
machine, the following conditions must be established:
1. The OverWatch™ system must be powered
2. The OverWatch™ system must be operational and pass all self-checks
3. The operator must be present and within the defined zone when the enable trigger is pressed. At this point,
the system measures the operator’s position relative to the platform control box. This calibration position is
reset when the enable trigger is released.
4. The operator sensor must not be obstructed
Elevate Mode
The OverWatch™ will apply the cutout when the machine mode is Elevate according to the following table:
Operator action
Elevate
Descend
Operator leaning over sensor
Cutout
No cutout
Operator far from sensor
Cutout
No cutout
Operator ducks down
Cutout
No cutout
Operator moving rapidly toward sensor
Cutout
No cutout
Operator moving rapidly away from sensor
Cutout
No cutout
Calibration position
Cutout
Operator is too far
Sensor
Cutout
Operator is too close or is
leaning over
No cutout
Operator is within safe working envelope

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Drive Mode
The OverWatch™ will apply the cutout when the machine mode is Drive according to the following table:
Operator action
Drive forward
Drive backward
Operator leaning over sensor
No cutout
Cutout
Operator far from sensor
Cutout
Cutout
Operator ducks down
Cutout
Cutout
Operator moving rapidly toward sensor
No cutout
Cutout
Operator moving rapidly away from sensor
Cutout
Cutout
Calibration position
Cutout
Operator is too far
Sensor
No cutout
Operator is leaning over
No cutout
Operator is within safe working envelope

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Wi-Fi Access
General Use
The OverWatch™ includes an embedded web server, accessible via Wi-Fi. The use of this interface is limited to
viewing the system’s diagnostic information, performing routine tests on all inputs / outputs and accessing the
time stamped log files.
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.
Enable Wi-Fi Connection
The system’s Wi-Fi module is disabled by default. In order to enable Wi-Fi, the user must turn the machine on and
allow the OverWatch™ to bootup until the green light is visible. Within 10 seconds of power up, the user must
press the dead-man trigger 10 consecutive times. The OverWatch™ will announce “Wi-Fi On” and the user can
access the web page by connecting to the module’s web server, using its SSID and generic password. Follow the
instructions below to switch on the OverWatch™ Wi-Fi with the dead-man trigger switch.
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. Toggle the dead-man joystick trigger 10 times or more within 10 seconds after power up
5. When the OverWatch™ detects more than 10 trigger presses an announcement “Wi-Fi On” will occur
In the event that there is a system fault, and the OverWatch™ cannot sense the dead-man trigger input signal, the
system’s Wi-Fi can be enabled by following the instructions below to switch on the OverWatch™ Wi-Fi using the
operator sensor:
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.

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After the Wi-Fi is enabled, the user may connect to the Wi-Fi network. The SSID OverWatch_6253E_XXXX_XXXX
will appear, the XXXX_XXXX being the device’s unique serial number. Connect to the Wi-Fi network and enter the
generic access point password which is 12345678.
SSID
OverWatch_6253E_XXXX_XXXX
Password
12345678
Accessing the Home Page
Once the user’s Wi-Fi enabled device is connected to the OverWatch™, open a web browser and enter the IP
address of the device’s internal web server 192.168.4.1. Press enter and the following main page will be displayed:

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Diagnostics
The diagnostics page allows real time monitoring of the sensor data. The graph shows the raw position, raw velocity,
computed displacement and velocity.
Below the graph the diagnostics page also shows the state of the various subsystems in the OverWatch™.

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Retrieving Event logs
The Log Viewer page allows viewing and downloading of the log file information. The log information is time stamped
and details the event and associated parameters / measurements at the time of the event. The log data can be
downloaded in a csv format if required. This page also allows adjustment of the system’s real time clock and calendar
if required. Please note, any time or date change is logged and recorded.

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Inspection & Maintenance
Periodic Maintenance
Regular maintenance must be performed on the OverWatch™components to ensure the system operates
correctly. This maintenance must be performed every 12 months in a rental situation, or before the machine is
released to the hire customer.
Inspect the sensor module for any cracks or damage that may compromise
the seal. Replace the sensor module, if required.
Clean the surface of the sensor using soap and water. DO NOT HIGH-
PRESSURE WASH. Replace the screen protectors on the Lidar, if required.
Blow out any dust that may block or muffle the speaker behind the sensor
module. This can be done with low pressure < 10 psi compressed air.
Inspect the cable running from the sensor to the cable gland and into the
EWP control box. Check for any cuts or wear on the cable especially around
the entry points for any exposed wires. Patch or replace the cable, if
required.

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Periodic Testing
Testing must be performed on the OverWatch™components to ensure the system operates correctly. This testing
must be performed every 12 months or after any type of maintenance or repair work has been carried out on the
machine’s control box. Connect to the OverWatch™Wi-Fi, then access the main page and select the test menu.
Follow the instructions on the screen to complete the system test.