GemOne Sapphire v3 User manual



Hardware installation guide of the Sapphire v3


Never use any of the Sapphire v3 components with a voltage other than
that specified. Use the included DC/DC converter for machines with a
voltage above 12V. Avoid situations that can cause damage to the power
cable.



Should any of the Sapphire v3 components become hot, start to emit
smoke, or a strange odor; immediately turn the power off and contact
GEM One. Continued usage is dangerous and may result in fire or
electrical shock.

Never apply heavy pressure on the Sapphire v3 display or subject it to
strong impact. Doing so may crack the screen or LCD panel glass,
resulting in personal injury or major damage to the device.


This document is to be used as a guide to install the Sapphire v3 onto
various types of equipment, whether they are internal combustion or
electric equipment.

This document is to be used by a trained and authorized person(s) with
the necessary PPE as a guide for the installation, operation, and
management of the Sapphire v3. It provides information on the
components of the Sapphire v3, installation procedure, and general
troubleshooting methods.




The Sapphire v3 contains multiple components, depending on the
features used. The main components can be found below.
●Sapphire v3 interface box
●Sapphire v3 display
●DC/DC converter
●RFID keypad
●Strobe alarm
●Weight sensor (transducer)
●Various wiring and antennas
●Various mounting kits
A picture of each item can be found on the following pages.




Sapphire v3 Display
RFID keypad
Sapphire v3
Interface box
Strobe alarm
DC/DC converter Weight sensor
(transducer)


Overhead plate
mounting kit Display mount
Wiring harness (X1)
GPS and data antenna
Display data
connector


The main wiring harness of the Sapphire v3 has two bundles. Each
bundle has its own flexible tube protecting the wires from heat and
vibrations.

The 7-pin Weipu extensions connector is reserved for future use and
should not be connected.

The machine wire bundle on the main wiring harness contains all wires
and splits required for installation on an asset. This includes ignition,
usage and extra inputs, power to the display and all necessary
connections to the RFID keypad, relays and weight sensor. A complete
overview and pinout can be found on the next page.



Display enable
Display ground
Din3 - fwd/rev
Extensions
Transd. +12V
Transd. GND
Transd. 1 Analog
Din1 - Ignition
Din2 - Usage
CAN1-H
CAN1-L
24
13
Black - Ground
Red - +12V
Power +12V
Power GND
24
Black - Ground
Red - +12V
Yellow - Feedback
Green - 1-wire data
Black - Ground
Red - +12V
Blue - Transd. 1
Red - +12V
Grey - Dout2 - Aux
Yellow - Dout1 - Ign.
Black - Ground
Orange - +5V
White - CAN2-H
Red - +12V
20AWG - Shielded - Length 30cm
20AWG - Shielded - Length 15cm
Display data
Green - CAN2-L
Blue - RS232_RXD4
Brown - RS232_TXD4
Black - GROUND
Orange - +5V
White - CAN2-H
Red - +12V
Green - CAN2-L
Blue - RS232_RXD4
Brown - RS232_TXD4
1
2
3
4
5
6
7
16
18
19
3
4
23
25
5
6
Purple - Din1 - Ignition
Red - Din2 - Usage (hours)
White - Din3



Purple - CAN1-H
Grey - CAN1-L


 




USB Data+
USB ground
USB Data -
USB Vbus +5V Fitted through cable
gland on OWA4x IP67
cover

Black - Display ground
Red - Display +12V

Orange - Display enable
~ 30cm / 0.5mm²
Split x 5
Split x 5
Keypad, transducer, relays,
display and extensions
Split x 5

Keypad +12V
Keypad GND
Keypad 1-wire
Keypad feedback
Split x 1 (Ignition relay)
Split x 2
Transducer and display
Split x 2
14
22
20
24
13
15
17
Split x 1
Keypad feedback
20
21
~ 1.5m / 0.5mm²
26
Display +12V
~ 1.5m / 0.5mm²
Relays power 86
Ignition relay 85
Aux relay 85
~ 1.5m / 0.5mm²
~ 30cm / 0.5mm²
~ 1.5m / 0.5mm²
Split x 2
13
~ 15cm
~ 1.5m / 1.5mm²
Split x 5
Split x 1 (Keypad)
Split x 1 (Extensions) Split x 5
24
Split x 5
24
1
13
7
8
27
28
24 



The
next few pages describe the necessary electrical connections
component by component.
●DC/DC converter
●Asset inputs
●Display
●RFID keypad
●Drive Inhibit Relay
●Aux relay: Strobe light / Buzzer
●Load sensor

Please note that every machine is different. This document contains
general guidelines that apply to most machines. Always consult your
vehicle’s technical manual in case of doubt.



Relays power 86
Power GND
Red - +12V

Black - Ground
1 = Enable - Connect to Bat +
2 = Bat+
3 = Bat-
4 = Out-(Common with Bat -)
5 = Out +12V
P12W180
1234 5
24
13



Always power the installation using
.
Do not install behind the ignition key
switch, emergency button or any
other supply that might cut of power.
The LED indicates if 12V output is available.
If this led is off, please verify the installation
Make sure to connect pin #1 which
enables the DC/DC converter.
This DC/DC converter is a non
isolated converter. Grounds on pin
#3 and #4 are common.
The complete Sapphire v3
installation, including all accessories
.
If the machine has a battery voltage
of  (eg. 24V, 36V, 48V, ..),

.

Din3 - fwd/rev
Din1 - Ignition
Din2 - Usage
3
4
23
25
5
6
Purple - Din1 - Ignition
Red - Din2 - Usage (hours)
White - Din3







16
18
19

All inputs have a .
Use measurement points in the machine which will never
exceed this voltage (eg. during charging, regenerative
braking, …)
 and should always be connected.
●Must be 
●Must be  - before engine is on
●Must 
●Must go back 
Connecting the  but recommended.
Must be 
Free to connect to any point in the machine which you refer to as
‘usage’.
● with on/off input
●Signal indicating 
● pumps on/off
● - driver present?
● - operator using machine?
 and free to use. Common use
cases are forward/reverse signal, seat switch, seat belt
switch, … Voltages  are detected as .
Key switch
Hour counter
Solder these connections
and cover with heat shrink
to isolate.

Display enable
Display ground
Display +12V


Black - Display ground
Red - Display +12V
Orange - Display enable
26
13
24
Length 15cm
Display data
Fitted through cable
gland on interface box

Cover USB connections with heat
shrink tubing to prevent disconnects
from vibration.
Display can be powered on using
the red push button on top.
Not used and
should not be
connected.
Once started, the display 
. Other
functionality is triggered if the 
 on the interface box is turned on.
Solder these connections
and cover with heat shrink
to isolate.


The Sapphire v3 has an 

 to get the vehicle location.
Always connect both mobile
antenna connectors (purple) -
position is not important.
Always connect the GNSS
connector (blue)
The antenna should have an 
. This is especially important to receive the
GPS signal. Please make sure that the antenna is 
 or other impenetrable
material. The best mounting position is 
.


Black - Ground
Red - +12V
Yellow - Feedback
Green - 1-wire data

Keypad +12V
Keypad GND
Keypad 1-wire
Keypad feedback
24
14
22
20
Solder these connections
and cover with heat shrink
to isolate.
Mount the RFID keypad on a location 
 to enter a pin or
swipe an RFID card.
This led indicates if the machine is actively
being blocked (red) or not (green). Ignition
blocking only triggers when the ignition
input on the interface box is high.


Red - +12V
Yellow - Dout1 - Ign.

Relays power 86
Ignition relay 85
20
24
The Sapphire v3 can 
 to prevent an operator from driving.
Which connection to interrupt depends on the
machine type. This will be different between
 and .
In a vehicle with a combustion engine, the easiest
connection to interrupt is the .
An electrical vehicle usually prevents an operator from
driving when one of the following connections is
interrupted:      

Make sure you never circumvent any of the safety
features of your machine; always consult your vehicle’s
technical manual.
The Sapphire v3 will use active blocking, so make sure
to use the  of the relay.
Only use a 
 - as
included by default in the kit.

Aux relay 85
Relays power 86
Power GND
Red - +12V
Grey - Dout2 - Aux

21
24
13
Black - Ground

Solder these connections
and cover with heat shrink
to isolate.
Only use a 
 - as
included by default in the kit.
The optional  can
 of an incident such as
an impact lockout, critical checklist failure
or a manual lockout.
The Sapphire v3 will use active
warning, so make sure to use the
 of the relay
to connect the strobe light.


Solder these connections
and cover with heat shrink
to isolate.
The optional  translates the pressure
in a hydraulic line to a corresponding voltage.
The       
 on the forks of the machine.
Transd. +12V
Transd. GND
Transd. 1 Analog
Black - Ground
Red - +12V
Blue - Transd. 1

24
13
15
The load sensor will 
   on ‘Transd. 1 Analog’, using the
ground as a reference. This output voltage is
linear with the pressure in the hydraulic
system.
●0 PSI will output 0V
●3000 PSI will output 5V
Correct installation can be verified by
measuring the voltage without load and with
load. The value with load should be
significantly higher than the value without load
and still between 0 and 5V.
Pressure port uses a  connection.
Maximum pressure is 

Power Ground

Red - +12V
Black - Ground

Power +12V
13
24
Some machines use a 
 such as the key switch or
hour counter. The Sapphire v3 needs a
logic high voltage on the inputs to be
detected.
The following circuit can be used 

.
Converted , ready to be used
directly as input source for the Sapphire v3(eg. key
switch, usage, …). Outputs  and
pulls to .


(pull-to-ground) that
needs to be converted
to active high. (eg.key
switch, usage, …)

Power Ground

Red - +12V
Black - Ground

Power +12V
13
24
Some machines have isolated 
 To detect a signal, the
signal must use the same ground as the Sapphire
v3. Measurements and detection will be unreliable -
since 
The following circuit can be used 


Converted , ready to
be used directly as input source for the Sapphire
v3(eg. key switch, usage, …).If needed, pin 87a and
87 can be swapped to 
.


The grey wire in this example is a
 not shared with
the Sapphire v3. The orange wire is
a  you want to
measure, based on the grey
ground.Make sure to use a suitable
relay for this machine signal (coil
voltage and current).