SYNC 3000

Hardware User Manual

www.kalkitech.com

Version 2.2.6, May 2018

 Copyright Notice
© 2018 Kalki Communication Technologies Pvt. Ltd. All Rights reserved.
This user manual is a publication of Kalki Communication Technologies Private Limited and it is
intended for its customers use only. Content of this manual is copyrighted and reproduction in whole or
in part, for use other than in support of Kalkitech equipment, is prohibited without the specific written
permission of Kalkitech.

Disclaimer
Information in this manual is subject to change without any notice.
Information provided in this manual is intended to be accurate and reliable. However,
Kalki Communication Technologies Private Limited assumes no responsibility for its use. and makes no
commitment to update or keep the information current in this manual.

Contact Information

Kalki Communication Technologies Pvt. Ltd.

The Address, 4th Floor,
# 17/1, Outer Ring Road,
Opposite to Prestige Cessna Business Park
Kadubeesanahalli, Bangalore - 560103, INDIA

Telephone: +91- 8067021900

Email: sales@kalkitech.com

Technical Support Contact Information

E-mail Support: support@kalkitech.com

SYNC 3000 Hardware User Manual 2

Table of Contents

1. Introduction 6
1.1. Overview  6
1.2. Hardware Features 6
1.3. Hardware Block Diagram 7
1.4. Product Hardware Specification 8

2. Product Appearance and Characteristics 9

2.1. Appearance 9
2.2. Environmental Characteristics 9
2.3. Mechanical Dimensions 10
2.4. Mounting Details 11
2.5. LED Indications 12

3. SYNC 3000 Hardware Details 13

3.1. Electrical Characteristics 13
3.1.1. Power Input Details - Universal Power Supply 13
3.1.2. Power Input Details - DC Power Supply 13
3.1.3. Power Consumption 13
3.2. Power Supply Details 13
3.2.1. Power Connector  14
3.2.2. Power Input Wiring Description 15
3.2.3. Power Input Wiring Scheme 16
3.2.4. Grounding Scheme 17
3.3. Communication Ports 18
3.3.1. Copper Ethernet Ports 18
3.3.2. Fiber Ethernet Ports 19
3.3.3. Serial Port 20
3.3.4. Time Synchronization using IRIG-B I/O 23
3.4. Control Switches 24
3.4.1. Console Switch 24
3.4.2. Reset Switch 25

4. SYNC 3000 Product Variants and Options 26

Appendix A: Troubleshooting  27

Appendix B: Guidelines to Handle ESD  28

Appendix C: Guidelines for Surge and Fast Transient Protection 29

Appendix D: RS485 Daisy chain termination and Multi-drop 30

Appendix E: Certifications 31

Glossary 33

SYNC 3000 Hardware User Manual 3

List of Figures
Figure 1: SYNC 3000 Hardware Block Diagram 7
Figure 2: View of SYNC 3000 9
Figure 3: Dimension of SYNC3000 M1/M2/M3 10
Figure 4: Dimension of SYNC3000 M12 10
Figure 5: SYNC3000 mounting details 11
Figure 6: L-Shape Mounting Bracket 11
Figure 7: Symbolic representation of power connector for option1 (universal input) 14
Figure 8: Symbolic representation of power connector for option 2 14
Figure 9: Power connector pin numbering 15
Figure 10: Power Channel Numbering 16
Figure 11: Power Input wiring scheme 16
Figure 12: Shorting Clamp Position 17
Figure 13: Shorting Clamp 17
Figure 14: Ethernet Pin Definition 18
Figure 15: Ethernet Port Arrangement 19
Figure 16: ST Fiber Optic Cable 19
Figure 17: Fiber Optic Ports Symbols 19
Figure 18: RJ45 Serial Dual Stacked Port’s -Connector 21
Figure 19: RS485 Stacked Terminal Block Port’s -Connector 21
Figure 20: 12-Serial Port Arrangement 22
Figure 21: IRIG-B Connector’s Symbol 23
Figure 22: Debug Switch-Rear Panel Details 24
Figure 23: Reset Switch- Rear Panel Details 25
Figure 24: ESD Characteristic 28
Figure 25: RS485-Termination Scheme 30

SYNC 3000 Hardware User Manual 4

List of Tables
Table 1: Specification of SYNC 3000 Product Series 8
Table 2: Environmental Characteristics 9
Table 3: LED Details of SYNC 3000 12
Table 4: Power Input 13
Table 5: Power Input 13
Table 6: Power Consumption 13
Table 7: Universal Power Supply Characteristics 14
Table 8: Power Connector Pins Description 15
Table 9: Default IP Address 18
Table 10: Fiber Technical Specification 19
Table 11: Serial Ports Arrangement 20
Table 12: Full MODEM Port Pin Details 21
Table 13: PORT’s Pin Details (RS232 Mode-2wire) 22
Table 14: PORT’s-Pin Details (RS485 Mode-2wire) 22
Table 15: PORT’s-Pin Details (RS232 Mode-4wire) 22
Table 16: PORT’s-Pin Details (RS485 Mode-Dedicated) 22
Table 17: IRIG-B Technical Specification 23
Table 18: IRIG-B Terminal Block Connector Signal Details 23
Table 19: IRIG-B BNC Connector Signal Details 23
Table 20: Debug Switch Configuration 24
Table 21: Reset Switch Configuration 25
Table 22: Type Test Details 32
Table 23: List of Abbreviations 33

SYNC 3000 Hardware User Manual 5

 1
1. Introduction
This user manual gives comprehensive information about the SYNC 3000 product series. It
covers hardware installation and its mounting. For software installation and configuration, please
refer to the Software User Manual Guide in the CD or download it from our website www.kalkitech.
com.

This chapter covers:

• Overview
• Hardware features
• Hardware block diagram
• Product hardware specification

1.1. Overview
SYNC 3000 is a high-performance data concentrator and communication device that serves
as an ideal substation communication hub with advanced features including redundancy,
robustness and security. The SYNC 3000 series of products are rugged and come with reliable
communication and computing processors capable of handling extreme substation rugged
environments. The product supports IEC61131 based programming capability providing enough
engineering flexibility for user data computation.

SYNC 3000 DCUs are high performance front end gateways for heavy duty substation data
concentration and other similar applications. These devices are field proven and secure to meet
wide ranging protocol communication integration and translation requirements for large sized
applications in power generation, transmission and distribution including Disturbance Data
Collection and Wide Area Monitoring. SYNC 3000 supports up to 12 Serial and 6 Ethernet ports,
and scalability to support a large number IEDs.

1.2. Hardware Features

The key features of SYNC 3000 product series include:
• CPU - QorIQ integrated quad core communication processor
• Ethernet communication ports - Two 10/100 Mbps ports & four 10/100/1000 Mbps ports
with Auto MDIX capability. 100Mbps Fiber optic ports are also available as hardware variant
• Serial communication ports - up to 12 ports supporting wide range of Baud-rates
• Time synchronization using IRIG-B DCLS signal Input
• Time synchronization using IEC60870/DNP3/NTP/SNTP/IEEE1588
• SATA hard disk connectors for storage expansion
• Option for expanding communication ports using terminal server and LAN switches
• Full MODEM port available for connecting external GPRS/CDMA/RF/PSTN MODEMS
• Wide range of AC and DC power supply
• Power supply redundancy option
• IEC61850-3 certified hardware
• Optimized heat sink design for heat dissipation
• Fan-less design
• 19-inch rack mountable, 1U height

SYNC 3000 Hardware User Manual 6

1.3. Hardware Block Diagram
SYNC 3000 product series uses a communication processor that combines four cores with high
performance data path acceleration logic and network and peripheral bus interfaces required
for networking, telecom/datacom, wireless infrastructure, and aerospace applications. This
device can be used for combined control, data path, and application layer processing in routers,
switches, base station controllers, and general-purpose embedded computing. Its high level of
integration offers significant performance benefits compared to multiple discrete devices.

In the case of the SYNC 3000 product series, different variations of the products are available
in the market.

SYNC3000-Series Product Block Diagram

Redundant*
Power Supply
LAN-1
Power Supply
LED Indications USB PORT* Control Switches
LAN-2

LAN-3
Memory Interface
DDR3 SO-DIMM
LAN-4

10/100/1000Mbps
10/100Mbps
LAN-5 NAND Flash*

CPU
LAN-6

NOR Flash*
Ethernet Ports* Serial Interface

LAN-1
P2 LAN-1
P1 Assynchronous Interface SATA-DOM Flash*

LAN-1
P4 LAN-1
P3

SATA Hard Disk*

LAN-1
P6 LAN-1
P5

LAN-1
P8 LAN-1
P7
RTC Watch Dog Timer Temperature
TemperatureSensors
Sensors SD Card*
LAN-1
P10 LAN-1
P9
CO-PROCESSOR

LAN-1
P12 LAN-1
P11

Serial Ports *
IEC61850-3 Certified System
* Optional Ports / Memory - Product Variants are available.

Figure 1: SYNC 3000 Hardware Block Diagram

A total of 12 serial ports and 6 LAN ports are available for communication with external devices.

SYNC 3000 Hardware User Manual 7

1.4. Product Hardware Specification

Features SYNC 3000

Processor QorIQ integrated communication processor
1GB-DDR3 SO-DIMM (4GB DDR3 optional available on request)
4GB -SATA DOM NAND flash
System Memory
512MB-NAND flash
SSD Hard disk (optional available on request)
SYNC 3000-M3:
4 numbers of
10/100/1000 Mbps
Ethernet ports
with auto MDIX SYNC 3000-M3 & M12: 2 numbers of
Network Support capability 10/100 Mbps Ethernet ports with auto MDIX
or capability.
SYNC 3000-M12: 2
numbers of 100Mbps
Fiber Optic Pots with
Full duplex capability
COM1-COM4-RS232/ COM5-RS232 full
RS485. Also, COM1 MODEM COM9-COM12-
Serial Ports
is configurable to COM6-COM8 RS232. RS485
CONSOLE.
IRIG-B DCLS TTL 5V signal input with B000 time code format
Time Synchronization
(licensed on request)
LAN (6 Ports)-link & activity
LAN FO Ports-Activity
Serial(12-Ports)- Tx & Rx
LED Indications
Power 1-power healthy/unhealthy
Power 2-power healthy/unhealthy
Processor status-active/fail
Option 1: 90-260VAC (47-63Hz) or 100-360VDC)
Power Input
Option 2: 38-68VDC
440mm x 338mm x 45 mm
Dimensions
484mm x 338mm x 45 mm (with mounting bracket)
Mounting Standard 19 inch rack mount
Weight 4.5 kg
Operating
-40°C to +70°C
Temperature
Table 1: Specification of SYNC 3000 Product Series

SYNC 3000 Hardware User Manual 8

 2
2. Product Appearance and Characteristics
The following topics are covered in this chapter:
Physical properties of the device including
• Appearance
• Environmental characteristics
• Dimension
• LED indications

2.1. Appearance

Figure 2: View of SYNC 3000

2.2. Environmental Characteristics

Operating Condition
Description Min Max Unit
Operating temperature -40 +70 °C
Storage temperature -40 +85 °C
Table 2: Environmental Characteristics

SYNC 3000 Hardware User Manual 9

2.3. Mechanical Dimensions

337.9 315

44.5

440

Figure 3: Dimension of SYNC3000 M1/M2/M3

337.9 315

44.5

440

Figure 4: Dimension of SYNC3000 M12

SYNC 3000 Hardware User Manual 10

2.4. Mounting Details
SYNC 3000 is designed for 19 inch rack mounting. The following points should be kept in mind
while mounting the devices to the required panel:

• Maintain space between devices - Ensure minimum distance/ clearance between rack
and neighboring devices. Users need these minimum clearances during installation and
operation; it is required for setting up and removing the units and ensuring airflow required
for cooling the modules during operation. Space should be provided for running cable
channels.

• Mounting the device - Rack mounting for SYNC 3000 models - The SYNC 3000 models
can be mounted on a standard 19-inch rack. Use the enclosed pair of L-shaped metal
plates (shown in the figure 5 as 19 inch rack-mount ear) and screws to fasten the SYNC
3000 models to the rack-cabinet such that the front panel of SYNC 3000 is affixed to the
front side of the rack.

11.9

31.8
6.3
462
484

Figure 5: SYNC3000 mounting details

Figure 6: L-Shape Mounting Bracket

SYNC 3000 Hardware User Manual 11

2.5. LED Indications
The SYNC 3000 product series comprises four types of indications:
• Ethernet communication ports LED
• Serial communication ports LED
• Power indication LED
• Processor status LED

LED Indication Inference

Green Power 1 Healthy
Power 1 indication
Red Power 1 Unhealthy
Green Power 2 Healthy
Power 2 indication
Red Power 2 Unhealthy
Green (blinking) System booting in progress
Green (glow) System is ready
Processor status
OS boot up failure or other
Off
system initialization error.
Green (glow) Link established
Yellow (blinking) Communication in progress
Cable error detected or faulty
Ethernet grounding. In this case,
Communication- please ensure that the
Green (blinking)
LAN1-LAN6 optional earth wire is
connected to this device as
per ground wiring.
Green/Yellow (Off) Cable disconnected
Serial Communication- Port 1 Green (blinking) Serial port is transmitting data
to Port 12 Yellow (blinking) Serial port is receiving data
Table 3: LED Details of SYNC 3000

SYNC 3000 Hardware User Manual 12

 3
3. SYNC 3000 Hardware Details
This chapter covers the following topics:
• Electrical characteristics
• Power supply details
• Power connections & grounding scheme
• Communication ports and switches

3.1. Electrical Characteristics

3.1.1. Power Input Details - Universal Power Supply
Power Input
Universal Power Supply
Parameter Description Min Typ Max Unit
VAC Supply Voltage 90 220 260 VAC
VDC Supply Voltage 100 - 360 VDC
F Input Frequency 47 50 63 Hz
Table 4: Power Input
3.1.2. Power Input Details - DC Power Supply
Power Input
DC Power Supply
Parameter Description Min Typ Max Unit
VDC Supply Voltage 38 - 68 VDC
Table 5: Power Input
3.1.3. Power Consumption
Parameter Min Typ Max Unit
Total power consumption 18 26 35 W
Table 6: Power Consumption

3.2. Power Supply Details

The SYNC 3000 product series uses universal power supply modules to power the product.
The product series also includes power supply redundancy option (available in some product
variants).

SYNC 3000 Hardware User Manual 13

The main parameters of power supply are mentioned below:
Parameter Value
Output short circuit protection Yes (auto recovery)
Input – output isolation Yes
Input protection Transient, Surge and over current protection.
Table 7: Universal Power Supply Characteristics

3.2.1. Power Connector

SYNC 3000 product series is available in single power and dual power input options. In SYNC
3000, a special type power connector with 10 pin dual row (each row has 5 connect points) is
available. For single power supply option, you can plug the power input to the power slot 1 and
for power supply redundancy variant product you can connect power 1 to the power slot 1 and
power 2 to the power slot 2.

Connect the power connector of SYNC 3000 (3 pin power jack with redundant power supply) to
power line. If the power is properly supplied, the LED on the front panel will glow green otherwise
it will glow red.

After powering up, check the status of the processor. (See LED indication section for more
information).

90-260VAC (50/60Hz) /100-360VDC

Figure 7: Symbolic representation of power connector for option1 (universal input)

38-68VDC

Figure 8: Symbolic representation of power connector for option 2

SYNC 3000 Hardware User Manual 14

3.2.2. Power Input Wiring Description
User must follow the given wiring instructions. Otherwise, the product may be irreparably
damaged.

Connector
Input Line Description
Number
Power 2 Neutral / Power 2 source connected to the neutral line if the power source is
1*
DC - AC, or to the negative (-) terminal if the power source is DC
Power 2 Line / Power 2 source connected to the phase line if the power source is
2*
DC + AC, or to the positive (+) terminal if the power source is DC
Must be connected to the earth ground. Chassis ground connected
3 Chassis Ground
to the surge ground via a removable metal clamp.
4 NC No connect
Must be tied to the chassis ground for normal operation. Use metal
clamp provided to connect the surge ground and chassis ground
together. Surge ground is used as the ground for all the transient
5 Surge Ground
and surge suppression devices.
Note: Surge ground must be disconnected from the chassis
ground during dielectric (HiPot) testing.
Must be tied to the chassis ground for normal operation. Use metal
clamp provided to connect the surge ground and chassis ground
together. Surge ground is used as the ground for all the transient
6 Surge Ground
and surge suppression devices.
Note: Surge ground must be disconnected from the chassis
ground during dielectric (HiPot) testing.
Must be connected to the earth ground. Chassis ground connected
7 Chassis Ground
to the surge ground via a removable metal clamp.
8 NC No connect
Power 1 Neutral / Power 1 source connected to the neutral line if the power source is
9
DC - AC, or to the negative (-) terminal if the power source is DC
Power 1 Line / Power 1 source connected to the phase line if the power source is
10
DC + AC, or to the negative (+) terminal if the power source is DC

Table 8: Power Connector Pins Description

*Power2 slot is dedicated to the power supply redundancy option

Figure 9: Power connector pin numbering

SYNC 3000 Hardware User Manual 15

3.2.3. Power Input Wiring Scheme
Users must follow the given wiring scheme.

Figure 10: Power Channel Numbering

Figure 11: Power Input wiring scheme

SYNC 3000 Hardware User Manual 16

3.2.4. Grounding Scheme
Users must take the following actions before switching on the system.

Figure 12: Shorting Clamp Position

Figure 13: Shorting Clamp

For normal operation, chassis ground and surge ground should be connected together
as shown in figure 11 using the metal clamp provided. Users must use 3-Pin AC power
connector for powering AC input. For DC input, user must connect the surge/chassis
ground to the earth ground.

Proper connection to earth required for better unit performance, efficient port
communication and complete protection. To increase the noise immunity of the system,
it is suggested that the chassis is connected to earth ground using thick copper wire as
shown in the power input wiring scheme section.

HIPOT or DIELECTRIC STRENGTH TESTING

The connection between chassis ground and surge ground must be disconnected
during HIPOT or dielectric strength testing. Please make sure this is done before
testing. In case users require the power input to be isolated from the ground, remove
the ground shorting clamp between surge and chassis ground. Note that all the
transient suppression devices will be inactive.

SYNC 3000 Hardware User Manual 17

3.3. Communication Ports
The following topics are covered in this section:
• Copper Ethernet Ports
• Fiber Ethernet Ports
• Serial Ports
• IRIG-B Port

3.3.1. Copper Ethernet Ports

The SYNC 3000 product series is equipped with upto 6 Ethernet Ports for communication with
external devices. Out of six ports, 4-Ethernet ports are able to communicate at a speed of
10/100/1000 Mbps while the remaining 2-Ethernet ports support speeds of 10/100Mbps. The
RJ45 stacked connector has two LEDs embedded in its: link (green) & activity (yellow).

The pin details of the connector are shown below in figure 13:
10/100/1000Mbps Port Signals

10/100Mbps Port Signals

Pin Number
[ LAN 5-6 ]

1 TRD0+ RX+
2 TRD0- RX-
3 TRD1+ TX+
4 TRD2+ -
5 TRD2- -
6 TRD1- TX-
7 TRD3+ -
8 TRD3- -
Figure 14: Ethernet Pin Definition

Ethernet Port Number Default IP Address Net Mask

LAN1 192.168.0.121 255.255.255.0
LAN2 192.168.1.121 255.255.255.0
LAN3 192.168.2.121 255.255.255.0
LAN4 192.168.3.121 255.255.255.0
LAN5 192.168.4.121 255.255.255.0
LAN6 192.168.5.121 255.255.255.0
Table 9: Default IP Address

LAN5 and LAN6 are switching ports and should not be connected to the same Ethernet
switch.

SYNC 3000 Hardware User Manual 18

 Figure 15: Ethernet Port Arrangement

Information on the LED indication can be seen in table 3.

3.3.2. Fiber Ethernet Ports
The SYNC 3000 product series have optional Fiber Optic Ports (maximum of 2 ports). These can
be used for fiber backbone connectivity of Fiber Distributed Data Interface (FDDI) like network.
The Fiber Optic Ports can communicate at a speed of 100 Mbps in Full Duplex mode. They also
have an activity indication LED (yellow). Technical specifications are given in table 15:

Fiber Technical Specification

1 Speed 100Mbps
2 Duplex Mode Full
3 Fiber connectivity ST Connector
4 Fiber Cable Type Multi-Mode- 50/125µm (expect an optical decline of 2 dB)
& 62.5/125µm
5 Wavelength Supported 1300nm
6 Optical Reach 1.5Km
Table 10: Fiber Technical Specification

Figure 16: ST Fiber Optic Cable

Figure 17: Fiber Optic Ports Symbols

In the absence of fiber optic cables it is mandatory to use the plastic cap provided in both Tx and
Rx ports to avoid dust entry into the optical diode. Refer the ordering information section to see
the Fiber Optic ordering details.

SYNC 3000 Hardware User Manual 19

3.3.3. Serial Port
The SYNC 3000 product series is able to provide up to 12 serial ports for communication with
external devices. All of them are configurable to operate on a wide range of baud rates. The
full-modem signals in port 5 make it easier for interfacing GPRS/CDMA modems (external) for
wireless connectivity. Some of the ports are able to handle both RS232 and RS485 communication
standards. Check the serial ports arrangement details given below in table 9. The configuration
of RS232 or RS485* half duplex mode will be done through software. Also, LED indications are
provided for all Tx (green) and Rx (yellow) serial lines.

Port No Signal RS232- RS485- Act as Console Port Type

Count Support Support
1 2 Yes Yes* Yes** RJ45-Stacked
2 2 Yes Yes* - RJ45-Stacked
3 2 Yes Yes* - RJ45-Stacked
4 2 Yes Yes* - RJ45-Stacked
5 7 Yes - - RJ45-Full
Modem
6 4 Yes - - RJ45-Stacked
7 4 Yes - - RJ45-Stacked
8 4 Yes - - RJ45-Stacked
9 2 - Yes* - Terminal Block
10 2 - Yes* - Terminal Block
11 2 - Yes* - Terminal Block
12 2 - Yes* - Terminal Block
Table 11: Serial Ports Arrangement

* NOTE: No internal termination is considered for RS485 ports. It is recommended that

a termination resistance be placed in between the RS485 lines. See Appendix D for the
RS485 termination scheme.

** NOTE: It will act as debug console only when the console switch is in the ‘ON’
position. See section 3.3.3.1 on Console Switch for more details.

SYNC 3000 Hardware User Manual 20

 Pin 8 Pin 1

Pin 1 Pin 8
Figure 18: RJ45 Serial Dual Stacked Port’s -Connector

Figure 19: RS485 Stacked Terminal Block Port’s -Connector

Full Modem Port Signal Details

RS232 PIN ASSIGNMENTS ON PORT P5
Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8
DSR DCD DTR GND RXD TXD CTS RTS
Data Data Data
Receive Transmit Clear To Request
Set Carrier Terminal Ground
Data Data Send To Send
Ready Detect Ready
Table 12: Full MODEM Port Pin Details

SYNC 3000 Hardware User Manual 21

RS232/RS485-2Wire Port’s Signal Details-RJ45

These ports can be configured either as RS232 mode or RS485 mode depending upon the software
configuration.

RS232 -2 SIGNAL PIN ASSIGNMENTS ON PORTS P1-P4

Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8
NC NC NC GND RXD TXD NC NC
No No No Receive Transmit No No
Ground
Connect Connect Connect Data Data Connect Connect
Table 13: PORT’s Pin Details (RS232 Mode-2wire)

RS485 PIN ASSIGNMENTS ON PORTS P1-P4

Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8
NC NC NC GND NC RS485+ NC RS485-
Table 14: PORT’s-Pin Details (RS485 Mode-2wire)

RS232-4Wire Port Signal Details-RJ45

RS232-4 SIGNAL PIN ASSIGNMENTS ON PORTS P6-P8

Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8
NC NC NC GND RXD TXD CTS RTS
No No No Receive Transmit Clear to Request
Ground
Connect Connect Connect Data Data Send to Send
Table 15: PORT’s-Pin Details (RS232 Mode-4wire)

RS485-2Wire Dedicated Port Signal Details-Terminal Block

RS485 DEDICATED TERMINAL BLOCK SIGNAL PIN ASSIGNMENTS ON PORTS P9-P12

Pin 1 Pin 3 Pin 5 Pin 7 Pin 9 Pin 11
RS485_D0+ RS485_D0- GND RS485_D2+ RS485_D2- GND
Pin 2 Pin 4 Pin 6 Pin 8 Pin 10 Pin 12
RS485_D1+ RS485_D1- GND RS485_D3+ RS485_D3- GND
Table 16: PORT’s-Pin Details (RS485 Mode-Dedicated)

Figure 20: 12-Serial Port Arrangement

SYNC 3000 Hardware User Manual 22

3.3.4. Time Synchronization using IRIG-B I/O
IRIG-B is a standard time code format that allows synchronized time stamping among connected
devices in milliseconds. The SYNC 3000 series products support B000 IRIG-B time code format,
pulse width coded DC level shifted signal. External clock can be used for generating the IRIG-B
signal. This equipment can use a GPS satellite system to obtain the time reference in order to
synchronize devices in different stations. SYNC 3000 series products have an IRIG-B looping
option to maintain the time signal even when the device is power down.

The IRIG-B card accepts an IRIG-B signal in the following formats through a corresponding
connector type:
• Pulse Width Coded DCLS TTL-5V IRIG-B Input/output signal through BNC Connector
• Pulse Width Coded DCLS TTL-5V IRIG-B Input/output signal through terminal block.
• If the user given the input through BNC connector, the terminal Block can act as IRIG B
loop output or vice versa.

IRIG-B Input/ Output technical specifications are given in table 16.

IRIG-B Specification
1 Input/Output Connector Type BNC 50 Ohm
2 Input/Output Connector Type 5.08mm Terminal Block
3 Time Code B000-100PPS (with IEEE C37.118 CF extensions)
4 Signal Level TTL 5V level with High Level voltage 4 to 5.5V & Low
Level Voltage 0 to 0.2V
5 Input/Output Current 1.5mA (Min)
6 Galvanic Isolation 2500 Vrms for 1 minute
Table 17: IRIG-B Technical Specification

Figure 21: IRIG-B Connector’s Symbol

SL No Signal Description
2 TTL+ IRIG-B (DC) 5V TTL Signal IN/OUT
3 TTL- IRIG-B (DC) Signal Ground
Table 18: IRIG-B Terminal Block Connector Signal Details

SL No Signal Description
2 TTL+ IRIG-B (DC) 5V TTL Signal IN/OUT in the BNC Center Post
3 TTL- IRIG-B (DC) Signal Ground in the BNC Ground Post
Table 19: IRIG-B BNC Connector Signal Details

Note: For IRIG-B software configurations refer the Easy-connect Help file.

SYNC 3000 Hardware User Manual 23

3.4. Control Switches
There are two switches in the product:
• Console switch
• Reset switch
3.4.1. Console Switch
The console port is used for advanced diagnostics/debugging purpose. User can login to the
gateway by connecting the console port to a PC serial port using a serial cross-over cable. The
pin configuration of the console port is same as other serial port configurations of corresponding
gateways. User can use hyper terminal to connect to the console port. User must follow the steps
given in table 15 to activate the debug functionality. Port 1 can be configured to debug console
mode by the debug switch. To enable console mode, the switch should be in ON position before
turning the device on. The mode of communication will be RS232. Only 2 signals are required for
RS232 signaling (TX, RX, GND). For more information, contact support@kalkitech.com.

Figure 22: Debug Switch-Rear Panel Details

Debug Switch Position Function

When system restarts, make port 1 as
ON
console port in RS232 mode.
When system restarts, make port1 as normal
OFF communication port in RS232/RS485 mode
(depends on the selection in software).
Table 20: Debug Switch Configuration

Note: The device to be manually restarted when changing the console switch position.

SYNC 3000 Hardware User Manual 24

3.4.2. Reset Switch
This is a press button switch, which can be used for multipurpose activities listed below.

Reset Switch Press Function Inference

States
Press duration between
Manual safe power off 5-8 seconds, during normal
working conditions.
While the unit is in OFF
Manual power on condition, Press for 5-8
seconds duration
Press duration greater than
20 seconds, during power on
Load factory default
state to activate the default
factory settings procedure.
Table 21: Reset Switch Configuration
Processor active state LED on the
front panel will blink continuously
for 15 seconds and then go off
which indicates that the hardware
shut down process is successfully
completed
Processor active state LED on the
front panel will blink continuously
and then go to ‘ON’ state. This
indicates reboot process is
successfully completed.
Processor will re-boot to factory
settings including default IP settings
mentioned in table8. This procedure
may take some time.

Figure 23: Reset Switch- Rear Panel Details

For normal operations, users should not use the reset button. For normal working of
the system, user just needs to plug in the power supply. This action will lead to the
normal booting of the system. The processor status LED on the front panel will glow on
successful completion of the boot.

SYNC 3000 Hardware User Manual 25

 4
4. SYNC 3000 Product Variants and Options
SYNC 3000 comes under three standard variants based on the number of serial and ethernet
ports
• SYNC3000 M1: S12R2, 12 Serial port and 2 Ethernet port (Licensable)
• SYNC3000 M2: S12R4, 12 Serial port and 4 Ethernet port (Licensable)
• SYNC3000 M3: S12R2, 12 Serial port and 6 Ethernet port
• SYNC3000 M12: S12R2F2, 12 Serial port, 2 Fiber Ethernet and 2 Copper Ethernet ports

SYNC 3000 has numerous add-on options, apart from the Serial and Ethernet port variations
mentioned above. These include:
• SATA hard disk
• Redundant power supply
• IRIG-B addon License

For further assistance, please contact Kalkitech sales: sales@kalkitech.in

SYNC 3000 Hardware User Manual 26

 A
Appendix A: Troubleshooting
The SYNC 3000 Product Series is delivered in ‘Ready to Run’ mode and will automatically start
loading the operating system from the on board flash memory when power is supplied. Once
the device is up, the information in this manual will provide the user with guidance for installing
and using it. If user encounters problems with a particular feature of SYNC 3000 product
series, please refer to the relevant chapter in the manual. If user is unable to resolve the problem,
con- tact Kalkitech technical support team at support@kalkitech.com.

If SYNC 3000 product series does not start running when power is supplied, then there may be
a problem with the system configuration. The following steps will help to determine the cause of
the problem:

1. Switch OFF the module and disconnect the power input. Verify the connections to the power
connector. Switch ON the unit. Check the front panel power LED status. If the LED glows red,
check if the power cable connection is as per the power input wiring scheme or not. If the
board does not work, go to step 2.

2. Please contact Kalkitech technical support at support@kalkitech.com.

3. Ensure that the correct model of SYNC (SYNC 3000 Product Series) is selected in the
EasyConnect configuration utility. A wrong selection of the SYNC model will result in an
initialization failure.

SYNC 3000 Hardware User Manual 27

 B
Appendix B: Guidelines to Handle ESD
ESD- Definition: All electronic modules are equipped with large-scale integrated ICs or components.
Due to their design, these electronic elements are very sensitive to high voltages and thus to any
electrostatic discharge too. ESD stands for electrostatic discharge.

Electrostatic charging of persons: Every person with a non-conductive connection to the

electrical potential of his/her surroundings can be charged electrostatically. The following
figure shows user the maximum values for electrostatic voltages which can build up on a person
coming into contact with the materials indicated in the figure. These values are in conformity with
the specifications of IEC 61000-4-2.

Methods to avoid electrostatic discharge:

The following two methods are suggested to avoid electrostatic discharge.
1. Ensure sufficient grounding - Make sure that the personnel, working surfaces, and
pack- aging are sufficiently grounded when handling electrostatically sensitive devices. You
thus avoid electrostatic charging.

Figure 24: ESD Characteristic

2. Avoid direct contact – User should touch electrostatically sensitive devices only if it is
unavoidable (For example, during maintenance work). Hold modules without touching the
pins of components or printed conductors. In this way, the discharged energy cannot affect
the sensitive devices. If the user has to carry out measurements on a module, user must
discharge his body before starting the measurement by touching grounded metallic parts.
Use grounded measuring devices only.

WARNING:
Improper handling of electrostatic-sensitive devices can cause damage to the device
and person using the same.

SYNC 3000 Hardware User Manual 28

 C
Appendix C: Guidelines for Surge and Fast Transient
Protection
Lightning strikes, power source fluctuations, inductive switching etc. can cause damage to the
product by generating large transient voltages. The following specifications are relevant to the
above transients:

1. IEC61000-4-4 Burst/Fast Transients

2. IEC61000-4-5 Surge

The protection from the above transients is accomplished by clamping the voltage spike to a limit
that does not damage the device. The SYNC 3000 product series has inbuilt protection devices
to protect against the above transients and has been tested to meet the standards IEC61000-4-4
and IEC61000-4-5 for signal and power ports. These units can be directly connected to the field
devices through the cables connected to serial ports. The power terminals can also be connected
directly to the input supply. The above protection functionalities work with shorting clip and
proper earth connection to the unit.

For tests and standards refer to table IEC61850-3 immunity tests

SYNC 3000 Hardware User Manual 29

 D
Appendix D: RS485 Daisy chain termination and
Multi-drop
The RS-485 standard permits a balanced transmission line to be shared in a party line or
multidrop mode. As many as 32 driver/receiver pairs can share a multidrop network. Termination
should only be used with high data rates and long wiring runs. The signal ground line is also
recommended in an RS-485 system to keep the common mode voltage that the receiver must
accept within the -7 to +12 volt range. The transmission line is terminated on both ends of the
line but not at drop points in the middle of the line. There should be no more than two terminating
resistors in the network regardless of the number of nodes connected. Figure 21 shows a typical
two-wire multidrop network.

The termination resistor value is dependent on the total impedance of RS-485 network. Normally
120 ohms resistors are used as shown in figure 21. The value varies depending upon field
conditions such as the line impedance and number devices.

Figure 25: RS485-Termination Scheme

SYNC 3000 Hardware User Manual 30

 E
Appendix E: Certifications
Immunity
IEC 61000-4-3: 80 - 1000 MHz: 10V/m 80% AM, 1 kHz sine
Radiated Susceptibility
wave
IEC 61000-4-4: - ±4 kV serial ports, Ethernet port, AC Power
Electrical Fast Transient
Ports
IEC 61000-4-2:- +/- 6 kV Contact Discharge, +/- 15 kV Air
Electrostatic Discharge
Discharge
IEC 61000-4-5:
Serial port ± 4kV, 1.2/50 μs for common mode,
Surge Protection Ethernet port ± 2kV, 1.2/50 μs for common mode
AC Power port ± 4kV, 1.2/50 μs for common mode, ± 2kV,
1.2/50 μs for differential mode
IEC 61000-4-6: 0.15 - 80 MHz: 10 Vrms 1 kHz, 80%AM for
Induced (Conducted) RFI
power, serial and Ethernet port
Power Frequency Magnetic
IEC 61000-4-8: -30 A/m continuous & 1000 A/m for 1 sec
Field immunity
Damped Oscillatory Magnetic IEC 61000-4-10: Magnetic field strength: 30 A/m @
fields immunity test Oscillation frequency 1MHz
IEC 61000-4-18 Damped Oscillatory Frequency: 1MHz
Damped Oscillatory Wave Common Mode: up to ± 2.5 kV Differential Mode: up to ±1.0
immunity kV for power port 1 MHz Common Mode: up to ± 2.5 kV for
serial port and Ethernet port
Impulse voltage Immunity IEC60255-5 ±5kV for power port and earth
Conducted Common mode IEC 61000-4-16 Ed 1.1 30/300V at 50Hz, 3V/30V at 15 to
disturbances Immunity 150kHz
Emission
Conducted Emission EN 55022: Class A 150KHz to 30MHz
Radiated Emission EN 55022: Class A 30MHz to 6GHz
Range & Tolerance
IEC 61000-4-11 - AC Power port 0% short Interruption for 250
cycles,
AC Voltage Dips &
Dips -100% of AC mains voltage for 0.5 cycles and, -60%
Interruption
dips for 10 cycles, -30% dips for 25 cycles, -20% dips for 250
cycles
AC Voltage Range and IEC 60870-2-1 Ed 2.0: - 20% to +15% tolerance at AC power
Tolerance test port
Environment
Cold Temperature test As per IEC60870-2-2 tested at -40ºC for 16Hrs Class C
Hot Temperature test As per IEC60870-2-2 tested at +70ºC for 16Hrs Class C
Damp heat Cyclic As per IEC60870-2-2 95% RH 25ºC and 55ºC for 4 days

SYNC 3000 Hardware User Manual 31

 As per IEC 60870-2-2 Test range ambient level (91.6 kPa) to
Barometric Pressure test
3000m (70.0 kPa)
As per IECC60870-2-2, Class Bm, 5-500 Hz, displacement
Vibration 3mm 5-9Hz, acceleration 1g for 9Hz-200Hz, 1.5g for 200Hz-
500Hz
Shock test As per IEC60870-2-2 10g in X,Y, Z axis
Table 22: Type Test Details

SYNC 3000 Hardware User Manual 32

Glossary
The following table shows the acronyms/abbreviations used in this document:
Acronyms / Abbreviations Description
TX Transmit pair
RX Receive pair
Transmit/receive pairs designated in
TRD
10/100/1000 Mbps ethernet
LAN Local area network
Table 23: List of Abbreviations

SYNC 3000 Hardware User Manual 33