SYNC 2000

Hardware User Manual

www.kalkitech.com

Version 2.0.1, 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 2000 Hardware User Manual 2

Table of Contents
1. Introduction 6
1.1. Overview 6
1.2. Product Features 6
1.3. Product Hardware Specifications 7

2. Appearance and Dimensions 9

2.1. Appearance 9
2.1.1. SYNC 2000-M1/M2 (S2R1/S6R1) 9
2.1.2. SYNC 2000-M4 (S6F1) 10
2.1.3. SYNC 2000- M5 (S4R2) 10
2.2. Hardware Characteristics  11
2.2.1. Electrical Characteristics 11
2.2.2. Environmental Characteristics 12
2.3. Dimensions 13
2.3.1. SYNC 2000 M1/M2 (S2R1/S6R1) 13
2.3.2. SYNC 2000- M5 (S4R2) 14
2.4. LED Indications 14
2.4.1. SYNC 2000 M1/M2/M4 (S2R1/S6R1/S6F1) 14
2.4.2. SYNC 2000 M5 (S4R2) 15
2.5. Switches 15
2.5.1. Reset Switch 15
2.5.2. RS232/RS485 Selection Switch (SW2) 16
2.5.3. SYNC 2000 M5 (S4R2) DIP Switch for Termination 16
2.5.4. SYNC 2000 M5 (S4R2) Debug Switch 17

3. Installation Guidelines 18
3.1. Mounting Details 18
3.2. Wallmount Bracket Assy 19
3.3. 19” Rackmount Assy 20

4. External Interfaces and Indications 21

4.1.1. SYNC 2000 M1/M2/M4 (S2R1/S6R1/S6F1) Input Power Connector and
Grounding  21
4.1.2. SYNC 2000 M5 (S4R2) Input Power Connector and Grounding 22
4.1.3. Serial Interfaces 23
4.1.4. Debug (Console) Interface 27
4.1.5. Ethernet Interface 28
4.1.6. SYNC 2000 M4 (S6F1) Ethernet Fiber 28
4.1.7. Alarm Contact 29
4.1.8. Internal Modem 29

5. Troubleshooting 30

Appendix A – Guidelines for Handling ESD 31

Appendix B – Certifications 32

Glossary 33

SYNC 2000 Hardware User Manual 3

List of Figures
Figure 1: Front View of SYNC 2000 M1/M2 9
Figure 2: Front View of SYNC 2000 M4 (S6F1) 10
Figure 3: Front View – 2000-M5 (S4R2) 10
Figure 4: Left Side View 11
Figure 5: Right Side View 11
Figure 6: Dimensions of SYNC 2000 M1/M2 (S2R1/S6R1) 13
Figure 7: Dimensions of SYNC 2000 M4 (S6F1) 13
Figure 8: Dimensions of SYNC 2000- M5 (S4R2) 14
Figure 9: SYNC 2000 LED and RESET indications 14
Figure 10: LED Details – SYNC 2000 M5 (S4R2) 15
Figure 11: SYNC 2000 M1/M2/M4 (S2R1/S6R1/S6F1) DIP Switch Indication 16
Figure 12: SYNC 2000-M5-RS485 Terminations 17
Figure 13: Debug Switch (SW2) 17
Figure 14: Mounting Details Of SYNC 2000 18
Figure 15: Dinrail to Dinrail Clip Assy options 19
Figure 16: Wallmount Bracket Option 19
Figure 17: Rackmount Bracket Option 20
Figure 18: SYNC 2000 M1/M2/M4 (S2R1/S6R1/S6F1) Power Port 21
Figure 19: Device Grounding 21
Figure 20: Shielded Ground - SYNC 2000 M5 (S4R2) 22
Figure 21: SYNC 2000 -M1/M2/M4 (S2R1/S6R1/S6F2) Serial Ports 23
Figure 22: SYNC2000 M5 (S4R2) Serial Interfaces 25
Figure 23: RS485 Termination and Multidrop 26
Figure 24: SYNC 2000-M1/M2/M4 (S2R1/S6R1/S6F2) Console Port 27
Figure 25: SYNC 2000-M1/M2/M5 (S2R1/S6R1/S4R2) LAN Port 28
Figure 26: Interface diagram of fiber optic port 28
Figure 27: DO Connector 29
Figure 28: SIM card holder slot 29
Figure 29: SIM card insertion procedure 29
Figure 30: Electrostatic voltage trip off plot 31

SYNC 2000 Hardware User Manual 4

List of Tables
Table 1: Hardware Requirements 8
Table 2: Electrical Characteristics (option 1) 11
Table 3: Electrical Characteristics (option 2) 12
Table 4: Environmental Characteristics 12
Table 5: Mechanical Specification 13
Table 6: LED Details – SYNC 2000 M5 (S4R2) 15
Table 7: Reset Switch Details 15
Table 8: SYNC 2000 DIP Switch Indication 16
Table 9: Serial Port (S1) Pin Details 24
Table 10: Serial Port (S2-S4) Pin Details 24
Table 11: Serial Port (S5-S6) Pin Details 24
Table 12: Serials RJ45 Port (S2-S4) Pin Details SYNC 2000 M5 (S4R2) 25
Table 13: S1 -DB9 Serial Port Pin Details – SYNC 2000 M5 (S4R2) 25
Table 14: S2-Console Port Pin Details 27
Table 15: LAN Port Pin Details 28
Table 16: SYNC 2000 M1/M2/M4 (S2R1/S6R1/S6F1) type test detail 32
Table 17: List of Abbreviations 33

SYNC 2000 Hardware User Manual 5

 1
1. Introduction
This document gives a comprehensive information of SYNC 2000 pertaining to the hardware
installation and its mounting. Please note that for software installation and configuration, refer to
the Software User Manual found in the CD, or collect it by contacting support@kalkitech.com.

This manual introduces the hardware of the SYNC 2000 Protocol gateways. SYNC 2000 Protocol
Gateways are versatile communication controllers for Substation Automation, Smart Grid, M2M,
Automatic Meter Reading, Distribution Automation applications. This controller comes with
embedded Linux Operating system. Standard and proprietary protocols like IEC 61850, IEC
60870-5-101/104, DLMS, Modbus and a host of other smart grid protocols are supported in the
device. It also supports secure VPN connections for enhanced communication security and also
for managing connections in cellular networks.

Intended Audience
This guide is intended for equipment manufacturers and systems integrators working in energy
sector.

The following topics are covered in this chapter:

• Overview
• Product Features
• Hardware Block Diagram
• Product Hardware Specifications

1.1. Overview
The SYNC 2000 hardware platform provides upto 6 serial and 2 Ethernet ports (model
dependent) in a rugged package that is tested for IEC61850-3 compliance including strict EMI/
EMC requirements and Surge requirements on all ports and power supply (model dependent).
Hardware is also compatible for internal plug-able modem cellular modem (GPRS/CDMA/EVDO/
HSPA) in addition to low power radio frequency modem. Apart from internal modem, hardware
also provides option to connect external modem over serial or Ethernet port.

The SYNC 2000 is flexible to support other power system protocols there by enables Utilities
to exchange data with SCADA/ Local Monitoring systems if required. This device is also field
proven and secure solutions for protocol communication integration and translation requirements
for medium size applications in Power Generation, Transmission and Distribution, Oil & Gas,
Industrial Automation.

1.2. Product Features

Product features are given below:

• Software Features
–– Support more than 60 protocols including IEC 60870-5- 101/103/104, IEC 61850,
DNP3.0, Modbus RTU/TCP, and DLMS/COSEM
–– Automatic startup, initialization with restart notification following the power restoration
–– Multi master communication capability

SYNC 2000 Hardware User Manual 6

 –– File upload/download support, remote configuration
–– Time SYNC based on NTP/SNTP/NMEA/Protocol specific synchronization (IEC 104/
DNP3.0 etc.)
–– Transparent/tunnelling support for remote configuration and disturbance collection
–– Device management using SNMP/webserver
–– Configurable as a terminal server

• Reliability
–– IEC 61850-3 compliant hardware (model dependent)
–– KEMA certified IEC 61850 server

• Security
–– IEC62351-3 transport layer security
–– IEC62351-5/DNP3 secure authentication
–– lSSL based VPN with AES, DES or 3DES encryption over WAN/LAN
–– Compliant to NERC-CIP security standards

• Scalability
–– Internal or external pluggable cellular modem
–– Fiber optic or copper Ethernet option
–– Fibre Optic Ethernet
–– Wide range of AC and DC power supply
–– Customization of existing protocol as well as addition of new protocol possible

1.3. Product Hardware Specifications

The following table contains detailed specifications of SYNC 2000:

Features SYNC 2000 M1/M2/M4 SYNC 2000 M5 (S4R2)

(S2R1/S6R1/S6F1)
Processor ARM926EJ-S™ ARM core Processor- ARM® Cortex®-A8
Microprocessor Freq Max up to
600 MHz
Speed 190 MHz 600 MHz
RAM 32MB (Default) / 64MB SDRAM 256 MB DRAM
Flash 256 MB Flash 256MB 8-bit NAND Flash
Ethernet Port • Single 10/100 Base T • Dual 10/100/1000 Base T
• Standard: IEEE 802.3 • Standard: IEEE 802.3
• Data rate: 10/100 Mbps (auto-sensing) • Data rate: 10/100 Mbps
• Mode: Full duplex (autonegotiation) (auto-sensing)
• Connector: RJ 45 (for SYNC 2000 M1/ • Mode: Full duplex
M2 -S2R1/S6R1), Fiber ST port (for SYNC (autonegotiation)
2000 M4 -S6F1) • Connector: RJ-45
Serial Port • 6 RS-232 /4 RS-485 configurable Ports • 4 RS-232 /3 RS-485
• 1 Debug Port configurable Ports
• S1 Full Modem, S2-S4 TX, RX, RTS, CTS • 1 Debug Port
signals, S5-S6 TX, RX signals • S1 Full Modem, S2-S4 TX,
• Each port can have a maximum of 115.2 RX, RTS, CTS- RS232 ports
Kbps S2-S4 RS485 ports
• Each port can have a
maximum of 115.2Kbps

SYNC 2000 Hardware User Manual 7

 Features SYNC 2000 M1/M2/M4 SYNC 2000 M5 (S4R2)
(S2R1/S6R1/S6F1)
Output - 12VDC
Option 1: 19 - 58VDC
Option 1: 19 - 58VDC
Power Supply Option 2: 85 - 264VAC 50 - 60Hz or 100 - Option 2: Universal
370VDC (90-360VDC/85-264VAC)

Option 3: 9-36VDC
Power consumption 13.2 W 7W
Temperature -20°C to +70°C -10 to 60°C (14 to 140°F)
Humidity 5% to 90% 5% to 90%
Table 1: Hardware Requirements

SYNC 2000 Hardware User Manual 8

 2
2. Appearance and Dimensions
The following topics are covered in this chapter:
• Appearance
• Hardware Requirements
• Dimensions
• LED Indications
• Switches

2.1. Appearance
2.1.1. SYNC 2000-M1/M2 (S2R1/S6R1)

Figure 1: Front View of SYNC 2000 M1/M2

SYNC 2000 Hardware User Manual 9

2.1.2. SYNC 2000-M4 (S6F1)

Figure 2: Front View of SYNC 2000 M4 (S6F1)

2.1.3. SYNC 2000- M5 (S4R2)

The below figure shows the front panel view of SYNC 2000-M5 (S4R2) model containing the
details of the various components present on the unit.

Figure 3: Front View – 2000-M5 (S4R2)

SYNC 2000 Hardware User Manual 10

 Figure 4: Left Side View

Figure 5: Right Side View

2.2. Hardware Characteristics

Hardware characteristics of SYNC 2000 platform are listed below.
2.2.1. Electrical Characteristics
Operating Condition (Power Supply Option 1)
SYNC 2000 M1/M2/M4 SYNC 2000 M5
Parameter Description Unit (S2R1/S6R1/S6F1) (S4R2)
Min Max Typical Min Max Typical
Supply
VCC V 19 58 24/48 19 58VDC 24/48
Voltage (DC)
Table 2: Electrical Characteristics (option 1)

SYNC 2000 Hardware User Manual 11

 Operating Condition (Power Supply Option 2)
SYNC 2000 M1/M2/M4
Parameter Description Unit (S2R1/S6R1/S6F1)
Min Max Typical
Supply Voltage
VCC VAC 85 264 230
(AC)
Supply Voltage
VCC VDC 100 370 110/220
(DC)
Table 3: Electrical Characteristics (option 2)

2.2.2. Environmental Characteristics

Temperature
Description Min Max Unit
M1/M2/M4 M1/M2/M4
SYNC 2000- M5 SYNC 2000- M5
(S2R1/S6R1/ (S2R1/S6R1/
(S4R2) (S4R2)
S6F1) S6F1)
Operating
-20 -20 70 60 °C
Temperature
Storage
-20 -20 80 80 °C
Temperature
Table 4: Environmental Characteristics

SYNC 2000 Hardware User Manual 12

 2.3. Dimensions
2.3.1. SYNC 2000 M1/M2 (S2R1/S6R1)
The dimensions of SYNC 2000 are as given below:
SYNC 2000 M1/M2/M4
Operating Condition SYNC 2000- M5 (S4R2)
(S2R1/S6R1/S6F1)
Width (mm) 71 75 mm
Depth (mm) 140 140 mm
Height (mm) 164 160 mm
Table 5: Mechanical Specification

11.7

164.0

SMA Connector
71.0 14.2 140.0 7.6 11.6 (For Antenna)

Figure 6: Dimensions of SYNC 2000 M1/M2 (S2R1/S6R1)

Note: Dimensions are in Millimeter

11.7

164.0

SMA Connector
71.0 140.0 7.6 11.6 (For Antenna)

Figure 7: Dimensions of SYNC 2000 M4 (S6F1)

SYNC 2000 Hardware User Manual 13

2.3.2. SYNC 2000- M5 (S4R2)

Figure 8: Dimensions of SYNC 2000- M5 (S4R2)

2.4. LED Indications

2.4.1. SYNC 2000 M1/M2/M4 (S2R1/S6R1/S6F1)
• Power LED
• LED indication for Serial ports
• LED indication for Ethernet port

Power

Rx

Tx
Reset
Link
Status Rx
Tx
Figure 9: SYNC 2000 LED and RESET indications

SYNC 2000 Hardware User Manual 14

2.4.2. SYNC 2000 M5 (S4R2)
LED Color Inference
Ready/Power Green LED is lit when the unit is powered on
Status LED Bi Colour Will Change from Red to Green after boot up
LAN1 / LAN2 Yellow Blinking-10/100/1000 Mbps Ethernet communication is going on
Green Glow- 10/100/1000 Mbps Ethernet connection established
Off Ethernet cable is disconnected
P1-P4 Yellow Serial port is receiving data
Green Serial port is transmitting data
Off No data is being transmitted or received through the serial port
Table 6: LED Details – SYNC 2000 M5 (S4R2)

Figure 10: LED Details – SYNC 2000 M5 (S4R2)

2.5. Switches
2.5.1. Reset Switch
The Reset switch can be used to reset the module

Reset Switch Function

Press Module will reboot immediately
Table 7: Reset Switch Details
CAUTION: For model SYNC 2000 S4R2 (SYNC 2000-M5), pressing reset switch voids all
warranty and should not be pressed under any circumstances. Newer model of SYNC 2000
S4R2 covers the reset switch, but if not covered caution should be exercised not to press.

SYNC 2000 Hardware User Manual 15

2.5.2. RS232/RS485 Selection Switch (SW2)

12 3
ON 4

DETAIL D
SCALE 1 : 1

Figure 11: SYNC 2000 M1/M2/M4 (S2R1/S6R1/S6F1) DIP Switch Indication

ON - S1 in RS485 MODE
Actuator 1
OFF - S1 in RS232 MODE
ON - S2 in RS485 MODE
Actuator 2
OFF - S2 in RS232 MODE
ON - S3 in RS485 MODE
Actuator 3
OFF - S3 in Rs232 MODE
ON - S4 in RS485 MODE
Actuator 4
OFF - S4 in RS232 MODE
Table 8: SYNC 2000 DIP Switch Indication

2.5.3. SYNC 2000 M5 (S4R2) DIP Switch for Termination

The Switch SW1 are used to include the Termination for RS485 mode. This facility is applicable
for S2,S3 & S4. The Poles has to be in ON position, to include the Termination. This switch is not
accessible from outside of the enclosure. More details please see section RS485 Termination
and Multi drop.

SYNC 2000 Hardware User Manual 16

 Figure 12: SYNC 2000-M5-RS485 Terminations

2.5.4. SYNC 2000 M5 (S4R2) Debug Switch

Debug switch SW2 is used to switch mode of UART serial port S2 as RS232 port for communication
or as DEBUG port. Its mandatory to restart the device to make effect the change once switch
position is toggled.

Figure 13: Debug Switch (SW2)

SYNC 2000 Hardware User Manual 17

 3
3. Installation Guidelines
The following topics are covered in this chapter:
• Mounting Details
• External Interfaces and Indications
–– Power Input Connect
–– Serial Ports
–– Serial Interfaces
–– Debug (Console) Interfaces
–– Ethernet (LAN) Port

3.1. Mounting Details

The SYNC 2000 is designed to be mounted on a DIN rail. The enclosure features a DIN Rail
mounting clip at the back which snaps into the DIN rail. Tools are not required for mounting.

Note: Din rail mounting option is available only for all models of SYNC 2000

To mount the module on a DIN rail below steps can be followed:

• First Slot the top part of the DIN Rail mounting clip into the upper guide of the rail
• Lower the enclosure until the bottom of the DIN Rail mounting clip snaps into place

Figure 14: Mounting Details Of SYNC 2000

SYNC 2000 Hardware User Manual 18

 Figure 15: Dinrail to Dinrail Clip Assy options

3.2. Wallmount Bracket Assy

SYNC 2000 is designed to be mounted on a Wall. The enclosure features a mounting bracket
at the back side. The product can be mount using holes 1,2,5 & 6 (or) using holes 3 & 5 depend
upon the space constraints.

Note: Wall mounting option is available only for SYNC 2000 M5(S4R2)

Figure 16: Wallmount Bracket Option

SYNC 2000 Hardware User Manual 19

 3.3. 19” Rackmount Assy
SYNC 2000-M5 is designed to be mounted on a 19” Rack. The enclosure features a Rack
mounting bracket at the double side.

Note: Rack mounting option is available only for SYNC 2000 M5 (S4R2)

Figure 17: Rackmount Bracket Option

SYNC 2000 Hardware User Manual 20

 4
4. External Interfaces and Indications
4.1.1. SYNC 2000 M1/M2/M4 (S2R1/S6R1/S6F1) Input Power Connector and Grounding
Input supply need to be provided to the power connectors (comb icon) on the top side of the
device. DC Input should be powered with the correct polarity. The Red power LED will glow
indicating the unit is powered up properly.

Input Power Connector

Input Power Connector

Figure 18: SYNC 2000 M1/M2/M4 (S2R1/S6R1/S6F1) Power Port

Grounding
The ground is provided on the enclosure and the unit will get grounded on connecting the DIN
rail clip.

Connect the ring terminal of

Ground cable assembly in
between the washers & tighten
using nut

Figure 19: Device Grounding

SYNC 2000 Hardware User Manual 21

4.1.2. SYNC 2000 M5 (S4R2) Input Power Connector and Grounding
Power Connector
Connect the power line with terminal block of SYNC. If the power is properly supplied, the Ready
LED shows a solid green color when the device is ready.

Grounding
Grounding and wire routing help limit the effects of noise due to electromagnetic interference
(EMI). Run the ground connection from the ground screw to the grounding surface before user
connect devices. The Shielded Ground (SG), sometimes called Protected Ground, is the left
most contact of the 3-pin power terminal block connector when viewed from the angle shown
here in Figure 20. User have to connect the SG wire to an appropriate grounded metal surface.

Figure 20: Shielded Ground - SYNC 2000 M5 (S4R2)

SYNC 2000 Hardware User Manual 22

4.1.3. Serial Interfaces
SYNC2000 M1/M2/M4 (S2R1/S6R1/S6F1) Serial Interfaces.

SYNC 2000 M1/M2/M4 (S2R1/S6R1/S6F1) has 6 Serial Ports as given below:

Figure 21: SYNC 2000 -M1/M2/M4 (S2R1/S6R1/S6F2) Serial Ports

Note: While plugging/ unplugging External GPRS Modem from port S1, device need to
be in POWERED OFF state.

The serial interface of SYNC 2000 has following features:

• Ports S1 to S4 is configurable for RS232/485 using Dip Switches. For SYNC 2000 M1
(S2R1) only two ports shall be licensed
• Ports S5 and S6 are RS232 Ports
• Port S1 support full modem signals. Internal modem or external modem are connected to
port S1.
• Ports S2 to S4 have Tx, Rx, RTS and CTS signals
• Ports S5 and S6 have Tx and Rx signals
• Baud rate, start bits, stop bits are user configurable
• All ports have framing error and over run error detection

SYNC 2000 Hardware User Manual 23

 8 Pin plug (RJ45) RS232 Signal Name RS485 Signal Name
1 RS232_DSR NC
2 RS232_DCD NC
3 RS232_DTR NC
4 GROUND GROUND
5 RS232_RX NC
6 RS232_TX D+
7 RS232_CTS NC
8 RS232_RTS D-
Table 9: Serial Port (S1) Pin Details
8 Pin plug (RJ45) RS232 Signal Name RS485 Signal Name
1 NC NC
2 NC NC
3 NC NC
4 GROUND GROUND
5 RS232_RX NC
6 RS232_TX D+
7 RS232_CTS NC
8 RS232_RTS D-
Table 10: Serial Port (S2-S4) Pin Details
8 Pin plug (RJ45) RS232 Signal Name
1 NC
2 NC
3 NC
4 GROUND
5 RS232_RX
6 RS232_TX
7 NC
8 NC
Table 11: Serial Port (S5-S6) Pin Details

SYNC 2000 Hardware User Manual 24

SYNC 2000 M5 (S4R2) Serial Interfaces

Figure 22: SYNC2000 M5 (S4R2) Serial Interfaces

S1 serial port is DB9 Port and S2 to S4 ports are RJ45 connectors, and can be configured as
RS-232/422/485 by software. The pin assignments are described in the following table:

8 Pin plug (RJ-45) RS232 Signal Name RS485 Signal Name

1 NC NC
2 NC NC
3 NC NC
4 GROUND GROUND
5 RS232_RX NC
6 RS232_TX D+
7 RS232_CTS NC
8 RS232_RTS D-
Table 12: Serials RJ45 Port (S2-S4) Pin Details SYNC 2000 M5 (S4R2)
8 Pin plug (DB9) RS232 Signal Name
1 DCD
2 RXD
3 TXD
4 DTR
5 GND
6 DSR
7 RTS
8 CTS
9 RI
Table 13: S1 -DB9 Serial Port Pin Details – SYNC 2000 M5 (S4R2)

SYNC 2000 Hardware User Manual 25

RS485 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 below figure shows a typical two-wire multidrop network.

Note: 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 how many nodes are connected.

Figure 23: RS485 Termination and Multidrop

WARNING: Improper handling of electrolytically sensitive devices can cause damage

to the device and person using the same.

SYNC 2000 Hardware User Manual 26

4.1.4. Debug (Console) Interface
Console port is used for advanced diagnostics/debug 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 Mentioned in Table 3-4 below. User can use hyper terminal
or any such application to connect to the console port. For more information contact support@
kalkitech.com.

SYNC 2000 M1/M2/M4 (S2R1/S6R1/S6F1)

SYNC 2000 has one debug port in RS232 mode. DRX and DTX are receive and transmit signals
to debug the board.

Figure 24: SYNC 2000-M1/M2/M4 (S2R1/S6R1/S6F2) Console Port

SYNC 2000 M5 (S4R2)
The SYNC 2000 M5 (S4R2) console/Debug port is an 8-pin RJ45 RS-232 port. The pin definition
is the same as for RS232 details in the serial port interface section. COM2(S2) has an addition
feature to act as a Debug Port based on the DEBUG Switch position when the Product is Booting.
The Switch should be in Debug mode while restart to switch from normal mode to Debug Mode.
Switch Details are given in the following sections.

Pin Signal Name

1 NC
2 NC
3 NC
4 GND
5 RS232_DRX
6 RS232_DTX
7 RS232_CTS
8 RS232_RTS
Table 14: S2-Console Port Pin Details

SYNC 2000 Hardware User Manual 27

4.1.5. Ethernet Interface
SYNC 2000 M1/M2/M5 (S2R1/S6R1/S4R2) Ethernet Copper
The Ethernet port of the SYNC 2000 is an 8-pin RJ-45 port for 10/100 Base-T. The Ethernet
Port can be used to access network by connecting Ethernet RJ45 port with computer through
Ethernet Cross over cable. The Pin details of the connector is given below:

Figure 25: SYNC 2000-M1/M2/M5 (S2R1/S6R1/S4R2) LAN Port

Pin Signal Name
1 Transmit +
2 Transmit -
3 Receive +
4 Reserved
5 Reserved
6 Receive -
7 Reserved
8 Reserved
Table 15: LAN Port Pin Details

4.1.6. SYNC 2000 M4 (S6F1) Ethernet Fiber

SYNC 2000 M4 (S6F1) has one fiber optic Ethernet port. Device Ethernet is fiber optic transceiver
with ST connector.

The features of FO port are:

• 100 BASE FX
• ST connector, multimode fiber,1300nm

Figure 14 depicts the recommended interface diagram of fiber optic port:

Figure 26: Interface diagram of fiber optic port

SYNC 2000 Hardware User Manual 28

4.1.7. Alarm Contact
The DO connector is a Form C (CO) Type Relay is available in SYNC 2000-M5 The Poles of
DO connector N.O., COM and N.C. poles rated 5A, 230VAC Or 5A, 24VDC. A relay of 12V Coil
voltage and dielectric b/w Poles 1KV and 4KV B/w Poles & Coil considered.

Figure 27: DO Connector

4.1.8. Internal Modem

SYNC 2000 M1/M2/M4 (S2R1/S6R1/S4R2/S6F1) has an option to plug GPRS/CDMA/EVDO/
HSPA Modem card internally to COM1 interface.

Note: The requirement needs to be specified in the order. If modem board is plugged
on to the SYNC 2000, external COM1 (S1) port cannot be used for other purposes.

Position of SIM card holder is depicted in figure below:

Figure 28: SIM card holder slot

SIM card handling procedure is detailed out in following figure

Press the Button SIM Holder Tray gets Insert Mini SIM Card Push the Tray Inwards
Indicated as A unlocked. Pull tray outwards From Bottom Side of Tray SIM Locked In Tray
Till It Is Locked

Figure 29: SIM card insertion procedure

A SIM sealing option is given as shown in the above figure

SYNC 2000 Hardware User Manual 29

 5
5. Troubleshooting
The SYNC 2000 is delivered in ‘Ready to Run’ mode and will automatically start loading an
operating system from the on-board flash memory when power is applied. Once the SYNC
2000 is up, the information in this manual will provide user with the connection and guidelines
details for attaching and using IEDs to it. If user encounter problems with a particular feature of
SYNC 2000, please refer to the relevant chapter in the manual to ensure about the configuration
process. If user unable to resolve the problem contact Kalkitech technical support team at
support@kalkitech.com.

If SYNC 2000 does not start running when power is applied, 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 SYNC and disconnect the power input. Switch on the power supply and measure
the output voltage with Digital Voltmeter (DVM). This should be between the voltage ranges
specified. If this is incorrect adjust and re-apply the power to the board. If the board does not
work go to step 2.

2. Return the gateway to Kalkitech for repair. Please contact Kalki technical support department
who will provide the details for the RMA procedure.

3. Make sure that the correct model of the SYNC (SYNC 2000) is selected in the EasyConnect
configuration utility. A wrong selection of the SYNC model will result in an initialization failure.

SYNC 2000 Hardware User Manual 30

 A
Appendix A – Guidelines for Handling ESD
ESD-Defnition: All electronic modules are equipped with large-scale integrated ICs or
components. Due to their design, these electronic elements are very sensitive to over voltages
and thus to any electrostatic discharge too. These Electrostatically-Sensitive Devices are
commonly referred to by the abbreviation ESD.

Electrostatic Charging of Persons: Every person with a non-conductive connection to the

electrical potential of its surroundings can be charged electrostatically. The following figure
shows you 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.

Figure 30: Electrostatic voltage trip off plot

Methods to avoid Electrostatic Discharge: Following two methods are suggested to avoid
electrostatic discharge.
1. Ensure Sufficient Grounding: Make sure that the personnel, working surfaces, and
packaging are sufficiently grounded when handling electrostatically-sensitive devices. User
thus avoid electrostatic charging.
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 you have to carry out measurements on a module, you must
discharge your body before you start the measurement by touching grounded metallic parts.
Use grounded measuring devices only.

WARNING: Improper handling of electrolytically sensitive devices can cause damage

to the device and person using the same.

SYNC 2000 Hardware User Manual 31


Appendix B – Certifications
Immunity
Radiated Susceptibility
Electrical Fast Transient
Electrostatic Discharge
Surge Protection
Induced (Conducted) RFI
Power Frequency Magnetic
Field immunity
Damped Oscillatory Magnetic
fields immunity test
Damped Oscillatory Wave
immunity
Impulse voltage Immunity
Conducted Common mode
disturbances Immunity
Emission
Conducted Emission
Radiated Emission
Power Supply
AC Voltage Dips & Interruption
AC Voltage Range and
Tolerance test
Environment
Cold Temperature test
Hot Temperature test
Damp heat Cyclic
Barometric Pressure test
Vibration
Shock test
Table 16: SYNC 2000 M1/M2/M4 (S2R1/S6R1/S6F1) type test detail
SYNC 2000 Hardware User Manual
B
IEC 61000-4-3: 80 - 1000 MHz: 10V/m 80% AM, 1 kHz sine wave
IEC 61000-4-4: - ±4 kV serial ports, Ethernet port, DC Power Ports
IEC 61000-4-2: - +/- 6 kV Contact Discharge, +/- 15 kV Air
Discharge
IEC 61000-4-5:
Serial port ± 4kV, 1.2/50 μs for common mode,
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 power,
serial and Ethernet port
IEC 61000-4-8: -30 A/m continuous & 1000 A/m for 1 sec
IEC 61000-4-10: Magnetic field strength: 30 A/m @ Oscillation
frequency 1 MHz
IEC 61000-4-18 Damped Oscillatory Frequency: 1 MHz Common
Mode: up to ± 2.5 kV Differential Mode: up to ±1.0 kV for power port
1 MHz Common Mode: up to ± 2.5 kV for serial port and Ethernet
port
IEC60255-5 ±5kV for power port and earth
IEC 61000-4-16 Ed 1.1 30/300V at 50 Hz, 3V/30V at 15 to 150 kHz
EN 55022: Class A 150 kHz to 30 MHz
EN 55022: Class A 30 MHz to 2 GHz
IEC 61000-4-11 - AC Power port 0% short Interruption for 250
cycles, Dips -100% of AC mains voltage for 0.5 cycles and, -60%
dips for 10 cycles, -30% dips for 25 cycles, -20% dips for 250 cycles
IEC 60870-2-1 Ed 2.0: - 20% to +15% tolerance at AC power port
As per IEC60870-2-2 tested at -40ºC for 16 Hrs Class C
As per IEC60870-2-2 tested at +70ºC for 16 Hrs Class C
As per IEC60870-2-2 95% RH 25ºC and 55ºC for 4 days
As per IEC 60870-2-2 Test range ambient level (91.6 kPa) to
3000m (70.0 kPa)
As per IEC60870-2-2, Class Bm, 5-500 Hz- displacement 3 mm 5-9
Hz, acceleration 1g for 9 Hz-200 Hz, 1.5g for 200 Hz-500 Hz
As per IEC60870-2-2 10g in X,Y, Z axis
32
Glossary
Acronyms/ Abbreviations Description
ARM Advanced RISC Machine
DIP Dual Inline Package
LAN Local Area Network
SDRAM Synchronous Dynamic Random Access Memory
TTL Transistor – Transistor Logic
IEC International Electrotechnical Commission
GPRS General Packet Radio Service
RTS Request To Send
CTS Clear To Send
DSR Data Set Ready
DTR Data Terminal Ready
DCD Data Carrier Detect
Table 17: List of Abbreviations

SYNC 2000 Hardware User Manual 33