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SYNC 200: IED Protocol Upgrade Module


SYNC 200: IED Protocol Upgrade Module
SYNC 200 series of embedded chip level products enable equipment manufacturers the capability to have the latest protocols like IEC 61850, DNP3.0 and DLMS/ COSEM in their device, at minimal capital costs and faster go-to-market. SYNC 200 (formerly named as SYNC OEM) has been embedded in various devices like Protection Relays, Energy Meters, Mini RTUs, Transformer Monitoring Systems, PLCs, Switchgears and Alarm Annunciators, across the globe.

SYNC 200 modules are specifically designed for power industry applications, with its superior processing capabilities as well as numerous interfacing options. SYNC 200 are tested to stringent temperature and environmental levels and has proven experience in a variety of industry segments. Numerous products using Kalkitech SYNC 200 series embedded boards have been certified at KEMA and CPRI test labs by various customers.

SYNC 200 provide not just one-to-one protocol conversion, but also support the full set of protocols. Apart from the numerous protocols, the small size and the various interfacing mechanisms like TTL, I2C SPI and GPIO makes it ideal for a large variety of products and applications.

Kalkitech has developed a Developer Kit that will help to test and integrate the SYNC 200 modules to end devices quickly and with minimal capital costs. The Developer Kit comes with the necessary development board and sample SYNC 200 modules hardware, configuration tools and documentation, as well as 20 hours of free technical support.

Kalkitech also provides support for IEC 61850 Level A certification from KEMA on customer devices, CPRI as well as other certification agencies built on its expertise on IEC 61850 and product management.

Related Products:
Following are the key features:
  • General
    • Suitable for quick goto- market products
    • Adaptable for consuming less power from end device
    • Extensive support provided for integration and testing: Starter Kit available for all SYNC 200 Models, along with free remote support
    • Interface options for TTL, I2C, SPI, GPIO
  • Software features
    • Supports many-to-many protocol conversions. More than 30 protocols can be enabled
    • Meets high processing capabilities required for IEC 61850 GOOSE*
    • Store Sequence of events
    • Flexible for having new and customization in protocols
    • Multi master communication capability
    • Transparent/ tunneling support for end device parameterization/settings using Ethernet port
    • Automatic startup and initialization following power restoration
    • Device management using SNMP/web-server
    • Time synchronization using IEC60870/DNP3/SNTP
  • Reliability
    • KEMA Certified IEC 61850 Server
    • Supports temperature range from -40C to +85C
  • Security
    • NERC-CIP security compliant
    • IEC62351 support
    • SSL VPN with AES, DES or 3DES encrption
  • Scalability & Upgradability
    • Full modem Serial port for modem Plug-in
    • Option for adding customer specific applications
SYNC 200 series comes in numerous models for varying performance and dimension requirements:

SYNC 211: One Serial one Ethernet (low scale protocol conversion); very small form factor.
It is an ultra compact embedded module with an ARM7 based processor, one 10/100 Base T network interface, and one TTL serial interface. SYNC 211 enables the future-proofing of legacy devices at an attractive price-point. Dimensions: 36.7 mm x 19.05 mm x 21.69 mm


SYNC 221: Two Serial one Ethernet (medium/high duty protocol conversion like IEC 61850); small form factor.
SYNC 221 is the latest model in Kalkitech SYNC 200 family and is designed for the flexibility and performance requirements of small but powerful devices like RTUs and Relays. It has two TTL serial interfaces as well as one 10/100 Base T Ethernet interface. Dimensions: 45mm x 40mm x 21.6mm



SYNC 241: Four Serial one Ethernet (medium/high duty protocol conversion like IEC 61850); medium form factor.
SYNC 241 offers the scalability of 4 TTL interfaces and one 10/100 Base T network interface as well as the performance of a 180Mhz ARM9 Processor all in a form factor that is suitable for most applications. Dimensions: 63mm x 55mm x 18mm


SYNC 200 have been deployed in numerous IEDs across the world. The performance capabilities, versatility, and form factor make SYNC 200 modules ideal for a variety of applications, which require protocol conversion to latest protocols like IEC 61850/ DLMS/ DNP3.0 inside their device. SYNC 200 is powerful enough to handle more than just one-to-one protocol conversion and hence, another key application is for multiple protocol support (Eg: IEC61850+DNP3.0+IEC60870-103) in the vendor device.

Some of the common equipments where SYNC 200 modules have been used are:
  • Alarm Annunciators
  • Capacitor Banks
  • Circuit Breakers
  • Data Loggers
  • Energy Meters
  • Industrial Ethernet Switches
  • Intelligent Electronic Devices (IEDs)
  • Programmable Logic Controllers (PLCs)
  • Protection Relays
  • Remote Terminal Units (RTUs)
  • Switchgears
  • Transformer Monitoring Systems
SYNC 200 modules can be internally plugged to the device using TTL interface of the module while the Ethernet port on the SYNC 200 modules is used as the final output from the combined device.

There are other interfacing options including I2C interface for internal connection. TTL/RS232 or TTL/RS485 conversion (using external circuitry) can also be implemented on the module, to make the protocol available for the external communication. This conversion is required only if the protocol demanded is a serial protocol.

The complete integration process, including board design and testing, can be completed within a span of 2-3 weeks. Kalkitech provides a versatile SYNC 205 Starter Kit containing Development Board, SYNC 200 modules, design details and User Guide, along with free technical support of 20 hours.




SYNC 200 is plugged internally to the device connecting the TTL interface to the device port and Ethernet port is used to take the data out from the device. Other methods of interfacing are also possible including I2C for internal connectivity, as well as TTL/ RS232 or TTL/ RS485 conversion to expose the serial-based protocol outside. The complete integration process, including a minor board design and testing, can be completed in a time period of two to three weeks.

To facilitate easy development, Kalkitech provides SYNC 205 starter kit containing development board, embedded modules, design details and a support package of twenty hours.

All SYNC 200 module variants are available in starter kits, which contains a development board and other accessories required for testing the integration with the IED device. User can plug the module and get suitable inputs/outputs on RS232/ RS485 options provided on the development board for testing the integration requirements. Development board also has option for testing the general purpose I/Os (maximum 20 nos.) that can be configured for user requirements. The starter kit enables the user to test the SYNC 200 module integration with their devices in a single day with full protocol configuration.

Points to consider for Hardware Integration:
  • Decide on the model requirements considering factors like form factor, features and performance requirements
  • Decide on the interface with the vendor device – choose between TTL and I2C interfaces. TTL is easy for integration and is plug-and-play. TTL interface can only provide maximum speed of 115.2 Kbps. If the vendor device needs to be integrated using RS232/ RS485, a separate TTL to RS conversion circuit needs to be attached to the board. I2C allows high speed communication up to 400 Kbps I2C requires software modification for supporting the same.
  • If considering IEC 61850 for high-speed communication, then decide and go for direct I/Os from the embedded modules for fast transfer of GOOSE messages/ custom requirements. The circuitry for GPIOs from the modules to contact terminals of vendor devices for DI and DO need to be considered in this case.
  • Decide on RTC requirements. The embedded boards does not have an inbuilt RTC, however the same can be interfaced through the I2C.
  • Consider provision for 3.3V DC supply to the SYNC 200 modules with a maximum power consumption of 2W.
  • Provide provision for external communication connector. External communication can be through Ethernet (on-board)/ RS232/ RS485 (external).
Note: Kalkitech provide sample circuit where the above points need to be considered to build a development board.

Points to consider for Software Integration:
  • The configuration tool provided by Kalkitech for SYNC 200 is “EasyConnect”- a complete plug-and-play package. The manufacturer can configure the required points and protocol mapping using EasyConnect configuration utility. These configurations can be made as a standard package and supplied with the specific protection relay/ transformer monitoring device. The complete configuration for the device can be done in a day considering a specific ICD with 500 points mapped to IEC61850.
  • Customization of EasyConnect can also be provided, so that the configuration tool can be closely integrated to the existing IED manufacturer's tool. EasyConnect also has advanced diagnostic functions and other interaction requirements with the embedded modules like firmware update and IP configuration.
Kalkitech has developed a Developer Kit that will help to test and integrate Kalkitech SYNC 200 Modules to your end devices quickly and with minimal capital costs. The developer kit not only comes with the necessary developer board and sample embedded Modules hardware, Configuration tools and Documentation and also provides 20 hours of free Technical Support.


SYNC 205 Development board provides a development platform for the SYNC 200 products and projects all the features of a SYNC 200 module for testing and integration. The developer can use the board for customized developments on the SYNC 200 products and to explore the possibilities of integrating the device in to the system. This development platform gives all options to implement and test the solutions for verifying proper and intended operation.

The main features of development are:
  • Four serial RS232 ports with Full Modem on COM 1 and Console port
  • RS485 support
  • On-Board RTC
  • Wide Power input range
  • GPIO expansion with LED indication
  • Sockets for various SYNC 200 modules
The development board includes the following:
  • SYNC 200 Development Board
  • SYNC 200 series Quick Start Guide
  • SYNC 211/ 221/ 241 - 2 Nos
  • Easy Connect Configuration Tool (CD)
  • RS232 DB9 Female to DB9 Female Cross
  • User Manuals for Development board
  • Cable - 2 Nos.
  • Ethernet Cross Cable -1 no.
  • Power Adapter 12V
SPECIFICATION SHEETSYNC 211SYNC 221SYNC 241
GeneralManagementKalkitech EasyConnect Configuration Utility/ Web Server/ SNMP &SSH & SSH Interface over Secure Network
MaintenanceDirect over Debug Port or Console Port
System ProtocolsTCP/IP, UDP/IP, SMTP, POP, HTTP, FTP, SNMP, ICMP, DHCP, BOOTP, Telnet, DNS, ARP, PPPoE, DDNS
Device SecurityNERC/CIP Compliant, SSHv2
Communication SecuritySSL based VPN tunnel using Blowfish/AES/ 3DES
Logic Programming AND/OR/NOT/Bit SHIFT/Split/Index support for digital and analog data Delay Operations
Network ManagementSNMP
ApprovalsIEC61850-10 KEMA*
Communication CapabilityInterfacesTTL/ GPIO/ ETHERNET/ I2C/ SPI
Protocol support for external communicationIEC60850-5-101/103/104, DNP3 serial/TCP, Modbus RTU/ASCII/TCP, IEC62056-DLMS, IEC 61850, IEC61400
Protocol support for internal communicationIEC60850-5-101/103, DNP3 serial, Modbus RTU/ASCII/TCP, IEC62056-DLMS, ABB - RP570, 571, SPA bus, SEL - SEL 451, 421, 311, 300G, Schneider - SEPAM Modbus, Areva - Courier, RTK, EXCOM, CMC Master, SPORT, Triguard Peer to Peer and flexible to add proprietary protocol
Supported Data PointIEC61850, SPANot Available800800
DNP3, IEC60870, Modbus and other proprietary protocols100030003000
Communication InterfacesSerial1TTL (110bps-115.2kbps)2 TTL (110bps to 115.2 kbps)
GPIONot Available4-11 IO**16 to 20 IO**
I2CI2C Master
Ethernet1XRJ45
Physical Layer10/100 Mbps (auto-sensing)
Isolation1500VAC min per IEEE802.3/ANSI X3.263
Power RequirementsPower Supply3.3 VDC
Consumption900mW2W
PhysicalDimensions (H X W X D)21.69mm X 19.05mm X 35.7mm21.6mm X 40mm X 45mm21.6mm X 55mm X 63mm
Weight (in grams)202020
LED Indication LAN Link/ Status
EnvironmentalOperating Tempt.-40 to 85 °C
Rel. Humidity5%-95% RH non-condensing


* Certified for end products using 200 series
** Range depends upon IO used for full modem TTL/ I2C/ Debug port is multiplexed with GPIO


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