ROLEC Sinexcel ULTRACHARGE 160 User manual

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MAINTENANCE MANUAL
ULTR ACHARGE 160
Intelligent ultra-rapid EV charging station

Product Support
UltraCharge 160 DC Charger EVUCMM-V01R1 Maintenance Manual
Page 1of 22 October 2023
Amendments
Amendment
Number Details Date
Ver 1, Rev 0 New Document. Jan 2023
Ver 1, Rev 1 Update of wording throughout manual Oct 2023
Product: UltraCharge 160 DC Charger
Models: EVDC2010 – 60kW EVDC2030 – 120kW
EVDC2020 – 80kW EVDC2040 – 160kW
Document Type: Maintenance Manual
Document Code: EVUCMM-V01R1
Language: UK English (Original)
Date Published: October 2023
Rolec Services Ltd are the publishers of this document and own the rights to use the text, images and all technical
content contained within. Content supplied by third parties / partner organisations remains the property of that
organisation and is used by agreement with the supplier.
Rolec Services Ltd exercise care to ensure content is as accurate as possible at the time of publication. However, no
guarantee of accuracy should be inferred.
Rolec Services Ltd, Ralphs Lane, Boston, Lincolnshire PE20 1QU. United Kingdom.
[phone]
[e-mail]
Product Support
Updates to this manual will be made available on the Rolec website at
https://www.rolecserv.com/downloads-ev-charging
Check the document date, and the Version and Revision number shown at the
end of the Document Code (V01-R0, V01-R2, V02-R0, etc).
For installation assistance and advice, contact your preferred electrical installer.

Product Support
EVUCMM-V01R1 Maintenance Manual UltraCharge 160 DC Charger
October 2023 Page 2of 22
Contents
Product Support 1
Safety 3
Safety Advice Within this Manual 3
Disclaimer 4
Equipment Warnings 5
Safety Instructions for Use 6
Safety Instructions for Operation 7
Maintenance 8
Maintenance of Inactive Charging Stations 8
Charger Checks and Maintenance Cycle 8
Replacement of Common Devices 10
Electric Meter 10
Main circuit breaker 11
Cooling fan 12
AC contactor 13
Current transformer 14
DC contactor 15
Replacement of Dust Screen (Guidance) 16
Common Troubleshooting 19
Emergency Unlock 21
Tools 21
Procedure 21
Detailed View 22

Safety
UltraCharge 160 DC Charger EVUCMM-V01R1 Maintenance Manual
Page 3of 22 October 2023
Safety
This manual is specifically applicable to the UltraCharge 160 DC Charger and is provided
as a guide to its maintenance.
IMPORTANT: Engineers must read and understand the content of this manual
before installation and/or use of the product.
Engineers must be properly qualified and competent to do work on the equipment in
accordance with the current legislation applicable in the geographical region of the
installation.
xRolec Services Ltd cannot accept any responsibility for improper actions performed
by engineers or end users.
xThe information provided in this manual must ONLY be used with the model(s) listed on
page 1 of this manual.
xThe information provided in this manual must NOT be used with any other product.
xThe content of this manual may be updated by the manufacturer as required.
xDo NOT use the equipment for anything other than its intended purpose.
xDo NOT modify the equipment unless specifically instructed to do so by the
manufacturer.
xDo NOT attempt to repair the equipment unless specifically instructed to do so by the
manufacturer.
xTo maintain electrical safety, the body enclosure of the product (access covers) must
be secured in their correct location using the supplied fasteners and the seal must be
sufficient to maintain the IP rating of the enclosure.
xFasteners used to mount the product in its working location must be sufficient for the
task and the specific mounting point.
xDamage to the product may render it unsafe. The product must be electrically
isolated and NOT used until appropriate remedial action has been performed.
xRolec does NOT recommend the use of charging extension cables or adapters and
their use may invalidate the charge point warranty.
Safety Advice Within this Manual
Rolec manuals use a system of warnings, cautions and notes.
xWARNINGS concern the safety of installers/end user and will be given before the
detail/instructions in the manual.
xCAUTIONS concern the potential for damage to the equipment and will be given
before the detail/instructions in the manual.
xNOTES are given to provide additional information and/or to highlight information of
importance. They will be given either before or after the detail/instructions as
appropriate and may use different wording (such as IMPORTANT) where emphasis is
required.

Disclaimer
EVUCMM-V01R1 Maintenance Manual UltraCharge 160 DC Charger
October 2023 Page 4of 22
Warnings, Cautions and Notes may be repeated several times as appropriate and may
be preceded by a hazard symbol where appropriate.
Disclaimer
Rolec shall not be liable for personal injury, product damage, failure or defects in
scenarios such as but not limited to:
xInstallation and/or maintenance performed by unlicensed/unqualified personnel.
xLack of appropriate maintenance in accordance with the maintenance manual.
xLack of appropriate maintenance in accordance with local specifications and
standards.
xFailure to adequately record maintenance activities.
xUnauthorised changes to the design and/or functionality of the product.
xProduct damage or failure caused intentionally or by negligence.
xProduct damage or failure caused by improper/negligent actions performed by
Installation and/or maintenance personnel.
xProduct damage or failure caused by ‘force majeure’ (such as a bad weather,
natural disasters, etc.).
xMaintenance personnel not wearing appropriate protective equipment.
xThe failure (when requested) to return failed components to the
manufacturer/supplier for analysis.
WARNING: Personal Injury and Equipment Damage
xBefore maintenance, make sure the power supply to the charger has been
switched OFF.
xMake sure any faults have been eliminated and the electric circuit has been
connected properly before initiating a power on test.
xPersonnel who maintain the equipment, including operators, trained personnel
and professional must, where required, possess the local national qualifications to
work with high-voltages, work at heights, and to work in operations of special
equipment.

Equipment Warnings
UltraCharge 160 DC Charger EVUCMM-V01R1 Maintenance Manual
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Equipment Warnings
Symbol Meaning Description
DANGER Parts of the system are at High Power during operation.
Direct or indirect contact with these components can be
fatal.
DANGER
High voltage area may cause fire or electric shock.
The construction of the area and conduits for cables must
comply with national legislation.
Only staff authorised to work with high AC and DC voltages
can work in these areas.
DANGER It is forbidden to do maintenance work in bad weather.
DANGER It is forbidden to do maintenance work when the
equipment is live.
WARNING Special tools must be used when working with high AC and
DC voltages.
WARNING Wear the appropriate personal protective equipment (PPE).
CAUTION Read and understand the manual.
CAUTION Protective equipment and tools must be used. Make sure all protective items are removed from the
equipment before applying power.
CAUTION Always follow national legislation.
xThis product is high-power and high-voltage equipment. Construction and
maintenance personnel must have the appropriate certification for their region to
work with the equipment.
xAll personnel must abide by the construction standards and safety regulations
applicable in their region.
xThe equipment has been developed, manufactured, checked and certified in
accordance with the relevant safety standards. Therefore, if the instructions for the
specified use and technical instructions for safety are followed, under normal
circumstances the product will not cause property damage or endanger human
health.
xThe instructions contained in this manual must be strictly observed or safety may be
compromised. Although this manual explains the relevant safety instructions,
personnel must be aware of the type of hazards associated with their work and must
take the appropriate precautions to prevent accidents and injury.
xIn the event of problems and/or failures in the use of the equipment, the user shall
directly consult the supplier/manufacturer.

Safety Instructions for Use
EVUCMM-V01R1 Maintenance Manual UltraCharge 160 DC Charger
October 2023 Page 6of 22
xAny work performed by third parties without the approval of the
supplier/manufacturer is done at their own risk to health and to the serviceability of
the equipment. The supplier/manufacturer cannot be held responsible.
xMaintenance periods and tasks must be observed.
xA comprehensive record of maintenance must be available to support warranty
claims.
xMaintenance personnel must use the appropriate protective equipment/clothing
when engaging in work.
xAll electrical power to the charge point must be OFF before engaging in any work.
xEven when all the switches of the charger have been disconnected, the copper bar
of the charging line may still hold a dangerous voltage. During maintenance:
xTurn off the upper switch of the charger.
xDisplay a warning sign that maintenance is in progress.
xCheck whether there is a dangerous voltage with an instrument to ensure
that the charger is completely disconnected from the power grid.
xIt is strictly forbidden to do the maintenance work in a bad weather such as
thunderstorms.
xIt is strictly forbidden to do the power-on test before troubleshooting.
xAfter work, all doors, panels, etc must be securely closed.
Safety Instructions for Use
xThe UltraCharge 160 is an integrated charger to supply electricity to an EV either
outdoor or indoor.
xThe UltraCharge 160 is a high-power and high voltage electric power equipment.
Installation and maintenance must only be done by appropriately qualified
professionals.
xFollow local laws and regulations when installing, operating, or maintaining the
equipment.
xFollow the procedures of installation, operation, and maintenance and make sure this
document and accessories are available.
xPay attention to the safety symbols on the equipment and all the safety instructions in
this document.
xWhen operating equipment has encountered any problems or faults, please contact
Rolec Technical Support directly.
xUnauthorized third-party maintenance will invalidate the warranty,
xMakes sure the unit is not installed near to potentially dangerous equipment or other
hazards.
xMake sure that the space around the equipment cannot be blocked.

Safety Instructions for Operation
UltraCharge 160 DC Charger EVUCMM-V01R1 Maintenance Manual
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Safety Instructions for Operation
xBefore using for the first time, you must read this document carefully. Make sure the
equipment is installed and commissioned according to the instructions in the
installation manual.
xDo not perform unauthorized modifications to the product. The manufacturer will not
be liable for any consequence caused by the violation of the safety operation
regulations and design, production, and usage standards.
xDo not touch the EV charging connector or vehicle inlet, keep it dry and clean.
xDo not use this product if the power cord or connector shows any signs of damage.
xIn case of any abnormal operation or conditions, press the emergency button
immediately to turn off all electrical input and output.
xIf the emergency button is pressed, the system operator should be informed. The
charging station must not be restarted until the system operation technician resets the
system.
xMake sure there is no debris or fluids in the EV charging connector or vehicle inlet.
xDo not attempt to connect or disconnect power cables when power is on.
xWhen performing maintenance, turn off the power switch, ensure that electrical
connections are correct, and display warning notices in the area.
xPay attention to the copper wire carries dangerous voltage of equipment, even when
all circuit breakers of the charger are disconnected.
xConnect protective earth wire (PE) before connecting neutral line and phase line.
xAfter installation or maintenance, make sure that all doors are correctly secured.
xAdaptors or conversion adapters are not allowed be used.
xExtension cords are not allowed be used.

Maintenance
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October 2023 Page 8of 22
Maintenance
Maintenance of Inactive Charging Stations
xWhen the charger is not in use, the charger should be in a power-off state.
xTo maintain the service life of the charger, unnecessary load should be reduced,
Charger Checks and Maintenance Cycle
Item Period Details Action
Front-end
distribution
box Every 3 months
Each item is checked in accordance with the
maintenance manual of the distribution box.
(Note: The maintenance manual of the distribution box
is provided by the supplier of distribution box.)
Maintenance
and repairing
Appearance Every 12
months
Check the appearance of the cabinet for any stains.
Check whether the cabinet shell has any rust,
scratches, deformation, paint damage or other
defects.
Cleaning and
paint repair
Interior Every 12
months
Make sure the interior of the cabinet is clean and tidy.
Make sure the air inlet and outlet of the power module
are not blocked with debris or dust.
xClean air ways allow more effective cooling and
prevent premature failure of the power module.
Cleaning
Lightning
protector Every 12 months
Check whether the module is securely connected, and
the status indicator is normal. If the status indicator
changes to red, the dry contact NC-COM of alarm
becomes open or the NC-COM becomes short-
circuited, the surge protector has failed.
Replacement
Fan Every 6 months Make sure the fan is working correctly. Maintenance
and repairing
Signal lamp Every 6 months Make sure the signal lamp is working correctly. Make
sure it is fixed tightly and in a normal state. Maintenance and repairing
Components Every 6 months
Check whether components of the electric circuit
have discoloration, deformation, overheating, or other
defects, and make sure all accessible components are
secure.
If any abnormality is found, parts must be replaced in
a timely manner.
Maintenance
and repairing
Charging
connector Every 6 months
Make sure the fixing clasp is not damaged.
the needle of the charging connector is oxidized and
discoloured or obviously worn and deformed, whether
any foreign body has entered the hole on the head of
the connector, and whether the charging connector
cable is damaged.
Cleaning and
repairing
Power
module Every 6 months Check that the power module is normal and there is a
trouble-free display on the module screen. Maintenance and repairing
Human Every 6 months Check the display screen to see if it is cracked or not Maintenance

Maintenance
UltraCharge 160 DC Charger EVUCMM-V01R1 Maintenance Manual
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Item Period Details Action
machine
interface functioning properly. and repairing
Emergency
stop function Every 6 months
Press the emergency stop button to check that charge
point functionality is stopped.
Reset the emergency stop button to check that
charge point functionality is restored.
Maintenance
and repairing
Equipment
grounding Every 6 months Check whether the ground wire of the equipment
housing is tightened and connected. Maintenance and repairing
System
grounding Every 6 months Check whether the grounding cable inside the cabinet
is loose or detached. And check if the grounding sign is
complete and obvious.
Maintenance
and repairing
Slot Every 12
months Check whether the slot is fixed firmly, whether the cover plate is complete and tight. Maintenance and repairing
Breaker Monthly Press the TEST button of the circuit breaker to see
whether the circuit breaker can trip properly. Maintenance and repairing
Electric cable Every 12
months
Check whether the cable and switch are connected
closely, whether the grounding is reliable, whether the
power cable is normal, and whether the sealing
measures at the incoming cable of the cabinet are
intact.
Repairing and
replacement
of cables
Force
majeure
factor Immediately In case of flood, earthquake, impact, switch trip and
other events, the whole machine should be checked
immediately.
Maintenance
and repairing

Maintenance
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October 2023 Page 10 of 22
Replacement of Common Devices
Danger: Personal Injury
Do not perform maintenance when the charger is on!
Electric Meter
Items required: xScrewdriver.
xNew electric meter.
Replacement steps: 1. Remove the screw on the protective cover at the
lower end of the electric meter,
2. Open the protective cover and remove the
connecting cable of the electric meter.
3. Remove the fixing screws at both ends of the
connection area of the electric meter and the screws
at the upper end of the electric meter.
4. Remove the electric meter.
5. Replace with a new meter in an opposite sequence of
disassembly.
6. Refit the screw on the protective cover at the lower
end of the electric meter.

Maintenance
UltraCharge 160 DC Charger EVUCMM-V01R1 Maintenance Manual
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Main circuit breaker
Items required: xHex wrench.
xScrewdriver.
xSocket wrench.
Replacement steps: 1. Remove the screws in the fixed bus bar of the circuit
breaker by using a hex wrench.
2. Remove the input and output bus bar with a socket
wrench.
3. Remove the main circuit breaker by removing the
fixing screw at the upper, middle, and lower ends of
the main circuit breaker with a screwdriver.
4. Replace with a new main circuit breaker in an
opposite sequence of disassembly.

Maintenance
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October 2023 Page 12 of 22
Cooling fan
Items required: Screwdriver.
Replacement steps: 1. Remove the connecting terminals of the cooling fan.
2. Use a screwdriver to remove the four fixing screws of
the fan. And then the fan can be removed.
3. Replace with a new cooling fan in an opposite
sequence of disassembly.

Maintenance
UltraCharge 160 DC Charger EVUCMM-V01R1 Maintenance Manual
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AC contactor
Items required: Screwdriver.
Replacement step: 1. Use a screwdriver to unscrew the six screws fixing the
bus bar in the AC contactor. Note that these screws
cannot be taken out and can only be unscrewed.
2. Use a screwdriver to remove the fixing screw between
the bus bar and the insulation column.
3. Remove the bus bar from the AC contactor.
4. Use a screwdriver to remove the fixing screws in the
upper right and lower left corners of the AC contactor.
5. Remove the AC contactor.
6. Replace with a new AC contactor in an opposite
sequence of disassembly.

Maintenance
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October 2023 Page 14 of 22
Current transformer
Items required: Screwdriver.
Replacement step: 1. Use a screwdriver to remove the protective cover on
the transformer then remove the connecting cable.
2. Use the screwdriver to remove the four screws of the
fixed plate at the bottom of the current transformer.
Then the current transformer can be removed
3. Remove the cable crossing through the current
transformer from the bus bar. Then pass the transformer
through the cable to take out.
4. Replace with the new transformer in an opposite
sequence of disassembling it.

Maintenance
UltraCharge 160 DC Charger EVUCMM-V01R1 Maintenance Manual
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DC contactor
Items required: xScrewdriver.
xSocket wrench.
Replacement steps: 1. Use a socket wrench to remove the bus bar on the DC
contactor.
2. Remove the white signal line terminal on the side of
the DC contactor.
3. Use the screwdriver to remove the fixing screw in the
upper right corner and lower left corner of the DC
contactor. The DC contactor can now be removed.
4. Replace with a new DC contactor in an opposite
sequence of disassembling it.

Maintenance
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October 2023 Page 16 of 22
Replacement of Dust Screen (Guidance)
Items required: xScrewdriver.
xNew dust screen.
Replacement
steps: 1. Turn off the power supply, then open the left and right doors of
the cabinet.
2. Remove the left and right cover plates and their installation
screws (M4×16) with an electric screwdriver.
NOTE: The left cover plate must be lifted up for about 20mm, and then
taken out. Do not lose the cover plate and installation screw. They will
be used in the installation later.

Maintenance
UltraCharge 160 DC Charger EVUCMM-V01R1 Maintenance Manual
Page 17 of 22 October 2023
3. Use the pull ring of dust screen to remove the old dust screen
(which can now be scrapped).
4. Insert the new dust screen with the same technical parameters
into the left and right-side door respectively;
Note: One end of the pull ring shall be kept outside for the next
change.

Maintenance
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October 2023 Page 18 of 22
5. Install the side cover plate and secure the (M4×16) screw to a torque
of 16kgf. Cm (1.6 Nm).
NOTE: The top of the cover plate should be hung first for installation of the
left cover plate, as shown in the figure, after which the screws are
tightened.

Maintenance
UltraCharge 160 DC Charger EVUCMM-V01R1 Maintenance Manual
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Common Troubleshooting
No. Failure Cause Correction
1 Abnormal
communication
of control panel.
1. The CAN bus wiring
between the MCU and
the charging station is
loose.
2. Error of CCU address
setting.
3. The anti-interference
ability of CAN bus is not
good, or the bus
resistance has a
problem.
1. Use a multi-meter to check whether the
CAN communication line between MCU
and the charging controller is connected
correctly, whether the build-out
resistance is connected reliably, and
whether the shield layer of the
communication line is effectively
grounded.
2. Check CCU address, dial No. 4 for No. 1
CCU, and dial No. 3 for No. 2 CCU.
3. Testing with a replaced component.
Change if MCU is damaged.
2 Electric meter
communication
failure.
1. The connection
between CCU and
electric meter is loose.
2. The electric meter
address, baud rate,
check bit, stop bit and
other settings are
incorrect.
3. Electric meter failure.
1. Check whether the connection between
CCU and electric meter is loose.
2. Check whether the electric meter
address, baud rate, check bit and stop
bit are set correctly.
3. Testing with a replaced component. If it
has a failure, the electric meter shall be
replaced.
3 Action failure of
emergency stop
button.
1. The emergency stop
button of the charging
station is pressed in the
normal state, and the
button does not restore
after being pressed.
1. Turn the emergency stop button
clockwise to return to normal.
2. Testing with a replaced component. The
damaged emergency stop button shall
be replaced.
4 Lightning
protector failure. 1. The lightning protector is damaged. 1. Testing with a replaced component. The damaged lightning protector shall be
replaced.
5 DC lightning
protector failure. 1. The lightning protector is damaged. 1. Testing with a replaced component. The damaged lightning protector shall be
replaced.
6 Access control
failure. 1. The door is not closed.
2. The wire to the micro
switch is wrongly
connected or
damaged.
1. Close and lock the door again.
2. Check whether the wire to the micro
switch is connected correctly and the
spring status is normal.
7 Off-line. 1. Check whether the
router has network, or
the signal of the station
is weak.
2. Check whether the
MCU network setting is
correct (local IP,
subnet mask, gateway,
pile number, domain
name address).
3. Network back-end is
abnormal.
1. Check whether there is a network with a
router directly connected to a laptop.
Contact the local operator if not.
2. Re-set the correct parameters if the MCU
network settings are wrong.
3. Check the back-end status in back-end.