Sinexcel ROLECEV ULTRACHARGE 160 User manual

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INSTALLATION & OPERATION MANUAL
ULTR ACHARGE 160
Intelligent ultra-rapid EV charging station

Product Support
UltraCharge 160 DC Charger EVUCM-001-V01R0 Installation and Operation Manual
Page 1of 29 January 2023
Amendments
Amendment
Number Details Date
Ver 1, Rev 0 New Document. Jan 2023
Product: UltraCharge 160 DC Charger
Models:
EVDC2010 – 60kW EVDC2030 – 120kW
EVDC2020 – 80kW EVDC2040 – 160kW
Document Type: Installation and Operation Manual
Document Code: EVUCM-001-V01R0
Language: UK English (Original)
Date Published: January 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
EVUCM-001-V01R0 Installation and Operation Manual UltraCharge 160 DC Charger
January 2023 Page 2of 29
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
Product Overview 8
Short description 8
Charger Models 8
Product Views 8
Product Characteristics 9
Product Specifications 10
Installation instructions 11
Equipment Dimensions 11
Equipment Installation Requirements 12
Distribution Cables 13
Layout Requirements of Distribution Cables 13
Requirements for Distribution Cables 14
Cable Specifications for AC Input (Recommended) 14
Internal Wiring 15
Installation 16
Tools required 16
Unpacking the Outer Package of the Cabinet 16
Foundation Drilling 18
Site the Charger 19
Inspection After Installation 23
Stability 23
Clean Up 23
Operation Interface 24
Charging Process 24
Standby Interface 24
Code Scanning Charging Interface Process 26
Interface Process of Pay by Card Charging 27
Password charging interface process 28
Simple Troubleshooting 29
After-Sales Service 29
IMPORTANT:
This document is primarily intended for the following engineers:
xTechnical Support Engineer
xMaintenance Engineer
xEngineering installation team

Safety
UltraCharge 160 DC Charger EVUCM-001-V01R0 Installation and Operation Manual
Page 3of 29 January 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.
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.
Warnings, Cautions and Notes may be repeated several times as appropriate and may
be preceded by a hazard symbol where appropriate.

Disclaimer
EVUCM-001-V01R0 Installation and Operation Manual UltraCharge 160 DC Charger
January 2023 Page 4of 29
Disclaimer
Rolec shall not be liable for personal injury, product damage, failure or defects in
scenarios such as but not limited to:
xUnlicensed maintenance personnel or operators to maintain the product without
authorization.
xThe product is not maintained regularly and properly according to the requirements of
the maintenance manual.
xThe product is not maintained in accordance with local specifications and standards.
xMaintenance activities are not filed or reported to the equipment supplier.
xIn the process of maintenance, the original design of the product is changed without
authorization.
xProduct damage or failure is caused intentionally or by negligence in the process of
maintenance.
xProduct damage or failure is due to force majeure (such as a bad weather, natural
disasters, etc.).
xMaintenance personnel not wearing appropriate protective equipment.
xThe front-end power supply of the equipment has not been stopped before
maintenance, resulting in personal injury and/or equipment damage.
xMaintenance while the failure of equipment is not identified, or the circuit is changed
without consulting the supplier resulting in equipment damage.
xAfter maintenance, the door lock is not closed as required, resulting in damage to the
insulation of the equipment caused by water or other foreign matters in the
equipment.
xAfter maintenance, the device with a failure is not marked clearly and sent back to
the supplier for analysis.
xAfter maintenance, the device with a failure is discarded carelessly, resulting in the
absence of cause of failure.
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 professionals, should possess the local national required qualifications in
special operations such as high-voltage operations, working at heights, and
operations of special equipment.

Equipment Warnings
UltraCharge 160 DC Charger EVUCM-001-V01R0 Installation and Operation Manual
Page 5of 29 January 2023
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 shall work with the operation certificate.
xIn the maintenance of the equipment, the relevant construction standards and safety
regulations in different places and states shall be strictly followed.
xThe equipment is developed, manufactured, checked, filed and certified in
accordance with the relevant safety standards. Therefore, the product will not cause
property damage or endanger human health under normal circumstances if the
instructions for the specified use and technical instructions for safety are followed.
xThe instructions contained in this manual must be strictly observed. Otherwise, there
may be a safety hazard or failure of the safety device. Although this manual explains
the relevant safety instructions, note that safety specifications and accident
prevention specifications for the corresponding usage must be complied with.
xIn case of any problems and failures in the process of use, the user shall directly
consult the supplier. In the warranty period, if he/she asks a third party or non-
professional to maintain without authorization any safety consequences shall be
borne by the user.
xPlease strictly comply with the specifications formulated in this manual or by the
station for regular and correct maintenance of the charger.

Safety Instructions for Use
EVUCM-001-V01R0 Installation and Operation Manual UltraCharge 160 DC Charger
January 2023 Page 6of 29
xEach maintenance shall be recorded, components with a failure shall be identified
and, the failure description shall be prepared, and they shall be sent back to the
manufacturer for analysis. Do not discard carelessly.
xDo not change the original design of the product without authorization during
maintenance.
xMaintenance personnel shall properly wear protective equipment before entering the
field to avoid personal electric shock and equipment damage.
xAfter maintenance, close and lock the door properly so that the insulation of the
equipment will not be damaged due to water ingress or other foreign matters.
xThere is no lamp inside the charger. The installation and maintenance personnel must
bring their own lighting equipment.
xCharger is high-power and high-current equipment with a fatal dangerous voltage.
Do not repair and maintain it when it is running.
xEven when all the switches of the charger have been disconnected, the copper bar
of the charging line still has a dangerous voltage. During the maintenance of the
equipment, it is necessary to turn off the upper switch of the charger, hang the repair
sign, and check 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.
xMaintenance personnel shall wear professional protective tools, such as protective
clothing, insulation boots and insulation gloves, to avoid injuries in the process of
maintenance.
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 EVUCM-001-V01R0 Installation and Operation Manual
Page 7of 29 January 2023
Safety Instructions for Operation
xBefore using for the first time, you must read this document carefully, make sure that
the equipment is installed and commissioned according to the instructions in the
installation manual.
xWithout Sinexcel permission, do not unauthorized modifications to the product or
removal of the product. Sinexcel 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 is frayed, has broken insulation,
or shows any other signs of damage.
xIn case of any abnormal condition, press the emergency button immediately, which
will turn off all input and output to ensure safety.
xIf the emergency button is pressed, the system operator should be informed. The
charging station shall not be restarted until the system operation technician reset the
operation system.
xTo make sure that no foreign bodies residues in EV charging connector or vehicle inlet.
xDo not connect or disconnect power cables with power on. When maintenance, turn
off the power switch, ensure that electrical connections are correct, and putting
warning board.
xPay attention to the copper wire carries dangerous voltage of equipment, even all
circuit breakers of the charger are disconnected.
xWhen performing maintenance, portable lighting may be helpful.
xConnect protective earth wire (PE) before connecting neutral line and phase line.
xAfter installation or maintenance, ensure that door are locked correctly.
xAdaptors or conversion adapters are not allowed be used.
xExtension cords are not allowed be used.

Product Overview
EVUCM-001-V01R0 Installation and Operation Manual UltraCharge 160 DC Charger
January 2023 Page 8of 29
Product Overview
Short description
The UltraCharge 160 is an integrated DC fast charger that features high efficiency and
flexible configured. It supports the charging of two vehicles at the same time at same time
and meets the charging demand of larger capacity and high endurance electric
vehicles.
Charger Models
Station
Level
Connection
Type Power Allocation Input Current
Input
Power
Unit
Colour
Product
Code
60kW DC 1x CCS2
1x CHAdeMO
1x 60kW
1x 40kW / 1x20kW* 112A 67kVA White EVDC2010
80kW DC 2x CCS2 1x 80kW
2x 40kW* 150A 89kVA White EVDC2020
120kW DC 2x CCS2 1x 120kW
2x 60kW* 224A 133kVA White EVDC2030
160kW DC 2x CCS2 1x 160kW
2x 80kW* 299A 177kVA White EVDC2040
*When 2 vehicles are charging simultaneously
Product Views
A Status LED F Digital-input receiver (Antenna)
B Human machine interface (Screen) G Eye bolts for lifting
C Emergency button H Contactless payment card reader
D Door handle/ lock I Air outlet
E Charging connector
Figure 1 External View
A
B
C
D
E
F
F
G
H
I

Product Characteristics
UltraCharge 160 DC Charger EVUCM-001-V01R0 Installation and Operation Manual
Page 9of 29 January 2023
Figure 2 Internal View
Product Characteristics
xA variety of power configurations from 60kW to 160kW can meet the customized
requirements of customers. And more flexible power distribution, the dual connector
model can automatically switch the power according to the vehicle demand, which
can meet the rapid charging of two vehicles at the same time.
xThe constant current and constant power charging methods have the advantages of
high charging efficiency, simple operation and reliable performance.
xUltra-wide output voltage range, the highest output voltage can reach DC1000V. It
can not only meet the low-voltage charging of small cars, but also meet the charging
requirements of buses and high-voltage vehicles.
xWith overload, short circuit, leakage, lightning protection, overcharge, over voltage,
under voltage, reverse connection, over temperature and other multiple protection
functions.
xThe intelligent standby mode can effectively reduce the operation cost of customers
in the whole project life cycle and improve the return rate of station charging.
xThe cabinet shell is made of stainless steel with protection grade of IP55, which can be
applied to various outdoor environments.
A Main circuit breaker C Inlet hole
B AC incoming copper bar D Grounding bar

Product Characteristics
EVUCM-001-V01R0 Installation and Operation Manual UltraCharge 160 DC Charger
January 2023 Page 10 of 29
Product Specifications
Category Item Parameter
Input Characteristic
Input 3P+N+PE
Input Voltage AC 380~400V
Frequency 50/60Hz
Power Factor 0.99
THDi <5%
Output Characteristic
Output Voltage CCS2 : 200-1000 Vdc
CHAdeMO: 200-500Vdc
Rated power 60-160kW
Max Current CCS2 : 200A
CHAdeMO: 125A & 200A
Peak Efficiency 95% @half load
Connector Type IEC 62196
Standards System
Standards IEC 61851
Others
Energy meter High precision meter
Number of
connectors
1 (CCS Combo 2) or 2 (CCS combo 2,
CHAdeMO optional – Two connectors
can be used at the same time)
Network
Interface LAN
Size W1000*D700*H2000 mm
Protection level IP55/IK10
Gross Weight 535KG
Net Weight 460KG
Cable length 5mExposed cable length is 4.5m
Communication
protocol OCPP1.6J/2.0(Upgrade)
Display Screen 7 inch
Method of
payment
QR Code/RFID/Mobile phone
(Optional)
Language English
Environmental conditions
Cooling method Forced air cooling
Operating
temperature
-25 ~ 65 Ԩ( Derating operation over 45
Ԩ)
Humidity 5%~95%
Altitude P
Protection
Undervoltage & overvoltage protection
DC overcurrent protection
Over temperature protection
Surge protection device
Emergency stop button
Optional tilt, flood and smoke detection
Advanced dynamic power balancing
Supports static load management
(software configurable)

Installation instructions
UltraCharge 160 DC Charger EVUCM-001-V01R0 Installation and Operation Manual
Page 11 of 29 January 2023
Installation instructions
Equipment Dimensions
Figure 3 Outline and Dimension of Charger
Figure 4 Hole Size of Charger Base

Installation instructions
EVUCM-001-V01R0 Installation and Operation Manual UltraCharge 160 DC Charger
January 2023 Page 12 of 29
Equipment Installation Requirements
1. The charger is opened in front, left and right, and the connectors are used from
both sides. Space should be reserved around. See Figure 5 for the reserved size;
2. Installation on the foundation of channel steel or concrete; The cable shall be
embedded in advance, the reserved length of Ethernet cable should not be less
than 4000mm; the reserved length of control signal cable should not be less than
1500mm; the reserved length of power cable reserved shall be 700 mm ± 20 mm,
and the protruding of the base through which 5 wires pass shall be less than 30 mm,
as shown in Figure 6.
3. The height of the installation foundation is recommended to be 200 mm ± 20 mm,
and the vertical inclination of the installation shall not exceed 5°. See Figure 6.
4. Install 4 stainless steel M12 * 80mm expansion bolts between the base and the
cabinet. Note that the bolts need to be equipped with M12 stainless steel flat
gasket.
Figure 5 Requirements for Charger Placement

Installation instructions
UltraCharge 160 DC Charger EVUCM-001-V01R0 Installation and Operation Manual
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Figure 6 Base and Cable Reservation Requirements
Distribution Cables
Layout Requirements of Distribution Cables
1. The input cable of the system is introduced from the inlet hole at the bottom of the
charger, and the cable shall be laid through the cable trench.
2. The AC cable adopts copper core wire, and the cross-sectional area of the cable
shall adapt to the load.
3. The outdoor power cable shall be laid according to the power specification. The
power cable and the signal cable must be separated, and the signal cable should
be put through the tube separately to avoid the pressure loss and interference of
the communication signal.
4. The cable shall not be laid in the area easily damaged by mechanical damage,
corrosive medium emission, humidity, strong magnetic field and strong electrostatic
field interference. If necessary, please take corresponding protection or shielding
measures.
5. The AC input cable starts from the user's distribution switch and connects to the
copper bar of the charger's inlet cable switch. Protection devices shall be provided
at the user's power distribution.
6. The colour of AC input cable is brown (L1), black (L2), grey (L3), blue (n), yellow
green (PE). If the input cable has only one colour, it is necessary to paste cable
number identification (or tube with mark).

Installation instructions
EVUCM-001-V01R0 Installation and Operation Manual UltraCharge 160 DC Charger
January 2023 Page 14 of 29
Requirements for Distribution Cables
1. Cable laying shall be free from external force, distortion and damage of insulation
layer.
2. It is strictly forbidden to twist, flatten, break the protective layer and wear the
protective layer seriously.
3. The protective pipe shall be cleaned before the cable passes through the pipe,
and the wire shall not be damaged.
4. The cable arrangement shall be tidy. The binding should be neat and should not be
crossed.
5. Sufficient allowance shall be reserved for each wire of the cable, and the bending
degree shall be consistent.
6. Crimp the terminal of the cable head, and there should be no gap on the
penetration surface of the terminal after crimping.
7. When pressing the lug of inlet cable, the heat shrinkable tube should be set
between the cable and the lug, and the inside and outside of the tube should be
smooth without damage and crack. Before setting the heat shrinkable tube, the
sundries on the cable shall be removed, and there shall be no burr and iron filings
on the surface to prevent damage to the tube. The colour of the tube shall be in
accordance with the phase sequence. When the tube is heat shrinkable, the flame
should be avoided to spray on the inside of the cabinet to prevent burning the
internal components and cables of the cabinet. The appearance of heat
shrinkable casing should be flat, smooth, uniform shrinkage, no dust and crack.
8. Attention should be paid to the wiring sequence when pressing RJ45 connector for
Ethernet cable. Check whether the pressing is qualified after pressing.
Cable Specifications for AC Input (Recommended)
Capacity
(kW) Cable specification
Capacity
of superior
distribution
switch
Screw
specification
(diameter: mm)
Cable terminal
60kW 4*35mm²+1*35mm² 160A L1/L2/L3/ N/PE㸸
M8
L1/L2/L3/N/PE:
DT35-8
80kW 4*50mm²+1*50mm² 200A L1/L2/L3/ N/PE㸸
M8
L1/L2/L3/N/PE:
DT50-8
120kW 4*120mm²+1*120mm² 315A L1/L2/L3/ N/PE㸸
M12
L1/L2/L3/N/PE:
DT120-12
160kW 4*150mm²+1*150mm² 400A L1/L2/L3/ N/PE㸸
M12
L1/L2/L3/N/PE:
DT150-12

Installation instructions
UltraCharge 160 DC Charger EVUCM-001-V01R0 Installation and Operation Manual
Page 15 of 29 January 2023
Internal Wiring
The internal input cables are N, L1, L2, L3, PE, Ctrl and Eth from left to right.
The ‘Ctrl’ indicates a control signal cable and the ‘Eth’ indicates a ethernet cable .The
cabinet grounding is divided into two parts, one is the grounding bar inside the cabinet,
and the other is the grounding of cabinet shell.
Figure 7 Internal Wiring

Installation instructions
EVUCM-001-V01R0 Installation and Operation Manual UltraCharge 160 DC Charger
January 2023 Page 16 of 29
Installation
Tools required
xClaw hammer
xCross screwdriver
xStep ladder
xElectric drill
x(TXLSSHGZLWKǗPPGULOOELW
xInsulating gloves
xCable clipper
xInsulation shoes
xHydraulic clamp
xAdjustable wrench
xSecurity Hex wrench
xCraft knife
Unpacking the Outer Package of the Cabinet
1. Straighten the metal tabs on the top of the packing material and remove the
upper cover plate.
Figure 8 Unpacking 1
2. Straighten all metal tabs then remove the surrounding wood boards,

Installation instructions
UltraCharge 160 DC Charger EVUCM-001-V01R0 Installation and Operation Manual
Page 17 of 29 January 2023
3. Carefully cut the plastic bags wrapped around the cabinet and remove the PE
bags and foam.
Figure 9 Unpacking 2
4. Remove the four M12 bolts around the base.
Figure 10 Unpacking 3

Installation instructions
EVUCM-001-V01R0 Installation and Operation Manual UltraCharge 160 DC Charger
January 2023 Page 18 of 29
Foundation Drilling
xThe hole size is shown below:
Figure 11 Foundation Preparation 1
1. Drill four mounting holes with a diameter of 16 mm and a depth of 80-85 mm on the
cement mounting base.
2. Knock four M12 * 80 expansion bolts into the holes.
Figure 12 Foundation Preparation 2

Installation instructions
UltraCharge 160 DC Charger EVUCM-001-V01R0 Installation and Operation Manual
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Site the Charger
1. Use forklift to transport the cabinet to the installation base and use the crane to lift
the cabinet.
Figure 13 Site Location 1
2. Suspend the cabinet above the cement base, open the front door of the cabinet,
and extend the embedded cable from the bottom of the cabinet through the inlet
hole. At this time, slowly lower the cabinet and pull the remaining cables out from
the front door until the cabinet is completely placed on the base.