Sinexcel ROLECEV 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-V01R0 Maintenance Manual
Page 1of 21 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: Maintenance Manual
Document Code: EVUCMM-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
EVUCMM-V01R0 Maintenance Manual UltraCharge 160 DC Charger
January 2023 Page 2of 21
Contents
Product Support 1
Safety 3
Safety Advice Within this Manual 3
Disclaimer 4
Equipment Warnings 5
Maintenance 7
Maintenance of Inactive Charging Stations 7
Charger Checks and Maintenance Cycle 7
Replacement of Common Devices 9
Electric Meter 9
Main circuit breaker 10
Cooling fan 11
AC contactor 12
Current transformer 13
DC contactor 14
Replacement of Dust Screen (Guidance) 15
Common Troubleshooting 18
Emergency Unlock 20
Tools 20
Procedure 20
Detailed View 21

Safety
UltraCharge 160 DC Charger EVUCMM-V01R0 Maintenance Manual
Page 3of 21 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
EVUCMM-V01R0 Maintenance Manual UltraCharge 160 DC Charger
January 2023 Page 4of 21
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 EVUCMM-V01R0 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 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.

Equipment Warnings
EVUCMM-V01R0 Maintenance Manual UltraCharge 160 DC Charger
January 2023 Page 6of 21
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.

Maintenance
UltraCharge 160 DC Charger EVUCMM-V01R0 Maintenance Manual
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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, scratch,
deformation, paint damage and other defects.
Cleaning and
paint repair
Interior Every 12
months
Check if the interior of the cabinet is clean and tidy.
Check whether the air inlet and outlet of the power
module are filled with dust or not. The dust shall be
timely removed to prevent the 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 Whether the fan is working properly. Maintenance
and repairing
Signal lamp Every 6 months Check whether the signal lamp is burned out. 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, and other defects,
whether the fixation is loose, and whether the
connection of the components is burned out. If any
abnormality is found, parts shall be replaced in a
timely manner.
Maintenance
and repairing
Charging
connector Every 6 months
Check whether the fixing clasp of the charging
connector is damaged, whether 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 machine
interface Every 6 months Check the display screen to see if it is cracked or not
functioning properly.
Maintenance
and repairing

Maintenance
EVUCMM-V01R0 Maintenance Manual UltraCharge 160 DC Charger
January 2023 Page 8of 21
Item Period Details Action
Emergency stop
function Every 6 months
Press the emergency stop button to check whether the
emergency stop button is working normally, and reset
the emergency stop button after normal check.
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
UltraCharge 160 DC Charger EVUCMM-V01R0 Maintenance Manual
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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
EVUCMM-V01R0 Maintenance Manual UltraCharge 160 DC Charger
January 2023 Page 10 of 21
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
UltraCharge 160 DC Charger EVUCMM-V01R0 Maintenance Manual
Page 11 of 21 January 2023
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
EVUCMM-V01R0 Maintenance Manual UltraCharge 160 DC Charger
January 2023 Page 12 of 21
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
UltraCharge 160 DC Charger EVUCMM-V01R0 Maintenance Manual
Page 13 of 21 January 2023
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
EVUCMM-V01R0 Maintenance Manual UltraCharge 160 DC Charger
January 2023 Page 14 of 21
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. And then the DC contactor can be
removed.
4. Replace with a new DC contactor in an opposite
sequence of disassembling it.

Maintenance
UltraCharge 160 DC Charger EVUCMM-V01R0 Maintenance Manual
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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 shall 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
EVUCMM-V01R0 Maintenance Manual UltraCharge 160 DC Charger
January 2023 Page 16 of 21
3. Use the pull ring of dust screen to draw out the old dust screen
which will 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
UltraCharge 160 DC Charger EVUCMM-V01R0 Maintenance Manual
Page 17 of 21 January 2023
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
EVUCMM-V01R0 Maintenance Manual UltraCharge 160 DC Charger
January 2023 Page 18 of 21
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.

Maintenance
UltraCharge 160 DC Charger EVUCMM-V01R0 Maintenance Manual
Page 19 of 21 January 2023
No. Failure Cause Correction
8 Black screen. 1. Whether the power
supply of MCU is lower
than 12V.
2. The power supply wire
between the MCU and
the display screen is
loose.
3. The display screen is
damaged.
1. The auxiliary power supply is damaged,
or the connection is wrong. Check the
wiring. If the wiring is correct, replace the
auxiliary power supply with a new one..
2. Tighten the power supply wire between
the MCU and the display screen.
3. If it is damaged, replace the display
screen.
9 Over-temperature
failure of charging
station.
1. There is dust
accumulation on the
dust screen at the air
outlet.
2. The internal temperature
of the charging station is
too high.
1. Remove the dust on the dust screen.
2. Check whether the fan at the air outlet
fails and whether there is dust
accumulation at the air inlet.
10 DC contactor
failure.
1. DC contactor is sticking.
2. The DC contactor do not
react or react
incorrectly.
1. Replace the DC contactor.
11 Output fuse
failure.
1. The fuse is damaged. 1. Replace the fuse.
12 Incoming circuit
breaker status
failure/ Electric
leakage failure of
incoming circuit
breaker.
1. The circuit breaker
leakage protection
device trips.
1. Check whether the leakage current of the
charging station exceeds the threshold of
the circuit breaker. If so, contact the
manufacturer.
13 Input overvoltage
failure.
1. The grid voltage
fluctuates, and the input
voltage exceeds the
protection threshold of
input voltage of the
charging station.
2. Sampling error of
charging pile.
1. Use a multi-meter to measure whether the
input three-phase voltage exceeds the
protection threshold of input voltage of the
charging pile. If so, contact the local
power grid or temporarily raise the input
voltage protection threshold of the
charging pile.
2. Contact the manufacturer for handling.
14 Input
undervoltage
failure.
1. The grid voltage
fluctuates, and the input
voltage is lower than the
input voltage protection
threshold of the charging
pile.
2. Sampling error of the
charging pile.
1. Use a multi-meter to measure whether the
three-phase voltage input is lower than the
protection threshold of input voltage of the
charging station. If so, contact the local
power grid or temporarily reduce the input
voltage protection threshold of the
charging station.
2. Contact the manufacturer for handling.