VOLTA FLEX PACK User manual

Volta Power Systems
FLEX PACK
User Manual

VPS-DOS-TR-04-E / Rev 01
6-January-2022
Volta Power Systems Page 3 of 34
TABLE OF CONTENTS
Welcome to Volta � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 5
Freedom to Roam � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 5
Quiet and Clean � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 5
More Power � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 5
More Confidence � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 5
More Safety � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 5
Quick Start � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 6
Turning On Your Volta System � � � � � � � � � � � � � � � � � � � � � � � � � � � � 6
Turning Off Your Volta System � � � � � � � � � � � � � � � � � � � � � � � � � � � � 6
Using the Touchscreen � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 6
Introduction� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 7
About this User Manual � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 7
Servicing your Volta System � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 7
Return Policy � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 7
Contacting Volta Power Systems � � � � � � � � � � � � � � � � � � � � � � � � � � 7
Definitions� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 7
Safety � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 9
Warnings� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 9
Safety Guidelines � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 9
Volta System Overview � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 11
Volta System Components� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 12
Volta System On/Off Pushbutton � � � � � � � � � � � � � � � � � � � � � � � � 13
Turning On the Volta System � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 13
Turning Off the Volta System � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 13
Charge Only Mode � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 13
Pushbutton LED Indicators � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 14
Touchscreen Overview � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 15
Home Screen� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 15
Alerts Screen � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 17
Settings Screen � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 18
Inverter Screen� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 19
Charging the Flex Pack and Increasing System Runtime � � � � � � � � 20
System Runtime� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 20
Charging via Shore Power � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 20
Charging via the Secondary Alternator � � � � � � � � � � � � � � � � � � � � � � 21
Charging via Solar Power� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 21
Charging via Generator � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 22
Recovery from Zero State-of-Charge � � � � � � � � � � � � � � � � � � � � � � � � 22
Using the Volta System in Hot and Cold Temperatures� � � � � � � � � � 24
High Temperature Operation � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 24
Cold Temperature Operation � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 24
Flex Pack Programmed Operating Limits � � � � � � � � � � � � � � � � � � 26
Storing Vehicles with a Volta System � � � � � � � � � � � � � � � � � � � � � 28
Long Term Storage (Greater than 3 Months)� � � � � � � � � � � � � � � � � � � 28
Short Term Storage (Less than 3 Months)� � � � � � � � � � � � � � � � � � � � � 28
Installing MyVolta Bluetooth Module � � � � � � � � � � � � � � � � � � � � � 30
MyVolta App � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 31

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Troubleshooting and FAQs � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 32
How long will my Volta System run? � � � � � � � � � � � � � � � � � � � � � � � � � � 32
Why is there a system delay after I press the On/Off pushbutton? � � � � � � 32
Why won’t my Volta System charge? � � � � � � � � � � � � � � � � � � � � � � � � � 32
How can I tell if my solar panels are working?� � � � � � � � � � � � � � � � � � � � 33
Does the Volta System have to be turned on when charging? � � � � � � � � 33
When connected to shore power, should I leave the Volta System on or turn
it off? � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 33
Why can’t I connect my phone to my Volta System? � � � � � � � � � � � � � � � 33
How do I adjust the Date or Clock on my Touchscreen?� � � � � � � � � � � � � 34
How do I recover my Volta System if it reaches 0% SOC? � � � � � � � � � � � � 34
Why do I need to adjust my charge rate? � � � � � � � � � � � � � � � � � � � � � � 34

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WELCOME TO VOLTA
Experience camping like you’ve only dreamed of� Volta’s automotive-grade,
advanced energy storage systems deliver a true off-grid adventure without
sacrificing the comforts of home�
Freedom to Roam
Gain access to REAL off-grid capability without sacrificing the amenities you
want� Volta Systems provide all the power you need including all-night air
conditioning with none of the noise or emissions of a generator�
Quiet and Clean
Ditch the loud, smelly generator and choose clean, high-performance power
instead� Gain access to pristine wilderness without disrupting it with fumes and
noise� Unlike generators, our environmentally-conscious power systems charge
from solar, shore, or while you drive, using otherwise wasted energy� Leave no
trace with a Volta System�
More Power
Experience all the power you need� Volta Systems leverage the highest energy
density on the market to deliver more power in less space and with less weight�
Run 110V appliances simultaneously, including air conditioning, all day or over-
night� Take the comforts of home on the road without having to compromise�
More Condence
Built on the same automotive-grade technology that powers electric vehicles,
Volta Systems are easy to use, virtually maintenance free, and will last the
lifetime of your vehicle�
More Safety
Protected by seven layers of safety, our systems are engineered and tested
to meet rigorous auto-industry standards, ensuring a system that’s safe and
dependable for your whole family�

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QUICK START
Turning On Your Volta System
To turn your system on, simply press the button on the Volta control panel� After
a few seconds, the ON/OFF button and gauge will light up�
Turning Off Your Volta System
To turn your Volta system off, press and release the power button, then allow the
system a few seconds to power off� After it’s powered down, the touchscreen and
button will go dark�
Using the Touchscreen
Monitor the State-of-Charge (SOC) and control the Volta System via the touch-
screen�
The touchscreen turns on a few seconds after the pushbutton is pressed, a
charge source is sensed, or the vehicle is turned on�

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INTRODUCTION
About this User Manual
This manual represents a range of Volta Power Systems equipment� Some of the
systems or equipment described in this manual may not be available on your
vehicle� Descriptions, graphics, photos, and specifications were correct at the
time of publication� Volta Power Systems reserves the right to update or change
equipment and products without obligation to provide, install, or modify the
equipment on your vehicle�
The intellectual property contained in this manual is owned or licensed to Volta
Power Systems, LLC and is protected by applicable copyright and trademark
law�
The directions within this user manual represent basic operation of the Volta
System and may not describe unique installations or operational elements
installed by the Original Equipment Manufacturer (OEM).
Servicing your Volta System
If your Volta Power Systems product is not working as expected, please review
this user manual first for operation instructions and basic troubleshooting
techniques� Never attempt to modify or repair electrical components yourself�
Always work with an authorized dealer or maintenance facility for repairs�
If you purchased your vehicle with the Volta System already installed, you will
need to work directly with your dealer or original manufacturer to arrange
service�
If your vehicle was retrofitted with a Volta System, we can help with service
through an authorized retrofit partner� A list of our retrofit partners is available at
www�VoltaPowerSystems�com�
Return Policy
Returns are based on a field analysis conducted by a certified technician�
Contacting Volta Power Systems
Phone support is available during normal business hours� Visit the Volta Power
Systems website for additional troubleshooting, Frequently Asked Questions,
and instructional videos�
Phone: (616) – 226 – 4222
Web: www�VoltaPowerSystems�com
Denitions
Term Definition
Volta System The general term for the complete Volta energy
system solution and its power distribution
devices�

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Term Definition
Flex Pack The Volta energy storage pack, composed of one
or more electrochemical lithium-ion cells� It may
include a mechanical frame, a thermal manage-
ment system, an electronic management system,
a power circuit, protection devices, and interfaces
with external devices�
End User The owner/operator of the product into which a
Volta System is integrated�
OEM The company/organization, its staff, its subcon-
tractors, or any other person working under its
responsibility, its control, or appointed by it that
is in charge of testing, using, or integrating the
Volta System�
Volta Power Dis-
tribution Devices,
Components, or
Systems
These include but are not limited to the compo-
nents that comprise the Volta System, such as
inverters, chargers, and converters�
On/Off Pushbut-
ton
Main system pushbutton that when pressed,
turns on or off the Volta System�
SOC State of Charge (SOC) indicates a percent of total
pack charge�
Touchscreen Main system display�
Manufacturer
Documentation
Supplemental documentation from the original
manufacturer of components included in the
Volta System�
120V or 120 VAC Synonymous with 110 VAC when referring to
household appliances, devices, or outlets

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SAFETY
The user is responsible for safe use of the Volta System and Volta Power Distribu-
tion Devices or Systems� Before using the Volta System, Volta recommends that
all users read this manual and fully understand all instructions�
Warnings
The following symbol is used to denote a safety critical instruction or informa-
tional detail, which if not followed or fully understood, could result in death,
serious injury, or voided warranty�
Safety Guidelines
The following warnings represent instructions, which if not properly followed,
could result in death, serious injury, or voided warranty:
Warning: Components and devices in Volta Power Systems should not
be opened or modified� Only Volta technicians or trained profession-
als with in-depth knowledge of Volta systems should perform service
work on a Volta system� Any attempt to service a system by unapproved
personnel could cause damage to the system, voiding of the warranty,
injury, or harm�
Warning: The Volta System is designed for connection and operation
with Volta power distribution devices, or equipment expressly approved
by Volta Power Systems� This ecosystem of approved devices is a layer
of safety within a Volta system� Use of other devices compromises this
layer of safety� Use of the Volta System with other external devices could
present a hazard and is expressly prohibited by Volta Power Systems�
Use of unapproved devices results in voiding of the Volta Power Systems
warranty�
Warning: Do not place a Flex Pack on, in, or near fires, or other
high-temperature locations greater than 140°F (60°C)� This includes in-
tensive sunlight� Doing so may cause the Flex Pack to overheat and may
result in a loss of performance and/or a shortened life expectancy�
Warning: Careless handling of electrical components can be fatal� Never
touch or use electrical components or appliances while feet are bare,
while hands are wet, while standing in water, or while on wet ground�

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Warning: Always remove jewelry and wear appropriate personal protec-
tive equipment (PPE) before handling the Volta System and Volta Power
Distribution Devices or Systems�
Warning: Vehicle exhaust fumes are toxic� Do not start your vehicle in an
enclosed space�

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VOLTA SYSTEM OVERVIEW
A Volta System typically contains an energy storage source (Flex Pack), an
alternator for charging during driving operations, an inverter/charger for shore
power charging and 120 VAC power distribution, and converters to create DC
power at various voltages� Your actual system may vary in size, complexity, power
distribution devices used, or other application specific variations�
The Volta System and power distribution systems are similar in complexity
to a vehicle engine or generator� Therefore, only Volta technicians or trained
professionals with in-depth knowledge of Volta systems should service these
components�
The appearance and availability of components in
your Volta System may vary from what is shown.
Charge from
Solar Panels
Charge from
Secondary
Alternator
Flex Pack
120VAC
Devices
12VDC or
24VDC
Devices
DC-DC
Converter
Inverter
Operate Devices and
Charge Pack from
Shore Power

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Volta System Components
Your Volta System may be configured with the following options:
•Flex Pack: The Flex Pack is the energy source for your Volta System� A
14-gauge steel housing protects the lithium-ion cells, and an internal
Battery Management System monitors the system, balances the cells,
and controls energy output�
•Inverter/Charger: The inverter changes the Flex Pack’s energy from
direct current (DC) into alternating current (AC) to power the vehicle’s
120V AC devices (air conditioner, heater, cook top, etc.). The inverter also
converts shore power (AC) to direct current (DC) for charging the Flex
Pack�
•DC/DC Converter: The DC/DC converter drops the Flex Pack’s energy
from 51.5V DC to power your vehicle’s 12V DC or 24V DC devices (vehicle
electronics, lights, refrigerator, etc.).
•Secondary Alternator: The high-powered, secondary alternator provides
charging power directly from your vehicle’s engine to the Flex Pack�
•Solar Controller: The solar controller regulates solar power input from
external solar panels into a stable, usable form of energy to charge the
Flex Pack�
•On/Off Pushbutton: Press the On/Off pushbutton to turn on or off the
Volta System�
•Touchscreen: Use the Touchscreen to monitor and control the Volta
System�

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VOLTA SYSTEM ON/OFF PUSHBUTTON
Turning On the Volta System
Press the On/Off pushbutton to turn on the Volta System and power your
vehicle’s electrical systems and devices� When the On/Off button is pressed to
turn on the Volta System, a 2-5 second system check occurs. If all systems checks
are successful, the Flex Pack’s internal contactor engages, supplying power to all
Volta components, turning on the Volta System�
Do not repeatedly press the pushbutton. After pressing the button, wait 30
seconds for all system checks to occur before pressing the button again�
Turning Off the Volta System
Press the On/Off pushbutton to turn off the Volta System� After pressing the
pushbutton to turn off the Volta System, a few seconds will pass before the
pushbutton LED turns off and the Touchscreen shuts down, signaling that the
Volta System is turned off�
If the Volta System is off, and a charge source is detected, the Volta System
enters Charge Only Mode� Refer to Charge Only Mode below for additional
details�
Charge Only Mode
If the Volta System is turned off (no pushbutton LED indicator and Touchscreen
is off), the system enters Charge Only Mode in the following situations:
•Vehicle is connected to shore power�
•Vehicle is connected to a generator�
•Vehicle is turned on�
While in Charge Only Mode, the Pushbutton LED flashes green continuously,
and the Volta System allows the Flex Pack to charge, but all system loads are
disabled� You will not be able to operate vehicle electrical systems while in
Charge Only Mode� Press the On/Off pushbutton to turn the Volta System on for
full functionality�
Pushbutton

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Pushbutton LED Indicators
The Pushbutton LED flash codes and colors communicate basic system and
fault states, including:
LED Color System Status
Green System on
Green Flashing Charge Only Mode - System turned
off and charge source connected
Yellow Too cold to charge
Yellow Flashing (5
seconds)
Volta System is starting after press-
ing the pushbutton
Dim Yellow Flashing (5
seconds)
Volta System is shutting down after
pressing the pushbutton
Yellow Flashing (30
seconds then system
shuts down)*
System fault causing shutdown� If
possible, monitor the touchscreen
before shutdown to assist in diag-
nosing the fault
* If a system fault is present and a charge source is connected, the
LED remains dim yellow after blinking yellow for 30 seconds.

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TOUCHSCREEN OVERVIEW
Monitor and control the Volta System via the touchscreen�
The touchscreen turns on a few seconds after the pushbutton is pressed, a
charge source is sensed, or the vehicle is turned on�
Home Screen
A) State-of-Charge Gauge (SOC): Displays the approximate SOC of the
Flex Pack� The SOC gauge’s flash codes and colors communicate basic
system and fault states� Refer to State-of-Charge (SOC) Flash Codes on
page 16.
B) Charge Time Remaining: Displays the approximate charge time
remaining in the Flex Pack� This value changes depending on the
amount of load applied to the pack� For more information on increasing
the system runtime, refer to Charging the Flex Pack and Increasing
System Runtime on page 20.
C) Current Time: Displays the current time�
D) Menu Bar: Touch the menu bar buttons to access the corresponding
screens, including:
Alerts button: Refer to Alerts Screen on page 17.
Settings button: Refer to Settings Screen on page 18.
Inverter button: Refer to Inverter Screen on page 19.
F
G
C
D
A
B
E

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Sleep button: Press to put the Touchscreen to sleep� Touch
the screen to turn it back on�
Home button: Access the Home screen�
E) System Indicators: Appear to communicate system changes or status-
es, including:
Alternator Charging: Flex Pack is ready for charging from
alternator, or is currently charging from alternator�
Flex Pack Temperature Low: Flex Pack is too cold to charge�
Heating Pads On: Heating pads are on and actively warming
the Flex Pack�
Pack Temperature High: Flex Pack is at or near the high
temperature shutdown limit�
F) Pack Temp: Displays the current temperature of the Flex Pack�
G) Power Flow: Displays the power consumption (negative value) on the
Flex Pack or the rate of charge (positive value) to the Flex Pack.
State-of-Charge (SOC) Flash Codes
Gauge Color System State
Solid Green Normal Operating SOC (greater than
20%)
Solid Yellow Low SOC (10-20%)
Solid Red Very Low SOC (less than 10%)
Flashing Red High Temperature
Slow Flashing Blue Too Cold to Charge

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Alerts Screen
A) Alert Description: Displays a description and potential troubleshooting
of the selected alert�
B) Menu Bar: Touch the menu bar buttons to access the corresponding
screens, including:
–Home button: Accesses the Home screen�
–Settings button: Accesses the Settings screen�
–Inverter button: Accesses the Inverter screen�
–Sleep button: Puts the Touchscreen into sleep mode�
C) Navigation Arrows: Press to navigate the active alerts panel�
D) Active Alerts: Displays the current system alerts� Alerts reset automati-
cally after the alert condition is resolved�
C
D
C
A
B

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Settings Screen
A) Settings Adjustment Panel: Displays the adjustable values or toggle
buttons for the corresponding setting�
B) Menu Bar: Touch the menu bar buttons to access the corresponding
screens, including:
–Home button: Accesses the Home screen�
–Alerts button: Accesses the Settings screen�
–Inverter button: Accesses the Inverter screen�
–Sleep button: Puts the Touchscreen into sleep mode�
C) Navigation Arrows: Press to navigate the Settings Panel�
D) Settings Panel: Displays the adjustable settings� Use the arrow buttons
to scroll through the settings, the press the setting to adjust� Refer to
the Available Settings section below for details.
Available Settings
Some screens require a password to edit the settings� These screens include
settings that should only be adjusted by a Volta approved technician� The
following screens have settings that are accessible to all users:
•Screen Timeout: The screen timeout value adjusts the time after
inactivity before the touchscreen turns off� When disabled, the
touchscreen never goes to sleep� Touch the screen to wake up the
touchscreen�
•Units: Toggle the temperature units between °F or °C.
•Date Adjustment: Adjust the date (day, month, year).
•Time Adjustment: Adjust the current time (hour, minute, AM/PM,
12/24 hr).
•Theme: Toggle the touchscreen color theme�
•Screen Brightness: Adjust the screen brightness or toggle between
Auto and Manual mode�
C
D
C
A
B

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Inverter Screen
A) Inverter Status: Displays a description of the current inverter action or
status�
B) Menu Bar: Touch the menu bar buttons to access the corresponding
screens, including:
–Home button: Accesses the Home screen�
–Alerts button: Accesses the Settings screen�
–Settings button: Accesses the Setting screen�
–Sleep button: Puts the Touchscreen into sleep mode�
C) Inverter Power: Toggles the inverter On or Off� Whenever the inverter
is not needed (not using 120V devices), turn off the inverter to conserve
Flex Pack SOC� Refer to Charging the Flex Pack and Increasing
System Runtime on page 20.
D) Charge Rate Selection: Displays the current charge rate� Use the arrow
buttons to raise or lower the charge rate�
E) Charging Guidance: Displays a description of the recommended use
for the currently selected charge rate�
C
D
E
A
B

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CHARGING THE FLEX PACK AND INCREASING
SYSTEM RUNTIME
The Flex Pack accepts charge from the sources described in the following
sections� Monitor the Touchscreen for any alerts that may prevent charging�
The Flex Pack only charges when required� There may be several factors pre-
venting the Flex Pack from charging, even while connected to a charge source�
The most common reasons are the Flex Pack is too cold to charge, or the BMS is
inhibiting charge because of a high enough SOC�
System Runtime
Similar to fuel tank levels responding to driving style, the time it takes to drain
a Flex Pack from “Full” to “Empty” depends on usage� The two largest loads in a
vehicle that affect the runtime are typically heating and cooling� The more the
heating and cooling systems run to maintain the desired temperature inside the
vehicle, the more energy is used�
To maximize runtime:
•Turn off the inverter if 120 VAC loads are not required: When 120 VAC
devices (air conditioner, heater, cooktop, etc.) are not in use, turn off the
inverter via the touchscreen� Refer to Inverter Screen on page 19.
•Increase the thermostat in warm climates: Increasing the desired
vehicle temperature reduces the amount of time the air conditioner
compressor needs to run in warm climates�
•Decrease the thermostat in cool climates: Decreasing the desired
vehicle temperature reduces the amount of time the heating system
needs to run in cold climates� Generally, heating using electricity uses
almost twice the energy as cooling�
Charging via Shore Power
Volta recommends a minimum 120V/30A rated shore power cord less than 50 ft.
in length� The OEM should follow NEC or RVIA guidelines for the specific appli-
cation requirements�
When plugged into shore power, the Flex Pack samples incoming power for
a few seconds to ensure uniformity requirements are met� If incoming power
meets the requirements, the Volta System turns on and begins charging the
Flex Pack�
If the Volta System does not turn on or the Flex Pack does not begin to charge,
the incoming power is likely not meeting the Volta System requirements� This
feature protects the vehicle from brown outs due to insufficient power� Addi-
tionally, the system may not accept a charge if plugged into an electronic surge
protector�
When connected to shore power, the Volta System first provides power to any
accessories drawing power from the Flex Pack� The remaining current is then
used to charge the Flex Pack at the rate chosen on the Inverter Screen on the
Touchscreen� Refer to Inverter Screen on page 19 for details on changing
the charge rate selection.