RedEarth HoneyBadger User manual

HoneyBadger
Home Battery System – Off-Grid
Victron with Troppo-4841 Lithium Batteries
Installation Manual

HoneyBadger Installation Manual
HoneyBadger Install Version 2 Page 2 of 32 Issue Date 18/07/2022
Safety
The wiring diagrams and installation instructions are given as a guide only and
compliance to appropriate standards is the responsibility of the installer. Relevant
standards are listed below:
AS/NZS 3000:2018 Wiring rules
AS/NZS 5033:2021 (and 1&2) Installation and safety requirements for photovoltaic (PV) arrays
AS/NZS 4509.2:2012 Stand-alone power systems-Design
AS/NZS 1170.2:2011 Structural design actions-Wind actions
AS/NZS1768:2007 Lightning protection
AS/NZS 3008.1.1:2017 Electrical installations – Selection of cables
AS/NZS 5139:2019 Electrical installations-Safety of battery systems for use with power
conversion equipment
The HoneyBadger must only be installed by suitably qualified personnel who have read
and are familiar with its operation and hazards.
The battery provided with this system must be charged only by the Victron
inverter and MPPT. Do not attempt to charge the batteries with any other charger
device or connect any devices directly to the DC battery bus unless approved by
RedEarth.
In the event of a fire evacuate the area and call emergency services. A dry agent
fire extinguisher should be readily available and used. DO NOT use water.
Note: MSDS document is provided with the system and can be found at
www.redearth.energy
Do not use a damaged battery. Batteries should only be disposed of at an
appropriate recycling centre. Please contact RedEarth for advice.
A battery can present a risk of electrical shock and high short-circuit current. The
following precautions should be observed when working on batteries:
 Disconnect charging source prior to connecting or disconnecting battery
terminals.
In our efforts towards constant product enhancement, this document is subject
to change at any time. Please visit http://www.redearth.energy and download the
appropriate and latest version manual.
Symbol
Explanation
Refer to the operating instructions
Indicates additional information, emphasized contents or tips that may be helpful.
Caution, risk of electric shock.
Caution, risk of danger.
Do not touch live parts until 10 minutes after disconnection from the power
sources.

HoneyBadger Installation Manual
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Table of Contents
Home Battery System – Off-Grid ............................................................................................................. 1
Safety....................................................................................................................................................... 2
HoneyBadger Overview ........................................................................................................................... 4
Dimensions and clearance/positioning information ................................................................................ 5
Internal Components description ............................................................................................................ 6
8 steps to complete your HoneyBadger installation: ............................................................................ 11
Step 1. Transporting ..................................................................................................................... 11
Step 2. Positioning ........................................................................................................................ 12
Step 3. Solar Installation ............................................................................................................... 12
Step 4. Electrical connections ....................................................................................................... 14
4.1 Solar.................................................................................................................................. 15
4.2 AC Connections ................................................................................................................ 15
4.3 Battery .............................................................................................................................. 17
4.4 Remote Monitoring .......................................................................................................... 18
Step 5: Turn ON and Shutdown procedure .................................................................................. 19
Step 6: Commissioning ................................................................................................................. 20
Step 7: Activating Remote Monitoring and Communications ...................................................... 21
Step 8: Customer Handover ......................................................................................................... 24
Services and Options available for the HoneyBadger ............................................................................ 25
Appendix A – Single Line Diagrams ........................................................................................................ 26
Appendix B – Technical Specifications ................................................................................................... 28

HoneyBadger Installation Manual
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HoneyBadger Overview
The HoneyBadger is an Australian-made all-in-one battery system built for off-grid homes.
The system is designed to be easy to install and use. It is fully assembled, factory tested prior to
shipment and requires only limited programming on-site.
It includes a 10kVA Victron Quattro inverter, up to two Maximum Power Point Trackers (MPPT) and up
to 32.8kWh of self-managed Troppo-4841 lithium batteries.
Remote monitoring is available subject to mobile phone coverage.
This uses RedEarths EMU app. The Victron VRM portal is also
available for more detailed analysis.
HoneyBadger is ready to directly connect up to a 13.3kW PV Solar
array (maximum 250VDC (5 panels in series) and a generator (either
2-wire auto start or manual start). Note that an additional AC-
coupled solar inverter can be added if more Solar is required (e.g.
Fronius 8.2).
The HoneyBadger system can be installed either inside or outside,
ideally in a shaded area against a wall. A changeover switch is included in case of system problem. The
loads can then be run off a generator until the system is operational again.
A typical complete installation of the HoneyBadger will require the electrical connection of:
 The customers load: usually via an
external switch board with an earth stake
and MEN link – there are dedicated
terminals inside the unit to connect to.
 PV solar panels: with one array per MPPT
(maximum 250VDC per string) (with two
MPPTs, two different different PV array
orientations can be used).
 Generator: recommended (2-wire auto
start or manual start generator).
Terminals for connecting a dry-contact
compatible generator start or signal light are included. A Victron smart charger is also included to
keep the starter battery of the generator charged up.
 In addition, the installer may need to program the Victron CCGX controller for the customer’s
specific requirements (e.g., generator run times). RedEarth tech support is available 7-days a week.
 Remote monitoring: The HoneyBadger comes with RedEarth’s RedPi Lite 4G modem, with SIM card
built in. If there is mobile phone coverage, then remote monitoring is possible. Optimal positioning
of the antenna will help with reception. A direct connection from the customers router to the
HoneyBadger is also possible.
Note: The HoneyBadger is not designed to act as a main switch board for the premises, as it does
not include space for additional main & customer circuit breakers or RCDs. The MEN link and
Earth connection need to be in place at the premises as required.
Finally, the HoneyBadger conforms to the Australian Battery Safety Guide. This includes the
requirement to have an earth fault detection and alarm function on Victron MPPT equipment
operating at above 120Vdc. (AS5033:2021 paragraph 3.5.1)

HoneyBadger Installation Manual
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Dimensions and clearance/positioning information
Positioning information summary:
Minimum Clearance around
HoneyBadger where no windows
doors etc are allowed. According to
AS/NZS 5139.
Note: if the system is >300mm off the
wall then this does not apply.
The HoneyBadger is rated for outside
installation. It should be installed in a
shaded area.
HoneyBadger Weight:
 560kg with 8x Troppo LFP
batteries (42kg per battery)
 224kg without batteries
Dimensions w/ door closed: 169 H x 94
W x 65 D [cm]
Dimensions w/ door open: 169 H x 104
W x 144 D [cm]
IP rating: IP43

HoneyBadger Installation Manual
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Internal Components description
The HoneyBadger has two sections. The top area contains the inverters, MPPT’s and all of the electrical
switch gear. The bottom section is pre-wired for up to eight of RedEarth’s 4.1kWh Troppo batteries.
Each section has a key-lockable door. Note that the keys are not the same for each door.
External Power outlet – 10amp
On the right of the HoneyBadger is a 10amp power
outlet. This is available anytime the system is turned
on. It does not require the solar panels to be
connected.

HoneyBadger Installation Manual
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Face plate
Behind the face plate, are the connection points required for installing the system. This area should
only be accessed by qualified personnel. The faceplate is held in place by four screws in the corners of
the faceplate.
Face plate installed:
Face plate removed:

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AC Breakers
The AC Breakers include a two-pole breaker for connecting a generator as well as a By-pass switch to
use if the HoneyBadger has a problem and the load is to be run off the generator alone. Each switch
has an identification label directly below it. These are shown below.
Generator 2-wire auto-start
To the right of the AC breakers, on the DIN
rail, are the two terminals to connect the 2-
wire auto-start for a generator.
A Victron smart charger is also included in the
parts kit. This is to provide a continuous
trickle-charge to the starter battery of the
generator. It can be plugged into any
available power plug.
DC Breakers
The DC Breakers are used for isolating the PV
array and the MPPT from the battery.
If two MPPT’s are included in the system then
there will be two sets of breakers as shown,
otherwise there will be only one set.
This is also the connection point for the
external PV arrays.
Ensure that the maximum PV array volatge
does not exceed 250Vdc and that the polarity
is correct before connecting the PV array, as
if it is reversed it will destroy the MPPT.

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Earth fault alarm
Just below the MPPT, is the Earth Fault Alarm display. This monitors the unearthed PV Array (60-
300Vdc) and battery storage system for conductor insulation degradation. It satisfies the earth fault
detection requirements of both AS/NZS 5033:2021 and AS/NZS 5139:2019 with onboard audio/visual
alarms and an alarm relay output for external fault detection.
This device consists of two parts, the display interface
located under the MPPT in the face plate, and the
electronics section which in installed in the
communications compartment.
The ALL-CLEAR light is illuminated in normal operation.
If the device detects a fault, the FAULT DETECTED light
will illuminate and a buzzer will sound that can be muted
by pressing “Silence”. Contact your installer.
More information on the Earth Fault device is available at the following link, www.aerl.com.au/wp-
content/uploads/2020/10/EarthGuard-300-User-Manual-REV-1.2.pdf
Communications compartment
The communications compartment contains
the remote monitoring equipment and the
electronics section of the Earth Fault alarm.
It is located on the right side of the
HoneyBadger and is accessed by removing
the four screws holding the vent cover in
place.
The RedPi Lite monitoring equipment
installed consists of a RUT240 modem with a
RedEarth SIM-card for remote monitoring.
An antenna is included which should be
mounted externally during installation.
Additional Wi-Fi and mobile antennas are
connected directly to the modem, however
for optimal coverage the external antenna
should be installed outside the unit. Ideally in
a high location with clear visual access to the
outside. The antenna has a magnetic base to help with positioning.

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Battery compartment
The bottom compartment can hold up to
eight of RedEarth’s 4.1kWh Troppo batteries.
The compartment is separated from the
inverter compartment by a sealed divider.
A perforated base supports the batteries.
Two sets of front and rear rails secure the
batteries in place. The batteries can be
removed for transportation if required.
Passive ventilation is provided via the vents in
the base of the HoneyBadger and through the
vents in the top rear of the compartment.
Attached to the top of this compartment are
two fully enclosed battery busbars with a full
set of eight pairs of battery cables included,
to allow easy connection of additional
batteries in the future.
Parts kit - HoneyBadger
The HoneyBadger is supplied with documentation and a parts kit box to complete the installation.
 Documentation: (latest versions are available online at
www.redearth.energy)
o User manual
o Installation manual
o HoneyBadger Identification sheet (serial #s etc)
o HoneyBadger production checklist
o MSDS – Troppo-4841 battery
 Additional hardware:
o 1 x Victron Smart charger – for trickle charging a back-up
generator starter battery
o Inline string fusing for 4 parallel strings per MPPT (8 pieces for 1
MPPT and 16 pieces for 2xMPPTs)
o MC4 branch connectors x 12 (to combine 2 x 16 panels for both
MPPTs
 Parts Kit Box misc.:
o Stickers and Traffolytes required for the installation
o Screws and Dynabolts selection for fixing unit to wall and floor
(incl. 2x wall plates)
o Selection of glands for cable entry (suitable for 25mm and
32mm conduit)

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Installation – 8 steps for installation and customer handover
The SunRise system is designed to be easy to install. It includes prewired connection points and
comprehensive labelling and parts kit to simplify the installation.
Technical support is available directly from RedEarth during installation if required.
8 steps to complete your HoneyBadger installation:
1. Transporting getting the HoneyBadger to site
2. Positioning – the HoneyBadger in its final location on site
3. Solar Install
4. Electrical connections at the HoneyBadger
a. Solar
b. Battery
c. Load
d. Generator
e. Generator Auto-Start
f. Remote monitoring
5. Turn On and Shutdown procedure
6. Commissioning the HoneyBadger
7. Activating remote Monitoring – contact RedEarth to confirm remote operation
8. Customer Handover – including helping with access to RedEarth EMU app
Step 1. Transporting
The HoneyBadger system is supplied on a pallet as shown at right.
It is fully set-up, factory-tested and ready to run. The system weighs
around 392kg with 4x lithium batteries and requires lifting
equipment to handle it. The system can only be lifted from the
base.
The base of the system has spaces for either a forklift or a standard
trolley jack to be used.
If the HoneyBadger is too heavy to manage the lithium batteries
can be removed and replaced once the system is in position. Each
battery module weighs 42kg and up to eight (8) can be installed in
the system.
Cable entry options are available on both sides of the system. They
are designed for 25mm and 32mm conduit, and glands are
provided in the spares which clamp onto 25mm flexible conduit.
Air inlet vents are included in the base and sides of the system. Do
not block them.
The
Face Plate comes strapped to the side of the unit to avoid transport damage

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Step 2. Positioning
The HoneyBadger is designed to be a freestanding weatherproof
system. However, it is strongly recommended to place it against a
wall. It should be in a shaded area and protected from direct
sunlight.
With the help of a forklift of a pallet-jack, roll the system into place
and secure it to the wall as well as the floor. Wall fixing plates are
provided in the parts kit which can be used to ensure the system
cannot tip over. The HoneyBadger also has four holes in the base
to allow for securing the base. This can be done with Dynabolts or
material appropriate screws.
Securing the system to the wall is done by screwing through the
hole on the left and right corner of the systems roof.
Masking tape may be applied to the unit. This is strategically
positioned in common rubbing spots and the purpose of the tape
is to avoid paint chipping during transportation. This can now be
removed.
Step 3. Solar Installation
The PV Array should be designed and installed in accordance with
AS/NZS 5033 and the latest CEC Installation guidelines. Caution
should be taken in selecting PV panels and wiring method to
ensure Open Circuit Voltage (VOC) and Short Circuit Current (ISC) is not exceeded.
The maximum open circuit voltage is 250Vdc at the lowest expected
temperature.
Example calculation:
Overleaf are the specifications from a common 385-400W panel range.
Using data for the 400W panel,
Voc = 49.5V at 25degC. If the lowest expected temperature is 0degC then
the temperature correction is -25degC x -0.270% = 6.75%. This means
that at 0degC the Voc is 6.75% higher than at 25degC = 1.0675 x 49.5 =
52.84V.
MPPT 250V max / 52.84V = 4.73 which means a maximum 4 of these
400W panels can be put in series in a location where 0degC is expected.
IMPORTANT: Before positioning the HoneyBadger, be
sure that there is an available area of 1690 x 1040 x
1445 (H x W x D). This will allow a minimum of 90⁰ open
door angle as well as lateral ventilation.

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Maximum PV array current:
Maximum PV open circuit current = 70A for the Victron MPPT 250/100 installed in the HoneyBadger
As the Isc of the example 400W panel is 10.12 amps up to six (6) strings can be connected in parallel.
However as the nominal rating of the MPPT with a 48V battery is 5,800W. A single string of 4 x 400W
panels is 1.6kW, so 4 strings in parallel = 6,400W which is sufficient in most situations.
This also more than covers the recently introduced 1.25 times safety margin on manufacturers Isc.
Reverse polarity protection:
The MPPT is not protected against reverse battery polarity, however this is not an issue as it is pre-
wired by RedEarth.
Victron have the following comments about connecting the PV polarity in reverse, which is in the
installers hands,
Further details are available for the Victron MPPT at this link,
https://www.victronenergy.com/upload/documents/Manual_SmartSolar_MPPT_150-70_up_to_250-
100_VE.Can/MPPT_solar_charger_manual-en.pdf
A sizing calculator by Victron is available at this link, https://www.victronenergy.com/mppt-calculator
Example of Solar panel connections using the supplied in-line fuses and MC4 branch connectors:
As up to 4 strings are connected in parallel string
fusing is required on every string. In-line fusing is
supplied (8 for each MPPT) with the HoneyBadger.
This is sufficient for up to 4 strings per MPPT.
One in-line fuse is connected to each +ve and -ve
cable coming from each string.

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Using the supplied x12 MC4 branch connectors up to 4 strings can be paralled for each MPPT.
An example for paralleling thre strings of 2 panels each is shown below.
Note that the in-line fusing is not shown, but is required.
The maximum 50A rating of the MC4 connectors is not exceeded if 6mm2 PV cable is used after the
second branch connector. 4mm2 PV cable can be used before the second branch connector as the
current is below the 30A rating with 4mm2 cable.
Step 4. Electrical connections
To access the cable connection points, remove
the faceplate by undoing the 4 screws holding
it in place.
It is also possible to remove the vents on the
sides of the unit by unscrewing the four corner
screws.
This allows access into the unit to pull through
cables, as well as accessing the
communications area on the other side of the
unit.
NOTE: Before proceeding any further, ensure that all breakers and isolators, as well as those supplying
power to the unit, are turned OFF.

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4.1 Solar
Connect the PV arrays to the breakers shown
at right. If two MPPTs are present, then there
will be two sets of breakers as shown.
Ensure that the polarity is correct. You can
identify this by looking at the colour of the
cables connected to the bottom of the
breakers.
Note that the PV array must always be wired
in a way that maintains the voltage below
250VDC.
4.2 AC Connections
AC cables should be inserted through the existing holes on either the left or right of the system, then
sealed appropriately with 25mm or 32mm glands and conduit. The Appendix A contains a SLD for the
system wiring.
The AC wiring can be more easily completed by removing the vent on the left side of the HoneyBadger
as shown below.
4.2.1 Load connection
The active cable is connected to the bottom side of the unit’s
main breaker identified as “Inverter OUT”. Neutral and Earth
cables are connected to their respective busbars.
NOTE: The LOAD connection should come from a Switch
Board which contains a MEN link and a suitable earth as
required for the premises.
NOTE: Caution, while installing the Active cable ensure that the other smaller cable connected to the
same breaker remains in place.

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4.2.2 Generator connection
Active and neutral wires from the generator are connected to the bottom side of the “Generator IN”
breaker. The earth is connected to an empty slot in the Earth Bar.
NOTE: The MCBs are rated at 50A, be sure to use appropriate cabling.
NOTE: Generator quality and size: The quality of the power produced by the connected generator
(frequency, voltage and current waveforms) needs to be of sufficient quality otherwise it will be
rejected by the HoneyBadger.
The following specifications must also be met for a guaranteed compatibility with the inverter.
 Generator waveform THD: < 10%.
 Generator Vrms range: 180 ~ 264Vac
 Generator voltage crest factor (Vpeak/Vrms): < 1.6
 Generator peak voltage: <380V
 Frequency range: 45Hz ~ 55Hz
 Frequency slew rate: <0.3Hz/sec
The size of the generator should be sufficient to support the loads if the
operated in By-Pass mode.
4.2.3 Generator Auto-Start
The HoneyBadger contains two terminals on the right end of the AC din rail
that are covered when the faceplate is installed (see image at right). These
terminals are connected to a dry contact that can be programmed to
automatically start a generator, or it can be used to activate a signal light
indicating that a manual start generator should be started.

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4.3 Battery
The batteries are in the bottom section of the HoneyBadger. Additional batteries can be added in the
future
Removing or Installing a TROPPO battery:
To remove or install a battery follow these steps:
1. Remove the battery cables by pressing the
button on the side of the terminal and pull it
straight up
NOTE: When installing the battery cable, simply
push it onto the terminal until you hear a click.
2. Remove the bolt that holds the earth cable to
the battery
3. Remove the bottom door by pulling the pins of
the hinge
4. Remove the bolts the hold the Battery
Mounting Rail in place
5. Remove the Battery Mounting Rail by sliding
upwards and out
6. Slide out one battery at a time. Be careful as
each battery weighs 42 kilograms.
To install a battery, follow this process in reverse.

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4.4 Remote Monitoring
The HoneyBadger remote monitoring system,
RedPi Lite, is already installed when the system is
shipped, including a 4G SIM. The only
requirement during installation is to install the
supplied antenna in a good 4G reception area. If
installing in a closed area like a Shed, remember
to check the 4G signal with the shed doors closed
(e.g. by looking at how many bars of reception you
have on your mobile phone) as this will affect the
strength of the signal, otherwise position the
supplied antenna outside.
To access the antenna, remove the four screws
that hold the vent cover on the right side of the
unit.
Unplug the antenna from the RedPi Lite
monitoring device, pass it through the 16mm2 gland from the parts
kit, fit the gland in the 16mm hole on the side of the unit. Fit the
antenna to the RedPi Lite device and then tighten the gland. Once
this is done, place the antenna in an open area with good cellular
reception. The antenna has a magnetic base.
Note: if there is no mobile phone coverage then remote monitoring
is not possible.
Local monitoring:
Note that all information available remotely can also be
monitored on the local control screen in the HoneyBadger.
Detailed instructions are available from Victron at
https://www.victronenergy.com/upload/documents/Manual-
Color-Control-GX.0.3-EN.pdf

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Step 5: Turn ON and Shutdown procedure
Once the HoneyBadger is in place and correctly wired up, you may start the system.
To power up the unit follow the steps below:
1 Switch on the battery switch on the top of each lithium
battery. The display and LED light on each battery will
come on.
2 Switch on the BATTERY SYSTEM D.C. ISOLATOR; the
Quattro Inverter and CCGX display will start (note the
small black switch on the front of the Inverter itself
needs to be in the ON position)
3 Switch on the SOLAR D.C. ISOLATOR #1 and - if available
- #2 Isolator
4 Switch on the MPPT #1 and - if available - #2 Isolator
5 Position the Changeover switch upwards (position 1);
6 Turn ON all AC circuit breakers
Note: the shutdown procedure is shown is the reverse of the
start-up procedure. This label is affixed to the inside of the
HoneyBadger.

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Step 6: Commissioning
The HoneyBadger is commissioned and tested in RedEarth’s factory to guarantee correct operation.
However, on-site parameter adjustments may be required (e.g., modifying generator size or increasing
energy storage capacity).
There are four ways to change parameters,
1. Using the Colour Control GX display on the HoneyBadger – not all parameters can be changed
this way (e.g., generator size)
2. By connecting a laptop with Victron VEConfiguration software downloaded onto it. In
addition, a Mk3 device is required to physically connect the laptop to the Victron equipment.
3. On-line, by logging into Victron’s VRM portal once the system is connected to the internet via
RedEarth’s built-in 4G SIM.
4. Contact RedEarth tech support during the installation and they can change parameters for
you.
NOTE: Changes must be made by a qualified person.
NOTE: To make changes by directly connecting a laptop to the HoneyBadger a MK3 device is required.
This is not supplied with the HoneyBadger but is available separately. The VE Config program can be
downloaded from Victron’s web page (https://www.victronenergy.com.au/)
https://www.victronenergy.com/support-and-downloads/software
The original Victron Quattro inverter and
MPPT manuals are included with the
documentation supplied with the
HoneyBadger, along with the inverter
configuration sheet. These can be referred to
as required when adjusting system
parameters.
All parameters that are configured by using
the Victron MK3 device are printed in a sheet
and supplied with the rest of the
HoneyBadger documentation. To change
parameters using the MK3, please refer to the
VEConfigure Manual available on Victron’s web page.
https://www.victronenergy.com/upload/documents/VE.Bus_Configuration_Guide/VE_Bus_Configura
tion_guide-en.pdf
Changing parameters through the CCGX display unit. The CCGX display has several pages for monitoring
and setting parameters. Refer to https://www.victronenergy.com/live/ccgx:start or the included
Manual for details.
Complete programming of the CCGX according to the customers’ requirements.