RedEarth HoneyBadger User manual

HoneyBadger_UserManual
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HoneyBadger
Home Battery System – Off-grid
Victron with Lithium batteries
User Manual

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RedEarth Energy Storage Ltd
15 Fienta Place
Darra – QLD 4076
Australia
Tel: [phone]
Email: [email protected]
Web: www.redearth.energy

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Shutdown and safety procedures
WARNING: Working on the inside of the HoneyBadger system is restricted to qualified personnel.
In Australia this is typically qualified electricians with CEC accreditation for Solar and Battery.
WARNING: Lithium Battery hazard
Many of the procedures covered in the INSTALLATION manual have
inherent risks. Whilst the HoneyBadger is designed to be electrically safe,
including residual current device and double insulated cables, the voltages
connected or generated by the equipment are hazardous and potentially
fatal.
The HoneyBadger must only be commissioned by suitably qualified
personnel.
It is the responsibility of the installer to ensure the operation and all the wiring
is carried out according to all safety standards that are applicable to the
installation. The wiring diagrams and installation instructions are given as a
guide only and compliance to appropriate standards is the responsibility of
In our efforts towards constant product enhancement, this document is
subject to change at any time. Please visit www.redearth.energy and
download the appropriate and latest version manual.

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RedEarth’s HoneyBadger battery system is a ready-to-run energy storage system for off-grid
applications. It includes a 5 or 10kVA Victron Quattro inverter, one(1) or two(2) Maximum Power
Point Tracker (MPPT) and self-managed lithium batteries. It is fully assembled, factory tested and
requires no programming*.
It is ready to connect a PV Solar array (maximum 5 panels in series (250Vdc) and and generator
(either auto or manual start)
The HoneyBadger system is designed to be installed either inside or outside, ideally in a shaded
area against a wall. A changeover switch is included in case of system failure. In this case the
loads can then be run off a generator until the system is operational again.
The HoneyBadger can be remotely monitored and managed online using Victron’s VRM App or
VRM Website. RedEarth Energy Storage can also provide a remote monitoring service to ensure
ongoing operation of the HoneyBadger battery system.
A typical complete installation of the HoneyBadger with Victron inverter and Victron MPPT, will
require the electrical connection of:
The customers load – there are dedicated terminals inside the unit to connect to.
One array of PV solar panels (maximum 250VDC per string) (If two MPPTs are included in your
system then two arrays can be installed, with different orientations.).
Generator, if available (2-wire auto start or manual start generator). Terminals for connecting a
dry-contact compatible generator start or signal light are included.
In addition, the installer may need to program the Victron CCGX controller for the customer’s
specific requirements (e.g. generator run times) and connect the internet using one of the
available options; assuming remote monitoring is requested. The most reliable is a direct
connection from the customers router into the rear of the CCGX display. RedEarth can provide an
optional SIM-card based monitoring solution if the customer does not have internet and the
installation site has mobile coverage.
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.
About HoneyBadger
*If all details are provided upon purchase

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Dimension & Clearance
HoneyBadger Weight: 392kg with 4x Lithium batteries (42kg per battery)
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]
HoneyBadger Minimum Clearance
according to AS/NZS 5139:2019

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The Inside:
The HoneyBadger has two areas, one for the batteries and the other for the switches and
electronic equipment. Each section is secured be a key-lockable double door.
In the top area, you will find all electric-electronic equipment and also the switches and AC
connection terminals. Amongst the AC Breakers are several AC protective, isolation and the
changeover switch. Each device contains an identification labelled directly below it. Identification
can also be seen in the picture below.
Overview

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Directly below are the DC Breakers responsible for isolating the PV array and the MPPT.
The bottom area enclosure consists of a robust and perforated base to support full weight of the
batteries. Also, a front and rear rail to secure the batteries in place.
Attached to the upper back side of this chamber there can be up to two (2) fully enclosed battery
busbars with the correct amount of battery cables.
Upon request of an additional battery, we will provide the battery cables and extra Victron Busbar
(if needed).
Overview

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Quattro
Similar to the MultiPlus, the Quattro is also a combined inverter
and charger. Additionally, it can accept two AC inputs and
automatically connect to the active source. Its many features
include a true sine wave inverter, adaptive charging, hybrid
PowerAssist technology plus multiple system integration
features such as three or split phase operation and parallel
operation.
The Quattro will prevent overload of a limited AC source, such
as a generator or shore power connection. First, battery
charging will automatically be reduced when otherwise an
overload would occur. The second level will boost the output of
a generator or shore side supply with power taken from the
battery.
Features:
Two AC inputs with integrated transfer switch - The Quattro can be connected to two
independent AC sources, for example the public grid and a generator, or two generators. The
Quattro will automatically connect to the active source.
Two AC Outputs - The main output has no-break functionality. The Quattro takes over the supply
to the connected loads in the event of a grid failure or when shore/generator power is
disconnected. This happens so fast (less than 20 milliseconds) that computers and other
electronic equipment will continue to operate without disruption. The second output is live only
when AC is available on one of the inputs of the Quattro. Loads that should not discharge the
battery, like a water heater for example, can be connected to this output.
PowerControl - Dealing with limited generator, shore side or grid power- The Quattro is a very
powerful battery charger. It will therefore draw a lot of current from the generator or shore side
supply (16A per 5kVA Quattro at 230VAC). A current limit can be set on each AC input. The
Quattro will then take account of other AC loads and use whatever is spare for charging, thus
preventing the generator or mains supply from being overloaded.
Solar energy: AC power available even during a grid failure- The Quattro can be used in off grid
as well as grid connected PV and other alternative energy systems. Loss of mains detection
software is available.
System configuring - Off grid, grid interactive and self-consumption applications, involving grid-
tie inverters and/or MPPT Solar Chargers can be configured with Assistants (dedicated software
for specific applications).
On-site Monitoring and control - Several options are available: Battery Monitor, Multi Control
Panel, Color Control panel, smartphone or tablet (Bluetooth Smart), laptop or computer (USB or
RS232).
What is in my HoneyBadger

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SmartSolar MPPT 250/100
A solar charger gathers energy from your solar panels and stores
it in your batteries. Using the latest, fastest technology,
SmartSolar maximises this energy-harvest, driving it intelligently
to achieve full charge in the shortest possible time. SmartSolar
maintains battery health, extending its life.
An MPPT controller attempts to harvest power from the array
near its Maximum Power Point, whilst supplying the varying
voltage requirements of the battery plus load. Thus, it essentially
decouples the array and battery voltages, so that there can be a 12 volt battery on one side of the
MPPT charge controller and two 12 Vpanels wired in series to produce 36 volts on the other. If
connected to a PV array with a substantially higher nominal voltage than the battery voltage,
an MPPT controller will therefore provide charge current even at very high cell temperatures or in
low irradiance conditions when a PWM controller would not help much.
Bluetooth Smart built-in: dongle not needed- The wireless solution to set-up, monitor and update
the controller using Apple and Android smartphones, tablets or other devices.
VE.Direct- For a wired data connection to a Color Control panel, PC or other devices
Ultra-fast Maximum Power Point Tracking (MPPT) - Especially in case of a clouded sky, when
light intensity is changing continuously, an ultra-fast MPPT controller will improve energy harvest
by up to 30% compared to PWM charge controllers and by up to 10% compared to slower MPPT
controllers.
Load output - Over-discharge of the battery can be prevented by connecting all loads to the load
output. The load output will disconnect the load when the battery has been discharged to a pre-set
voltage (48V model: interface with a relay). Alternatively, an intelligent battery management
algorithm can be chosen: see Battery Life. The load output is short circuit proof.
Battery Life: intelligent battery management- When a solar charge controller is not able to
recharge the battery to its full capacity within one day, the result is often that the battery will
continually be cycled between a ‘partially charged’ state and the ‘end of discharge’ state. This
mode of operation (no regular full recharge) will destroy a lead-acid battery within weeks or
months. The Battery Life algorithm will monitor the state of charge of the battery and, if needed,
day by day slightly increase the load disconnect level (i.e. disconnect the load earlier) until the
harvested solar energy is sufficient to recharge the battery to nearly the full 100%. From that point
onwards the load disconnect level will be modulated so that a nearly 100% recharge is achieved
about once every week.
Programmable battery charge algorithm - See the software section on the Victron website for
details.
Programming, real-time data and history display options - Modern Apple and Android
smartphones, tablets, macbooks and other devices: see the VE.Direct Bluetooth Smart dongle and
the MPPT app discovery sheet for screenshots.
What is in my HoneyBadger

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Color Control GX
The Color Control GX is the communication-centre of your
installation. It offers at-a-glance live information, and lets you
control all products connected to it. Full system control is
gained - almost anywhere in the world - by accessing your
Color Control GX using the free-to-use Victron Remote
Management Portal (VRM).
Intuitive system overview
At a single touch, Color Control GX provides an instant
overview of your system: battery state of charge; present
power consumption; power harvest from PV; power provision
from mains/generator.
The full power of Victron Remote Management
Victron Remote Management (VRM) provides you with full access to the very extensive controls
and settings of all system-components which are connected to your CCGX. It allows remote user
and installer login - from anywhere, at anytime. This powerful application also provides for hassle-
free diagnostic checks and analysis of archived information.
Automatic Generator start/stop
The Color Control GX can be programmed to auto-start your generator - triggered by low-voltage;
high-demand; or battery state of charge. It can be further tailored to delay ignition until the end of
'quiet' periods - avoiding accidental nuisance at dead of night.
Remote Console
Control everything from anywhere with the Remote Console feature available. It's like carrying the
front face of your CCGX control panel around on your phone, or other device.
Energy Storage Systems - 24 hour Monitoring
The Color Control GX manages Energy Storage Systems. It keeps back-up batteries at 100% ;
kicks-in during power-cuts; and diverts excess (solar) power to self-consumption - saving you
money.
Temperature Sensor
A temperature activated relay is positioned on the top left-hand
side of the rear panel as shown in the picture. This relay is
connected to the two (2) fans also on the rear and will turn
them on once the set temperature is reached. The dial is set to
activate between the temperatures of 35⁰ and 40⁰ Celsius.
What is in my HoneyBadger

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Lithium Battery
Batteries are a critical part of the Off-Grid system as they store energy
generated from the solar panels and fuel powered Generators. This
power can then be utilised at times when solar energy is not available.
The battery bank has been carefully sized to meet your requirements
according to your Load Profile and energy assessment. They do need
monitoring and maintenance to guarantee safe operation and service
life.
The self-managed LFP battery with internal BMS offers you a safe
lithium option for any solution that requires reliability, ease of use and a
product that outperforms others.
Built to the highest quality standards, incorporating components of
exceptional reliability and durability, our Australian manufactured LiFe
Series are engineered to outperform and outlast its competitors.
Generator
Because the HoneyBadger is an off-grid system, it is highly recommended to purchase the unit
with one of our recommended generators. However, if purchasing separately, inverter-generators
are recommended for use with HoneyBadger due to their better power quality. If voltage,
frequency or current waveforms of the generator are not of a high enough quality, then it will be
rejected by the inverter.
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
Generator Auto-Start
RedEarth’s HoneyBadger is kitted with terminals that allow the connection of an auto-start
generator.
The CCGX is configured to start the generator when the batteries reach a State of Charge (SOC)
of 20% and stop when they reach a SOC of 30%. In the event that the generator does not turn on,
the batteries will discharge down to 48V and then the inverter will stop outputting power under
“LOW SOC fault”.
What is in my HoneyBadger

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To power up the unit you must follow the steps below:
1 Switch on the battery breakers on the top of each lithium battery. The LED light on each
battery will come on.
2 Switch on the Main Battery 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 MPPT #1 and #2 Isolator
4 Switch on the PV Array #1 and #2 Isolator
5 Position the Changeover switch upwards (position 1);
6 Turn ON all AC circuit breakers
The shutdown procedure is shown below. This label is affixed to the inside of the HoneyBadger.
How to Power-up / Shutdown my HoneyBadger

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Normal Operation
In this manual we are considering that “Normal” operation is the one where the Quattro will use the
solar power to charge the batteries and supply the loads during the day, use the battery during the
night and use the generator when needed/activated.
When this type of operation is desired, this is what the AC breakers must look like when
performing Step 5 of Power-up Procedure (see How to Power-up/shutdown my HoneyBadger).
ByPass Operation
In the event of maintenance or failure of the Victron Quattro and there is no power output from the
system, you can configure the system to operate in ByPass mode. This will allow the generator to
provide power directly to the loads.
To use this mode, the system must be set to the following configuration:
1. Turn OFF the Victron Quattro (switch on inverter)
2. Turn OFF the Generator breaker;
3. Turn changeover switch from position 1 to position 2;
4. Turn ON generator AC breaker;
5. Manually start generator.
By doing this, the generator will provide power directly to the loads.
How to Operate

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OPTION 1- On the CCGX:
The Color Control GX is the communication-centre of your installation. It offers at-a-glance live
information of the generator supply, power demand from the loads (house), power production from
the PV (solar) and the batteries info including State of Charge and charging/discharging power.
OPTION 2 – Victron’s on-line portal
If the CCGX is connected directly to the internet, Victron offers a monitoring platform called Victron
Remote Monitoring (VRM).
To access the VRM portal, open your browser and type https://vrm.victronenergy.com/. Input your
user name and password (provided with unit’s documentation)
How to Monitor my HoneyBadger

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OPTION 3 – SwitchDin’s Portal
The HoneyBadger can be monitored online through the SwitchDin platform.
SwitchDin has developed a droplet (router) that enables the management and orchestration of
solar, battery storage and electrical loads to improve energy efficiency and reduce costs and
maximise benefits to the owner and the utility. This droplet can be found in the rear side of the
electronic area (behind the Quattro inverter).
•Registering
1. OPTIONAL: During testing and commissioning, RedEarth will setup an account for the end
user and send out the following invitation.
2. Click on the link to create an account.
3. In a web browser, visit https://app.switchdin.com/accounts/sign-in?profile=redearth and log in
to view your system.
1. If you haven’t received this email from us, please email
[e-mail] with the following information:
1. full name, address, unit’s serial number with subject: Setup online monitoring
How to Monitor my HoneyBadger

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•How to monitor my system?
Once signed in, you will see the following page.
Overview Tab
LIVE DATA - Illustrates the movement of PV production, battery power, grid and load all in
Real Time.
WEATHER - Displays the current weather at the location of the system, time of day when
solar is available, wind speed and humidity.
SYSTEM STATUS - Shows the last time data was collected from the swtichDin droplet and
updated to this profile.
SOC - This graph shows the state of charge of the battery for today as a percentage value.
SO FAR TODAY – This section has three graphs. Two of these are doughnut graphs and
relate to Production (PV) and Consumption (Loads). The third graph shows power values from
solar, load, grid and battery over time.
In this example the solar PV is producing 22.94kW of power, there is 17.04kW of load and solar PV is exporting
5.9kW to the grid. The battery power is 0kW.
In the example above, 123.61kWh energy was produced from solar. 21.09kWh of it was
exported to the grid and 102.52kWh was consumed by the loads and 0W was stored in the battery.
123.61kWh energy was produced from solar. 21.09kWh of it was exported to the grid and 102.52kWh
was consumed by the loads and 0W was stored in the battery.
How to Monitor my HoneyBadger

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Performance Tab
The performance tab can be customised to see several historical data about the system.
If the “Grid Power” is a positive value (above the zero line) then the system is buys power from the
grid. If this is a negative value (below zero the line), then the system is selling power to the grid.
If the “Battery Power” is a positive value (above the zero line) then the in a charging state. If this is
a negative value (below zero the line), then it is discharging.
Live Tab
The Live Tab displays all the live readings of data in numerical form from the connected devices.
Users Tab
This tab shows the users who can view this system. This will include you, the customer, and the
RedEarth team involved in monitoring your system.
Alert Tab
The alert tab shows any errors or warnings received about the system. You will also receive an
email if an alert occurs.
Further Questions
For further questions, feel free to email us at [e-mail] or call us on 1800
733 637.
How to Monitor my HoneyBadger

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1. What should I do when my HoneyBadger turns off?
R: The most likely reason for this is that the inverter has reached the “low SOC” limit and has
stopped inverting (producing 230V). In this situation, turn the system off and then on again as
recommended by the “Shutdown and Start-up” procedure in this manual. HOWEVER, be sure to
leave the main breaker turned OFF. This will allow all the power generated to go directly to the
battery and not to the load. The batteries have to charge back up to 52V, then turn on the main
breaker.
NOTE: You can turn the main breaker on again but be careful not to use more than is being
produced. This will lead to draining the batteries again and consequently another shutdown.
2. What happens if my batteries go flat?
R: The HoneyBadger is configured so that the batteries will never drop beyond recovery. Attempt
to restart the system according to the response in FAQ #1, if that does not work after the 3rd
attempt, contact RedEarth’s technical support on [phone].
NOTE: If this happens, it means that the batteries are extremely low. If the batteries are not
immediately charged, they can drain beyond repair.
3. My Generator is turning on too frequently and/or staying on for too long. What does this
mean?
R: If connected to the auto-start, there are several reasons that it might be turning on. The default
settings are set to turn on the generator upon low State of Charge (SOC) and low voltage levels.
However, Victron has many adjustable parameters that may have been activated and are causing
the generator to run. Another possible reason for frequent and extended runtime is that the
batteries are constantly reaching low SOC meaning that the loads are too large compared to the
battery size. We recommend either reviewing your loads or contacting RedEarth for more energy
storage.
FAQ’s

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RedEarth can provide several options for the HoneyBadger;
•Additional batteries for system expansion.
•Extended warranty options.
•Miscellaneous spare parts (including indicator lights for Generator start)
•Solar kits, PV panels, racking and pre-terminated PV cables
•Diesel Generator with 2-wire auto start.
•Generator backup kit (for on-grid applications)
•Ongoing remote monitoring.
Contact RedEarth Energy Storage Pty Ltd
Tel: [phone]
Email: [email protected]
Web: www.redearth.energy
Options available from RedEarth