Explaining the Manager30's Bad Output Cable Detected Fault
Seeing the bad output cable fault on your Manager30 (BMS1230S2/S3) indicates that the BMS has detected a voltage difference between the charger assembly and the battery sensor.
Common issues that can contribute to this fault condition include;
- Poor, loose or high resistance connections
- Faulty fuse protection (blade fuses and circuit breakers can often be the culprit)
- Undersized cable
- Poor earth return connection
When the ‘Bad Output Cable Detected’ fault is displayed, this voltage difference can be diagnosed using a multimeter. To start, you will need to get a series of base voltages.
Measure and record the auxiliary battery voltage at the Battery Terminals.
Measure and record the voltage between pin 1 and 3 on the Green Manager30 Phoenix connector.
Hold the multimeter probes on pins 1 and 3 and proceed to cycle the BMS from touring mode to storage mode and back to touring mode again. This will reinitiate the charge cycle and push the BMS into the boost stage. Check the output status screen to ensure the BMS is outputting a high performance 25-30A.
If the batteries are at 100% state of charge, then apply a large load to make the BMS compensate for it and recheck the voltage.
You may measure a different voltage when compared to the auxiliary battery. If this is the case, it then needs to be determined whether the issue is on the positive supply to pin 1 of the BMS or earth circuit.
While in the boost stage, check the voltage between pin 1 and the auxiliary battery positive terminal. If there is a voltage, this indicates that there is a voltage drop on this cable. If the multimeter reads 0V, this cable is okay.
Measure the voltage between pin 3 and the GND side of the shunt. If there is a voltage, this indicates that there is a voltage drop in the earth circuit. If the multimeter reads 0V, this cable is okay.
If these are not the same voltage
Measure the voltage between pin 1 and the auxiliary battery positive terminal. If there is a voltage, this indicates that there is voltage drop on this cable. If the multimeter reads 0V, this cable is okay.
Measure the voltage between pin 3 and the GND side of the shunt. As above, if there is a voltage, this indicates that there is voltage drop on this cable. If the multimeter reads 0V, this cable is okay.
Please see the below diagram to assist in indentifying the areas to measure in a BMS installation.
If your installation incorporates a RedVision system
In addition to measuring the voltage between pin 1 and the auxiliary battery positive terminal, and pin 3 and the GND side of the battery sensor, the following terminating points can be tested for voltage drop.
- Between pin 1 and the TVMS positive
- Between the TVMS and the auxiliary battery positive
- Between pin 3 and the TVMS negative (ground)
Between TVMS negative (ground) and GND side of the battery sensorPlease see the below diagram to assist in identifying the areas to measure in a TVMS installation.
