Hybrid Battery Module Fault is Pending. Wait Till Current?

The nuts on the bus bars should be tightened to 48 INCH pounds. Buy yourself a small 1/4" torque wrench and use it to tighten the nuts.

 

Because poor electrical connections never start fires, right?

Many homes burn to the ground every year because of poor electrical connections. Why would you purposely make 56 poor connections in a high voltage, high current battery? You are practically begging to break down on the side of the road.
As mentioned, tighten them to 48 INCH pounds. Go to Harbor Freight and buy a $15 1/4" drive torque wrench and an 8mm socket. Do it once and be done with it, before you damage the terminals on the modules from arcing and heat generation..

 

Clean up the busbars to get a clean mating surface because they will now be arc pitted .... and voltage sensing wire tabs as well, give them all a coating with Alminox or the equivalent dielectric grease on both sides of the voltage sensing wire tab and the busbar, then tension the nuts correctly ..... that hard to turn the nut on the thread is because the terminal has arced through the nut because the busbar connection to the terminal boss was probably already arced and pitted resulting in a poor contact

T1 Terry

 

Are these busbars tinned with solder? They look like they are. I would highly recommend replacing these busbars with regular ones, copper or nickel plated, until it's too late. Otherwise they will kill the modules in your battery pack if they have not already done so. The solder deteriorate under such currents and creates a high resistance between module pole and busbar.

 

They look like tarnished and oxidised copper to me. I'd recommend polishing them on a wire brush or a sheet of wet and dry sandpaper using kero as the lubricant ..... that copper oxide near doubles the resistance compared to clean copper ...

T1 Terry

 

So, from this reply, do we infer you have used a ¼" torque wrench and all bus bar nuts are torqued to 48 INCH-lbs?

 

Sounds like you have a lot more problems than just lack of common sense.....did all that make you feel better? I'm pretty sure you need therapy more than I do. Everything in my post was truth. None of what's in your post is.

Arrogant? Maybe, but I've fixed more f'ed up DIY batteries than you'll ever even put eyes on in your entire life. Sounds like yours is probably going to be very similar, just for someone else to fix down the road. If you need more of the 8mm hex head nuts, let me know, I have a box of 5000 in the shop. Need a module? I have over a thousand. Need an ECU? I have 20 on the shelf. Need a new wire sensor harness? I have a couple dozen.

Nah, never mind, you got this.