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Mar 25, 2022 at 18:43 comment added Ed R. Thanks for the tip. The burn marks were primarily on the lug of the breaker that attaches to the bus bar. They were minimal on the bus bar itself.
Mar 25, 2022 at 11:41 comment added ThreePhaseEel @EdR. where precisely were the burn marks? the sandpaper job probably damaged the plating on the lug, so while it's holding together for now, I'd get a replacement main breaker for the subpanel on order
Mar 25, 2022 at 5:35 vote accept Ed R.
Mar 25, 2022 at 5:33 comment added Ed R. I think that was it. I pulled the cover off the panel and checked the connections between the 100 amp breaker and the two bus bars. Both were not even snugged down, much less torqued-down. I removed the breaker and there was some heavy burn marks on one of the two connections. I then scrubbed everything clean with some fine sandpaper and reinstalled it all. Now, the car has been charging for over an hour and the 100 amp breaker is as cool as a cucumber and the 40 amp is so lightly warm it's hardly noticeable. I think all is good now. Thanks!
Mar 25, 2022 at 0:56 history answered ThreePhaseEel CC BY-SA 4.0