2025-03-05

Powerwall+ Solar Assembly / Tesla Solar Inverter Fan Replacement

Prepare the following parts:
  • 2097525-00-A: Connector (need 4x per fan replacement)
  • 1540062-00-C: Fan (need 1x per fan replacement)
Work type: Remove/Replace
Required tools:
  • T20 Torx driver
  • Safety Glasses (ANSI Z87 rated)
  • Cut-resistant gloves (ANSI Cut Level 3)
  • Wire cutter
  • Pliers
  • Lockout/Tagout equipment
  1. Perform Lockout/Tagout.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Wear Safety glasses (ANSI Z87 rated) and cut-resistant gloves (ANSI Cut Level 3) to avoid injury.
  2. Remove the nut holding the ground wire to the cover.
  3. Remove the cover by sliding it to the right.
  4. Cut the wires connected to the fan, as close to the fan housing as possible.
    Informational PurposesAn informational icon, calling your attention
    Note
    Cutting wires close to fan housing ensures ample wire length to work with and will account for any mistakes requiring cutting of the wires.
  5. Pull wires out of the housing, being careful not to damage them.
  6. Remove four T20 fasteners holding in the fan, then remove the fan from the housing.
  7. Prep the now removed wire to be connected to a new fan:
    1. If wire ends are uneven or there is damage to the insulation, cut the wires to remove the damaged part.
    2. Cut as little wire as feasible to ensure ample length to work with.
    3. Cut back the black sheathing about 1 ½ in. to allow the 4 colored wires to be separated.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    When cutting black sheathing do not cut the colored insulation. If the colored insulation is cut it could cause a short and lead to fan failure.
  8. Prep the new fan to be connected into the existing wiring: Snip the wires on the end to make sure no copper is exposed.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    When cutting black sheathing do not cut the colored insulation. If the colored insulation is cut it could cause a short and lead to fan failure.
  9. Insert the new fan into the inverter housing, hand start the 4 fasteners removed from the previous fan.
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    Note
    Make sure the fan is oriented with the wires exiting the top left corner.
  10. The new fan will be connected to the old wiring with waterproof splice connectors. To attach:
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    Note
    Once connections are made bend the connection out of the way to make room for the next connection.
    1. Start with the black wires, bend all other wires out of the way.
    2. Insert the 2 black wires into the connector, each into their own hole, ensuring they are inserted all the way, you should be able to see them hit the top of the connector casing.
    3. Hold the wires in place with one hand, and clamp down on the connector with a set of pliers to engage the clip.
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    Note
    Once connections are made bend the connection out of the way to make room for the next connection.
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    Note
    Visually inspect the connection to ensure the wires are secure.
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    Note
    Do a light pull test on ALL wire connections to ensure they are properly secured and will not come loose over time. Do not pull hard, this should simulate a light load caused by moving of equipment or future service work.
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    Note
    These connectors are one time use only. If the connector must be removed use a new connector to redo the connection. Re-use of a connector will compromise the waterproof seal.
  11. Repeat the previous step to join the rest of the wires, once again matching them up in pairs by color. In total there should be 4 connections made.
    • Red-Red
    • Black-Black
    • Purple-Purple
    • Yellow -Yellow
  12. Tuck the connectors into the case so they are out of the way and will not interfere with the fan when operating.
  13. Tighten down the four T20 fasteners to 1.5 Nm to secure the fan.
  14. Re-install the door to the PVI by aligning the hinge pins and sliding them left into place.
  15. Attach the ground wire to the lug on the door panel and tighten down the nut to secure it.
  16. Close the PVI cover and ensure the latch engages.
  17. Re-energize the system by removing any locks, closing all breakers, and turning the Powerwall switch to the on position.
  18. Follow these steps to test fan operation using the Tesla One app:
    1. Log in to the Tesla One setup app and select Stop System.
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      Note
      Make sure that the Tesla One app is updated to the latest version and device version is 25.2.1 or higher.
    2. Select System and select the Powerwall+ being serviced from the list of Devices.
    3. Select Fan Self Test and press Start to begin test.
    4. When the test is complete, if the result is Pass, select Done to close this screen and proceed to step 19.
    5. If the test result is Fail, Perform Lockout/Tagout, select Troubleshoot Wiring to check for wiring issues and press Start to re-run the fan test.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      Warning
      Wear Safety glasses (ANSI Z87 rated) and cut-resistant gloves (ANSI Cut Level 3) to avoid injury.
  19. Select Start System and verify that the system is back online and operating normally.
  20. Re-energize the system by removing any locks, closing all breakers, and turning the Powerwall switch to the on position.