2025-08-27

Powerwall+ Solar Assembly Replacement

Correction Code: 1000001352

Safety and PPE

  • Safety glasses (ANSI Z87.1 or EN 166)
  • Class 0 electrical insulating rubber gloves with leather protectors
  • Lockout/tagout kit (locks, tags, hasps, lock box)

General Equipment

  • PH1 Phillips screwdriver bit
  • Channel Locks
  • Small flathead screwdriver
  • Electrical Tape
  • T30 Torx Bit
  • Step Drill Bit, up to 28mm diameter

Remove

  1. If the homeowner is home at the time of service, knock on the door and greet them. Let them know what service actions will be taking place and take time to answer any of their questions. Ask for any necessary gate/garage/lock codes to be able to access the equipment that is being serviced.

    If the homeowner is not at home at the time of service, call the homeowner to let them know you are there to perform service. If they are uncomfortable with service being performed while they are away, reach out to your manager to have the visit rescheduled.

  2. Survey the area and ensure there is enough working room to perform the service necessary. Ask the homeowner to move things if there is not enough room (i.e. car in garage).
  3. Put on required PPE: Safety Glasses (ANSI Z87 rated) and cut resistant gloves (ANSI cut level A2).
  4. Set exclusion zone with CAUTION tape and use delineators as needed to support the tape.
  5. Perform Powerwall+ Lockout/Tagout.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Prior to proceeding, complete all steps listed in the procedure, including de-energizing upstream AC power, turning off the Powerwall enable switch, applying lock and tag, and performing live-dead-live check for dead with the specified PPE to prevent serious injury or death.
  6. Remove the cover from the LB conduit body housings to access the wires inside.
  7. Take several photos of the wiring inside the terminals of the solar assembly. If wires are not already labeled, label the wires so they can be replaced later. Ensure your photo captures the placement of:
    • the PV DC wiring,
    • the PW Load wiring,
    • the AC load wiring,
    • the Comm wiring,
    • and the E-stop wiring.

  8. Remove the PV wires from the terminal by depressing the tabs with a small flathead screwdriver and pulling the wire out. Wrap the end of the wires in electric tape before moving on to the next wire.

    Tape both + and - wires.

  9. Remove the PV ground wire from the ground terminal by releasing the clamp with a small flathead screwdriver.

    Tape the end of this wire with electrical tape after removing it.

  10. From the open LB conduit housing, pull the PV wires out of the Solar Inverter housing. Move the wires out of the way of the PVI.
  11. If the system is equipped with an emergency stop switch, remove the two wires from the terminals by depressing the tabs with a small screwdriver and pulling the wires out. Place electrical tape on the end of the wires to protect them.

    The E-stop may also have a ground wire that must be removed. It is likely tied into another ground cable and inserted into the terminal. If that is the case, remove that wire from the terminal to free the E-stop wire.

  12. If the E-stop has a dedicated grommet, remove the grommet from the housing using a pair of channel locks.
  13. Remove the 4 comm wires from the terminals by pressing in on the tabs with a small flathead screwdriver and pulling the wires out. Place electrical tape over the ends of these wires to protect them and anything they may contact.
  14. Remove the AC Load wires by depressing the tabs with a small flathead screwdriver and pulling the wires out. Tape the end of the wires with electrical tape.
  15. Pull the AC and comm wires through the LB conduit body to remove them from the Solar Inverter casing.
  16. Remove the conduit from the Solar Inverter casing by unscrewing the nut on the inside of the enclosure.
  17. Unplug the two Powerwall harnesses from the terminals to free the Solar Inverter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Depress the clip on the top of the connector and pull out to remove the harness.
  18. Remove the Powerwall harnesses from the inverter by removing the bushing at the bottom of the assembly. This bushing can be removed by squeezing the plastic tabs and pulling out. A screwdriver may be needed to press against the tabs.
  19. Using a 6 in T30 Torx Bit, remove the mounting screw holding the Solar Assembly in place with a torx driver.
  20. The Solar Inverter should now be free and can be removed. Lift up the assembly to unmount it from the bracket and remove it.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Solar Assembly weighs 22 kg (49 lb); a 2 person lift is recommended to reduce the risk of injury when lifting or moving the Solar inverter.

Install

  1. Prepare the new Solar Assembly for installation: Remove the new Solar assembly from the box and note the knockouts used on the removed assembly. Use a screwdriver and hammer to remove the required knockouts for the conduit to fit in.

    To open a knockout, position the tip of a regular, blade-tip screwdriver near the inside edge of the knockout. Hammer the screwdriver to punch out the metal knockout; one well-placed strike is generally sufficient to dislodge the knockout.

    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Only remove knockouts that will have conduit inserted in them. Removing knockouts that will not be filled with conduit will cause water ingress into the inverter.
  2. The knockout holes on a PW+ Solar Assembly are 3/4" in diameter. If the conduits used are 1", the knockouts will need to be widened. Use a stepper drill bit to widen the holes to 1". Deburr the edge with a deburring tool.

    Clean up any metal shavings from inside the inverter as these could cause a short.

  3. Lift the new Solar Inverter Assembly up to mount it on the bracket. Align the assembly with the Powerwall and seat it on the cleat of the mounting bracket.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Solar Assembly weighs 22 kg (49 lb); a 2 person lift is recommended to reduce the risk of injury when lifting or moving the Solar inverter.
  4. Route the Powerwall harnesses into the bottom hole of the Solar Assembly. Press the bushing into place until the clips engage.
  5. Replace the mounting screw and tighten with a torx driver.
  6. Attach the conduit and E-stop grommet to the Solar Assembly using the knockouts.
  7. The removed conduit and fittings should be adequate from install, but inspect them to ensure no damage has occurred and that the connectors are rated appropriately. If there are any signs of damage, or if the conduit hub does not meet the recommended requirements, they should be replaced to prevent water ingress into the Powerwall unit. Attach the conduit into the Powerwall housing and attach it with the necessary hardware, ensuring a leak proof seal.

    Conduit Recommendations: Minimum NEMA 4 (IPX5) or higher conduit hubs

    Tesla recommends one of the following options which meet this requirement:

    • ¾ inch PVC-MC cable connector
    • 1 inch PVC-MC cable connector
    • ¾ inch Bridgeport 252-RTI2 connector
    • 1 inch Bridgeport 252-RTI2 connector
    • ¾ inch Rigid metal conduit (RMC) Myers hub with RMC conduit
    • 1 inch Rigid metal conduit (RMC)
    • Myers hub with RMC conduit
    • ¾ inch RMC sealing locknut with RMC conduit
    • 1 inch RMC sealing locknut with RMC conduit
    • 1-¼ inch RMC sealing locknut with RMC conduit
  8. Feed the AC and comm wires back through the conduit and into the Solar Assembly casing.
  9. Feed the PV wires into the Solar Assembly casing through the conduit. Keep them organized nicely so they are not crossing each other.
  10. Connect the Powerwall to the Solar Assembly by inserting the two connectors into their respective slots.
  11. Insert the E-Stop wiring into the correct terminals. If a ground wire is present, attach it in the same place it was removed from.

    Check the exposed conductor length using the gauge on the inverter assembly. Correct the wire by cutting or stripping to match the gauge.

    Leave a service loop inside the housing so future service has wire to work with.

    Informational PurposesAn informational icon, calling your attention
    Note
    A preinstalled jumper may be present in the E-stop terminals. This jumper overrides the E-stop button when installed. If installing an E-stop, remove this jumper. If no E-stop is being installed, ensure this jumper is present.
  12. Insert the AC load wires into the terminals. Insert the ground wire into the ground terminal.

    Check the exposed conductor length using the gauge on the inverter assembly. Correct the wire by cutting or stripping to match the gauge.

    Leave a service loop inside the housing so future service has wire to work with.

  13. Insert the PV wires into the terminals. Ensure they are placed into the correct spots. Reference the photos taken of the removed unit to check the placement. Insert the ground wire into the ground terminal.

    Check the exposed conductor length using the gauge on the inverter assembly. Correct the wire by cutting or stripping to match the gauge.

    Leave a service loop inside the housing so future service has wire to work with.

  14. Insert the comm wires into the correct terminals. Needle nose pliers may be needed to press the wires into the holes of the terminal.

    Check the exposed conductor length using the gauge on the inverter assembly. Correct the wire by cutting or stripping to match the gauge.

    Leave a service loop inside the housing so future service has wire to work with.

  15. Install the covers back onto the LB conduit housing.
  16. Install the PVI door by aligning the hinge and sliding the cover to the left to engage the hinge pins.
  17. Remove Lockout/Tagout and restore power to the Powerwall+ be turning ON the breaker and flipping the Powerwall+ enable switch to ON.
  18. In the Tesla One app, follow the steps to commission the new Solar Inverter and integrate it into the customer's system.

    Ensure the system shows no faults and solar is successfully generating power and the Powerwall is accepting it

  19. Close the cover of the inverter and ensure it latches.
  20. Clean up any tools and debris left behind from the installation. Remove the caution tape/cones from the work area and store your supplies in the work vehicle.
  21. Make contact with the customer to inform them the work is completed. Let them know what was done and any follow ups that are necessary.