Wall Mount an Expansion Unit

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Note
Follow all Powerwall 3 guidance for choosing a location to install Expansion units, clearance requirements, and instructions to remove the units from packaging and transport them with the Powerwall dolly.
  1. Determine whether Expansion units will be connected on only one side of Powerwall 3, or on both sides:
    • When Expansion units will be connected on only one side of Powerwall 3, the maximum combined harness length is 4 m (13 ft). The following table provides all allowable harness combinations for this configuration:
      Harness 1Harness 2Harness 3
      4 m (13 ft)1875157-40-x--
      2 m (6.5 ft)1875157-20-x2 m (6.5 ft)1875157-20-x-
      2 m (6.5 ft)1875157-20-x0.5 m (20 in)1875157-05-x0.5 m (20 in)1875157-05-x
      0.5 m (20 in)1875157-05-x0.5 m (20 in)1875157-05-x0.5 m (20 in)1875157-05-x
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      Using any other harness combination will result in excessive wire length, impacting product performance.
    • When Expansion units are connected on both sides of Powerwall 3, there is no limit on the maximum combined harness length. However, there is effectively a maximum combined harness length of 8 m (26 ft)* on each side of Powerwall 3 because:
      • Only (2) Expansion units can be connected on one side of Powerwall 3 (with (1) Expansion connected on the other side for a maximum total of (3) Expansion units)
      • The longest available harness is 4 m (13 ft) long. While any combination of harnesses can be used on either side of Powerwall 3 in this configuration, using the longest available harness results in a maximum combined length of 8 m (26 ft)

      *Only (3) Expansion units can be connected to the Leader Powerwall 3. With Expansion units connected to both sides of Powerwall 3, there will always be one side with only (1) Expansion unit connected; by default, the maximum harness length on this side is 4 m (13 ft), which is the longest available harness length.

      Informational PurposesAn informational icon, calling your attention
      Note
      The Expansion harnesses plugged in to the left and right ports on Powerwall 3 can be different harness models (e.g. the 4 m (13 ft) harness on one side and the 2 m (6.5 ft) harness on the other).
  2. Determine which Expansion Harness length will be used based on the planned distance between the units:
    1. Measure the distance between the units where they will be installed (A in the figure below).
    2. Calculate the Maximum Distance Between Units: Distance between units (measured in Step 2a) + 254 mm (10 in)
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      Note
      This accounts for the required minimum 127 mm (5 in) from the connector to the back of the bend on each end of the Expansion Harness.
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      Note
      As displayed in this diagram, the Expansion Harness can be plugged into the Expansion port (on Expansion or Powerwall 3) on either side of the unit.
    3. Use the table below to determine which Expansion Harness to use (must be equal to or longer than the Maximum Distance Between Units calculated above)
      Table 1. Expansion Harness to Use Depending on Distance Between Units

      Expansion
      Harness Part Number

      (A)
      Maximum Distance Between Units, Accounting for Bend Radius

      Tesla P/N 1875157-05-x0.25 m (10 in)
      Tesla P/N 1875157-20-x1.75 m (5 ft 9 in)
      Tesla P/N 1875157-40-x3.75 m (12 ft 3 in)
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      Note
      The Expansion Harness connector can only be oriented with the cable at the bottom of the connector. Do not attempt to plug the connector in upside down.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      Warning
      Do not modify the Expansion Harness in any way. Doing so would result in product damage that could void the product warranty.
  3. Safely shut the system down:
    1. If a System Shutdown Switch is present, push it to initiate Rapid Shutdown. If there is no System Shutdown Switch, turn the Enable switch on the Powerwall 3 to OFF.
    2. Open the Powerwall 3 AC circuit breaker.
    3. Wait 30 seconds before proceeding with any work.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      Warning
      Risk of electric shock from stored energy. Wait 30 seconds after disconnecting all sources of supply before proceeding.
  4. To lift and transport the Expansion unit, follow all instructions in STEP 2: Remove Powerwall 3 from Packaging and Transport Using the Powerwall Dolly to use the Powerwall dolly, noting where the two lift handles are connected on the Expansion (X):
  5. Using a drill and level, mount the Expansion unit bracket to the selected wall. See Powerwall 3 Wall Bracket Anchoring Details for Wall-mounting or Ground-mounting on Approved Foundation for additional details on the type and number of fasteners to use.
    Figure 1. Bracket Measurements Relative to Expansion Unit and Floor
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    Note
    These bracket measurements are the same for both Expansion and Powerwall 3 units.
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    Warning
    Only install fasteners in the (4) slots on the horizontal bracket segments. Do not install fasteners on the vertical (center) segment, as these are not structural mounting holes.
  6. Move the dolly toward the wall, positioning the Expansion unit so that the mounting cleats are just above the flanges on the bracket.
  7. Lower the Expansion unit until both the upper and lower sets of cleats engage the flanges on the bracket.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Confirm the unit is fully seated on all four cleats before proceeding.
  8. Clean the front edge of the Expansion unit enclosure with a microfiber cloth to remove any debris that might interfere with the seal.
  9. Carefully remove the glass front cover from its packaging and, using a microfiber cloth, clean the sealing gasket around the edge of the front cover to remove any debris that might interfere with the seal.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Take extreme care when handling the sealing gasket. Damage to or contamination of the gasket or its mating surface could compromise Powerwall's ingress protection, resulting in product damage.
  10. Carefully install the glass front cover:
    1. Align the lower mounting tabs with the two alignment shelves in the enclosure (A).
    2. Rotate the front cover toward the enclosure to engage the top mounting tabs with the enclosure (B). Maintain pressure (15-20 lb force) on the front of the cover to compress the sealing gasket.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      Maintain pressure to keep the sealing gasket compressed until all fasteners are installed and tightened. If the sealing gasket is not compressed, the fasteners may thread form in the enclosure, breaking the front cover mounting tabs.
    3. Install and tighten the top (2) T20 fasteners in the fastener slots.
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      Note
      T20 fasteners (Tesla P/N 1847553-00-A) are included in the accessory bag:
      • Early revisions of the fasteners (left, below) are single use; to reuse these fasteners, remove the black gasket from the fastener
      • Later revisions of the fasteners (right, below) do not include a gasket and can be reused without any alteration
      The gasket is not required and does not impact the enclosure rating of Powerwall 3.
    4. Install the remaining (4) T20 fasteners in the side fastener slots.
    5. Tighten all (6) fasteners to approximately 25 in-lb (2.8 Nm) or hand-tight.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      Do not use an impact driver to torque the fasteners.
  11. Before removing the Expansion Harness protective packaging, mock up the cable routing by holding the Expansion Harness against the wall, confirming each connector reaches its Expansion port. If either or both connectors do not reach the Expansion port, use a longer Expansion Harness.
  12. Connect the Expansion unit to the Powerwall 3 (or to another Expansion unit):
    1. Using a Torx T40 bit, loosen the fastener holding the Expansion port cover.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      Warning
      STOP. Before opening Expansion port covers:
      • Do not open the Expansion Port cover if Expansion / Powerwall 3 is directly exposed to any of the following conditions:
        • Rain
        • Snow
        • High winds (>30 mph)
      • Do not leave the Expansion Port open for extended periods or in high debris/dust conditions
      Doing so may allow water and/or debris to contact the sensitive internal components of Powerwall 3 / Expansion. This may lead to product damage and could potentially void the product warranty.
    2. Insert a cabinet tip screwdriver in the small slots at the top and bottom of the port cover to pry it loose. Remove the cover.
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      Note
      When the Expansion port cover bolt is loosened, depending on site conditions such as elevation, it is normal to hear a hissing sound until the air pressure has equalized.
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      Note
      Keep the Expansion port cover in case the Expansion port needs to be covered again for any reason. Store the cover in the protective packaging from the harness to keep it clean.
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      Note
      If replacing the Expansion port cover, torque the port cover screw to 100 in-lb (11 Nm).
    3. Visually inspect the Expansion port and confirm there is no debris in the port.
    4. Remove the protective packaging from the end of the Expansion Harness being plugged in.
    5. Visually inspect the Expansion Harness connector and confirm there is no dirt or debris on the connector. If there is dirt / debris on the connector:
      • Clean the dirt / debris from the connector
      • If it is not possible to adequately clean the connector, recycle the Expansion Harness and use a new one
    6. Plug one end of the Expansion Harness into the Expansion unit. Ensure the connector is fully seated in its port; it will be possible to confirm the connector is fully seated when there is no gasket exposed.
    7. Torque the T40 harness screw on the connector to 100 in-lb (11 Nm).
  13. Plan the Expansion Harness cable routing, noting the following:
    • The minimum bend radius of the cable is 95 mm (3.75 in). Bending the cable to a lesser radius may result in damage to the Expansion Harness
    • When a long Expansion Harness must be used, route and secure the cable so that there is no slack; the following examples illustrate some of the ways cable slack can be consumed (note the Bridgeport US-6171 straps represented in black):
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      Note
      Take care to route and strap the Expansion Harness so that it forms right angles and generally looks as neat as possible. Do not leave the Expansion Harness drooping or otherwise routed sloppily.
    • Each unit (Powerwall 3 or Expansion) must only be connected to another unit via one harness. Do not connect two units using two separate harnesses
  14. Secure the Expansion Harness cable using Bridgeport US-6171 straps, noting the following requirements for strap placement:
    Strap PlacementMaximum DistanceMeasurement Color in Diagram
    Each end of Expansion Harness483 mm (19 in) from connectorRed
    Horizontal Run610 mm (24 in) between strapsPurple
    Vertical Run915 mm (36 in) between strapsGreen
    Inside or Outside Corner 305 mm (12 in) from corner (recommended but not required)Orange
    Figure 2. Maximum Distance Between Expansion Harness Cable Straps
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    Note
    Keep the Expansion Harness cable flat and as close to the wall as possible when routing it.
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    Note
    When routing around an outside corner, the Expansion Harness cable may need to be routed with an offset to ensure the cable stays flat and as close as possible to the surface of the wall.
  15. Plug the remaining Expansion Harness connector into the other Expansion or Powerwall 3. Ensure the connector is fully seated in its port; it will be possible to confirm the connector is fully seated when there is no gasket exposed.
  16. Torque the T40 harness screw on the connector to 100 in-lb (11 Nm).