Wall Mount an Expansion Unit

Determine whether Expansion units will be connected to the left or right side of Powerwall 3, or to both sides. The maximum combined length of Expansion harnesses plugged into the left OR right port is 12 ft.

The following table provides harness combinations that, when added together, are less than or equal to 12 ft (applicable to both left and right side):


Harness 1	Harness 2	Harness 3	Total Length
12 ft (Green tag)	-	-	12 ft
9 ft (Yellow tag)	1 ft	1 ft	11 ft
7 ft (White tag)	1 ft	1 ft	9 ft
5 ft (Blue tag)	5 ft (Blue tag)	-	10 ft
5 ft (Blue tag)	1 ft	1 ft	7 ft
1 ft	1 ft	1 ft	3 ft

Note

See Expansion Harness to Use Depending on Distance Between Units for the Tesla part number associated with each harness length listed above.

If Expansion harnesses are only connected on the left OR right side of Powerwall 3, ensure the total combined length of all harnesses is less than or equal to 12 ft
If Expansion harnesses are connected on the left AND right side of Powerwall 3, ensure the total combined length of all harnesses is less than or equal to 12 ft on each side
Note
The Expansion harnesses plugged in to the left and right ports on Powerwall 3 can be different lengths (e.g. a 12 ft and a 9 ft harness).

Determine which Expansion Harness length will be used based on the planned distance between the units:

Measure the distance between the units where they will be installed (A in the figure below).
To calculate the Maximum Distance Between Units (this value represents the shortest possible Expansion Harness that can be used), add 254 mm (10 in) to the distance measured in (A). 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.

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.

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*	Expansion Harness Part Number	Color ID	(A) Maximum Distance Between Units (Harness Length - 254 mm)
1 ft Harness	(Tesla P/N 1875157-05-x)	N/A	0.25 m (10 in)
5 ft Harness	(Tesla P/N 1875157-20-x)	Blue	1.75 m (5 ft 9 in)
7 ft Harness	(Tesla P/N 1875157-25-x)	White	2.25 m (7 ft 4 in)
9 ft Harness	(Tesla P/N 1875157-30-x)	Yellow	2.75 m (9 ft)
12 ft Harness	(Tesla P/N 1875157-40-x)	Green	3.75 m (12 ft 3 in)

* Harness length in feet is approximate.

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

Do not modify the Expansion Harness in any way. Doing so would result in product damage that could void the product warranty.

Safely shut the system down:

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.
Open the Powerwall 3 AC circuit breaker.
Wait 30 seconds before proceeding with any work.

Warning
Risk of electric shock from stored energy. Wait 30 seconds after disconnecting all sources of supply before proceeding.

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):

Using a drill and level, mount the Expansion unit bracket to the selected wall. See Anchoring Details for Ground- or Wall-mounting Powerwall 3 with Wall Bracket on Existing Approved Foundation for additional details on the type and number of fasteners to use.

Figure 1. Bracket Measurements Relative to Expansion Unit and Floor

Note

These bracket measurements are the same for both Expansion and Powerwall 3 units.

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.

Move the dolly toward the wall, positioning the Expansion unit so that the mounting cleats are just above the flanges on the bracket.

Lower the Expansion unit until both the upper and lower sets of cleats engage the flanges on the bracket.

CAUTION

Confirm the unit is fully seated on all four cleats before proceeding.

Clean the front edge of the Expansion unit enclosure with a microfiber cloth to remove any debris that might interfere with the seal.

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.

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.

Carefully install the glass front cover:

Align the lower mounting tabs with the two alignment shelves in the enclosure (A).
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.

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.
Install and tighten the top (2) T20 fasteners in the fastener slots.
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.
Install the remaining (4) T20 fasteners in the side fastener slots.
Tighten all (6) fasteners to approximately 25 in-lb (2.8 Nm) or hand-tight.

CAUTION
Do not use an impact driver to torque the fasteners.

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.

Connect the Expansion unit to the Powerwall 3 (or to another Expansion unit):

Using a Torx T40 bit, loosen the fastener holding the Expansion port cover.
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.
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.

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.

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.

Note
If replacing the Expansion port cover, torque the port cover screw to 100 in-lb (11 Nm).
Visually inspect the Expansion port and confirm there is no debris in the port.
Remove the protective packaging from the end of the Expansion Harness being plugged in.
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
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.
Torque the T40 harness screw on the connector to 100 in-lb (11 Nm).

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):
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

Secure the Expansion Harness cable using Bridgeport US-6171 straps, noting the following requirements for strap placement:


Strap Placement	Maximum Distance	Measurement Color in Diagram
Each end of Expansion Harness	483 mm (19 in) from connector	Red
Horizontal Run	610 mm (24 in) between straps	Purple
Vertical Run	915 mm (36 in) between straps	Green
Inside or Outside Corner	305 mm (12 in) from corner (recommended but not required)	Orange

Figure 2. Maximum Distance Between Expansion Harness Cable Straps

Note

Keep the Expansion Harness cable flat and as close to the wall as possible when routing it.

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.

Torque the T40 harness screw on the connector to 100 in-lb (11 Nm).