2025-10-15

Multiple Powerwall 2/Powerwall+ Units to Powerwall 3 Upgrade

Overview

This procedure outlines the steps for upgrading a site with multiple Powerwall 2/Powerwall+ units to a multi-Powerwall 3 with Expansion site.

Note

The following table provides general guidance for common Powerwall upgrade procedures; always follow the site design for specific guidance on the site.


Existing Equipment	Replacement Equipment	Scope of Work	Current / Power Output Setting
2 Powerwall 2 units	1 Powerwall 3 with 1 Expansion	Remove 30 A circuit, rework circuit to a single 60 A breaker	41.7 A (10 kW)
3 Powerwall 2 units	1 Powerwall 3 with 1 Expansion	Remove a 30 A circuit, rework circuit to a single 60 A breaker	41.7 A (10 kW)
3 Powerwall 2 units	1 Powerwall 3	Reuse an existing 30 A circuit	24 A (5.8 kW)
4 Powerwall 2 units	1 Powerwall 3 with 1 Expansion	Remove 30 A circuit, rework circuit to a single 60 A breaker	41.7 A (10 kW)
4 Powerwall 2 units	1 Powerwall 3 with 1 Expansion	Remove 30 A circuit, rework circuit to a single 60 A breaker	41.7 A (10 kW)
1 Powerwall+ and 1 Powerwall 2	1 Powerwall 3	Reuse the 30 A circuit	24 A (5.8 kW)
1 Powerwall+ and 1 Powerwall 2	1 Powerwall 3	Reuse the 50 A circuit	32 A (7.6 kW)
1 Powerwall+ and 2 Powerwall 2 units	1 Powerwall 3 with 1 Expansion	Remove 30 A circuit, rework circuit to a single 60 A breaker	41.7 A (10 kW)
1 Powerwall+ and 2 Powerwall 2 units	1 Powerwall 3	Reuse the 50 A circuit	32 A (7.6 kW)
2 Powerwall+ units	2 Powerwall 3 units	Reuse both 50 A circuits	32 A (7.6 kW)

If the site has a single Powerwall 2/Powerwall+ to be swapped, refer to the appropriate procedure below:

Note

If the original site had a Backup Gateway 2 acting as the Site Controller, the Gateway will remain installed but it will function only as the Islanding Controller after the swap (at which point the Leader Powerwall 3 will act as the Site Controller). Once Powerwall 3 has been installed, it will detect the Gateway and will trigger a command to deactivate the Site Controller in the Gateway.

Prerequisites

Before visiting the site:

Confirm the original site is visible in Powerhub
- If the swap is being completed by a subcontractor company, ensure the site has been shared with that subcontractor company's Powerhub instance. See Site Sharing in the Powerhub User Manual for instructions to share a site
Ensure the updated planset is available (indicating that a site redesign was completed). The new site design should be compliant with all existing permits, or re-permitted according to the new design

Warning

This procedure is to be performed on a de-energized Powerwall.

Hazards

Safety and PPE

Safety glasses (ANSI Z87.1 or EN 166)
Cut-resistant gloves (ANSI Cut Level 3 or EN 388 Level C)
Safety rated shoes with leather upper

General Equipment

Paint pen

Remove

Complete the Powerwall 2 Lockout/Tagout or Powerwall+ Lockout/Tagout de-energize the system.
Follow the steps below to remove all the Powerwall units on the site.

CAUTION
ALL Powerwall 2 or Powerwall+ units must be replaced, as Powerwall 3 is not compatible with older generations of Powerwall. A site cannot include a mix of these.
If replacing a Powerwall+, follow the Powerwall+ Solar Assembly Removal procedure to remove the PVI portion of the system from the wall.
Follow the Removing Powerwall 2 procedure procedure to remove the standalone Powerwall 2 units and the battery portion of the Powerwall+ units.
Remove the screws securing the Powerwall mounting bracket to the wall.

Remove the mounting bracket and clean the wall surface from any sealant or dirt.
Patch the holes created from the mounting bracket hardware using a method suitable for the wall surface.
Remove the conduit fittings and determine the changes needed in the conduit run to accommodate the new Powerwall system. In most multi-unit installations, the total number of AC connections will be reduced by using DC Expansion units.

In most cases where the run is short, the conduit should be removed and new conduit should be run.

In cases where the conduit can be reused or extended, make sure that the fittings are appropriate and all the connections are compliant with local code.

Seal any knockout holes left by removed conduit using the appropriate plugs and ensure the seal is watertight.

Install

Use the guidelines below to plan the installation locations of the new units, which generally should mirror the locations of the previous Powerwall units.
1. When using DC Expansion units, be mindful of the distance restrictions. If the removed Powerwall units are spaced further apart than allowed by the Expansion harness, they should be relocated within the harness's reach.
  
  Refer to Wall Mount an Expansion Unit in the install manual for more information.
  
  Note
  Note that there is a combined maximum distance restriction.
2. If the removed Powerwall units were installed in a stacked configuration, the replacement units should also be stacked.
  
  CAUTION
  Note that in cases where multiple Powerwalls are stacked, the increased load of PW3 may exceed the threshold of the wall. Powerwall 3 itself can support up to 4 units in a stack.
1. Do not mount multiple brackets on the same studs as this might overload them. If units need to be relocated, they must not be placed above or below another unit on the same stud.
2. Before mounting any units, create a diagram of the planned setup. Each site has a unique configuration of Powerwall 3 and Expansion units and the layout should be optimized to minimize cable runs.
  - Each Powerwall must have an AC connection to a dedicated breaker in the load center.
  - For sites with more than two units, a communication wire should be run between the Powerwall units.
  - DC Expansion units only require the DC Expansion harness connected to a Powerwall unit or another Expansion unit to form a chain.
  Rearrange the units as needed to ensure the cleanest possible wire runs and avoid excessive use of conduit.
3. In a Powerwall+ setup, the solar wires that previously ran to the solar assembly must now be routed to the Powerwall 3. This should be taken into consideration when selecting a mounting location.
  
  This requirement does not apply if standalone solar inverters are used instead.
Follow the instructions in Powerwall 3 Installation Manual with Backup Gateway 2 to install the new Powerwall 3 and Expansion units.
1. When mounting the Powerwall 3 and DC Expansion brackets, note that the bracket differs in both size and position compared to Powerwall 2. Reusing the existing mounting holes will cause the Powerwall to sit in a different position on the wall. Refer to the diagram below for bracket dimensions relative to the edges of the unit.
2. The wires and breakers need to be re-run. Follow the guidance in the installation manual to run the correct gauge wire and the proper overcurrent protection.
If a Rapid Shutdown Device (RSD) is connected to the Gateway 2, it must be moved to the Powerwall 3.

Follow the instructions in STEP 8: Install System Shutdown Switch Where Required in the Powerwall 3 Installation Manual to switch the RSD from the Gateway to the Powerwall 3. The jumper should be removed from the Powerwall 3 and installed in the RSD port of the Gateway 2, from which the switch wire was removed.

Note
The RSD may need to be replaced if multiple Powerwall 3 units are being installed, as the switch requires a dedicated terminal for each Powerwall in the system.
Once all conductors are installed, follow these steps to commission the new unit.

Note
Do NOT complete the Powerwall 3 commissioning procedure outlined in the Powerwall 3 Install Manual. Instead, use the steps provided below which detail several deviations from the standard commissioning procedure.
Turn on all the Powerwall 3 switches and connect to the leader Powerwall 3 using the Device Setup interface in Tesla One app.

Note
After turning on the unit, allow 2 - 3 minutes for the Wi-Fi signal to begin broadcasting.
Navigate to the Networking tab and connect the unit to the customer's Wi-Fi, if available. Refer to Configure Internet Connection section in the Powerwall 3 Quick Guide for more information.
On the Software tab, check for software updates and download any available updates.
Navigate to the System tab and verify that the Gateway is communicating with the Powerwall 3 without any errors. If the communication is not established, inspect the CAN wiring between the units.

Verify that all installed units are present and displaying no errors. If any units are missing or showing any errors, troubleshoot the issue before proceeding.

Refer to the Check Connected Devices page for more information.
If applicable, set the Powerwall's maximum power/current output using instructions in the Configure Powerwall 3 Maximum Power / Current Output section.

This value must be set to comply with permit requirements. Refer to the site design to determine the correct values.

Warning
This step is critical. Failure to complete it can result in electrical faults in the wiring due to overcurrent. Do NOT start the system before setting this limit.
Document the configured limit on the product label on the left side of the Powerwall unit. Use a paint pen to mark the box corresponding to the limit set.
Navigate to the Metering tab to confirm the meter(s) are configured correctly. Powerwall 3 only supports Tesla Remote Meters or wired meters, so any third-party meters, such as Neurio meters, must be replaced with a Tesla Remote Meter.

Replace meters as necessary and configure them in the Metering tab using the instructions in the Configure Meters and CTs section.
Note
Replacing a meter with a Tesla Remote Meter is common at sites with AC-coupled solar or non-backup loads. Follow this guidance to correctly set up the meters: Install Tesla Remote Energy Meter and CTs.
Note
If Meter Y is used in the Gateway, it does not need to be replaced.
Navigate to the Settings tab to set the grid code and solar installation type. If the site requires additional settings, set those under the Advanced Settings option.

Refer to Configure Settings for more information.
Complete the Installer Registration as follows:
1. Select Registration > Installer Info.
2. In the Company Name field, verify that the name of the company performing the installation has automatically been filled in. If the company name is not present or is not correct, search for your company to select it.
  
  Note
  The Company Name is the field that links a partner to a site, meaning this is the field that allows a company to view the site in Powerhub.
3. In the Email field, leave the email address of the installer completing the installation. This email address is used to track Tesla Academy training completion and the Pro Score inside Tesla One.
4. If there are additional Partners that should have access to the site in Powerhub, add them as follows:
  1. Select Add Partner and search for the partner name to select it.
  2. Repeat this step if needed (up to two partner companies can be added).
Complete the Customer Registration as follows:

Note
Customer registration is the action that triggers the API call to the cloud, which transmits the new device configuration for the site. This will ensure the customer can see the updated site in their Tesla Mobile App, and the Partner(s) can see the correct device in Powerhub.
1. On the Registration page, select Customer Registration.
2. Enter the customer's email address.
  
  Note
  Ensure the correct customer email is entered; this must be the email address the customer is using in their Tesla Mobile App to monitor their existing site.
3. Select the "Suggested" site that appears. This action indicates that you are intending to register the new Powerwall 3 to the customer's existing site.
  Note
  If you do not see a suggested site, it means that either:
  The installer email address currently logged in to Tesla One is not associated with the installer instance for this site (this installer needs to have a Partner Portal account created with their email address)
  The installer instance does not have access to the original site in Powerhub (see Site Sharing)
  The customer email address is not the one that the customer is using to monitor their system in the Tesla App
4. Select Register. This will submit the registration to the cloud, completing the final step in the on-site work.
Start the system.
Before leaving the site, inform the homeowner that their unit has been replaced with a Powerwall 3, and that the device configuration will update overnight. They will see the new data and can control their new Powerwall 3 starting the following morning.

Additionally, advise the customer that some app settings might have been reset with the swap and to check their configurations if they have been changed from default values.

Confirm Site Updates in Powerhub

Once back in the office, confirm the site has been updated in Powerhub:

Confirm the new Powerwall 3 now appears in the Devices list in Powerhub
- The new Powerwall 3 will appear instantly after registration
- Note that Powerhub and the customer's Tesla App will not display data (telemetry or settings info) from the new Powerwall 3 right away. This data will appear after the overnight sync
Note that the old Powerwall 2 will still appear in the Devices list
- Powerhub will consider these devices "Deactivated" after 30 days of no communication
- Note that this will not impact the customer's app experience, telemetry, or ability to control their Powerwall 3
- Once the 30-day period has passed and the Powerwall 2 device(s) are automatically deactivated, they will no longer appear in the Devices list in Powerhub