2025-09-20

Single Powerwall+ to Powerwall 3 Upgrade

Prerequisites

Before visiting the site, ensure that 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 IconA warning icon, calling your attention to a possibly risky situation
Warning
This procedure is to be performed on a de-energized Powerwall.

Hazards

Figure 1. Shock
Figure 2. Arc Flash
Figure 3. Cut Hazard

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

  1. Complete the Powerwall+ Lockout/Tagout procedure to de-energize the system.
  2. Follow the Powerwall+ Solar Assembly Removal procedure to remove the PVI portion of the system from the wall.
  3. Follow the Removing Powerwall 2 procedure procedure to remove the Powerwall portion of the system from the wall.
  4. 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.

  5. Patch the holes created from the mounting bracket hardware using a method suitable for the wall surface.
  6. Remove the conduit fittings and determine the changes needed in the conduit run to accommodate the new Powerwall.

    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.

Install

  1. Follow the instructions in Powerwall 3 Installation Manual with Backup Gateway 2 to install the new Powerwall 3.
    1. When mounting the Powerwall 3, note that the bracket differs in both size and position compared to Powerwall+. 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 existing wires and breakers can be reused, as the Powerwall is limited to 32 A, and a 50 A breaker - commonly used in Powerwall+ installs - will provide sufficient overcurrent protection.
      Informational PurposesAn informational icon, calling your attention
      Note
      Verify that the AC wire used for the Powerwall+ install is at least 10 GA, and the AC breaker is either 40 A or 50 A.
  2. If a Rapid Shutdown Device (RSD) is connected to the existing Gateway 2, it must be connected 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.

  3. Once all conductors are installed, follow these steps to commission the new unit.
    Informational PurposesAn informational icon, calling your attention
    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.
  4. Turn on the Powerwall 3 switch and connect to it using the Device Setup interface in Tesla One app.
    Informational PurposesAn informational icon, calling your attention
    Note
    After turning on the unit, allow 2 - 3 minutes for the Wi-Fi signal to begin broadcasting.
  5. 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.
  6. On the Software tab, check for software updates and download any available updates.
  7. 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.

    Refer to the Check Connected Devices page for more information.

  8. Set the Powerwall's maximum power/current output to 32 A (7.7 kW) using instructions in the Configure Powerwall 3 Maximum Power / Current Output section.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    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.
  9. Document the configured limit on the product label on the left side of the Powerwall unit. Use a paint pen to mark the box to show the current has been limited to 32 A.
  10. 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.
    Informational PurposesAn informational icon, calling your attention
    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.
    Informational PurposesAn informational icon, calling your attention
    Note
    If Meter Y is used in the Gateway, it does not need to be replaced.
  11. 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.

  12. Complete the instructions on the Registration tab and register the system to the customer using the same account that was previously used to set up the site.
  13. Start the system.
  14. Before leaving the site, inform the homeowner that their unit has been replaced with a Powerwall 3 and explain the differences between their old system and the new one.

    Ask the customer to check their Tesla app, as the newly installed Powerwall may have created a separate site. If so, advise them to contact Tesla to merge the sites and preserve their existing data.

    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.