Tesla Powerwall 2 User manual

Powerwall 2 Stack Kit Installation Manual

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www.tesla.com/support/powerwall.
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completing the commissioning process and sending system information to Tesla.
Warning: Read this entire document before installing or using Powerwall. Failure to
do so or to follow any of the instructions or warnings in this document can result in
electrical shock, serious injury, or death, or can damage Powerwall, potentially
rendering it inoperable.
PRODUCT SPECIFICATIONS
All specifications and descriptions contained in this document are verified to be
accurate at the time of printing. However, because continuous improvement is a goal
at Tesla, we reserve the right to make product modifications at any time.
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Depending on product version and market region, details may appear slightly
different.
ERRORS OR OMISSIONS
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ELECTRONIC DEVICE: DO NOT THROW AWAY
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requirements.
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strictly prohibited.

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TABLE OF CONTENTS
Powerwall Stack Kit Contents ...................................................................................................................... 2
Required Tools ................................................................................................................................................... 2
Site Requirements............................................................................................................................................. 3
Installation Instructions...................................................................................................................................4
Step 1. Prepare for Installation ...........................................................................................................................................................4
Step 2: Choose a Wiring Option .......................................................................................................................................................6
Step 3: Prepare for Concealed Wiring...........................................................................................................................................6
Step 4. Join the Powerwall Units.................................................................................................................................................... 10
Step 5. Wire the Powerwall Units....................................................................................................................................................17
Step 6. Close the Wiring Compartments and Replace the Covers...............................................................................19
Step 7. Turn On and Commission the System ........................................................................................................................22
Revision Log........................................................................................................................23

2 Powerwall Stack Kit Installation Manual
Powerwall Stack Kit Contents
•(2) Side clips
•(1) Top cover
•(1) Conduit nipple
•(2) Conduit insulation bushings
•(2) Conduit sealing O-rings
•(1) Bridge piece
•(1) 5-conductor communication cable
•(1) Wiring interface cover
•(4) Magnetic camshaft caps
•(1) 6 mm Allen wrench
•(1) Drill guide (two pieces)
Required Tools
•Personal protective equipment (safety glasses, gloves, protective footwear)
•Drill and 6 mm (1/4-inch) drill bit (for drilling pilot hole in Powerwall chassis)
•35 mm (1-3/8 inch) hole saw (for drilling conduit hole in Powerwall chassis)
•Small metal file (for removing burrs from Powerwall chassis sheet metal)
•Rubber mallet or small hammer and wood block (for seating side clips in Powerwall)
•Wire strippers/cutters for 1.5 to 8 mm2(24 to 8 AWG) wires
•Small grease applicator (wooden craft stick or cotton swab)
•Water-resistant heavy-duty grease (Dow Corning Molykote BR-2 Plus High
Performance Grease or equivalent, for preventing corrosion on side clips)
•Installation tools (level, tape measure, pencil, flashlight)

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Site Requirements
Stacked multi-Powerwall systems must be floor-mounted and must be anchored to an
adjacent wall. The wall must be capable of supporting the lateral load of the Powerwall stack.
A maximum number of 3 floor-mounted Powerwall units may be joined together with two
Powerwall Stack Kits. For systems with more than 3 Powerwalls, separate groups of 3 units
should be assembled, with each group of 3 attached to a wall.
For complete Powerwall Mechanical Specifications and Site Requirements, see the Powerwall 2
AC Installation Manual.
Figure 1: Dimensions for 2-unit and 3-unit Powerwall Stacks

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Installation Instructions
These instructions assume that at least one Powerwall has already been installed at the site
and that additional Powerwall units are being added. For complete instructions on installing
Powerwall, see the Powerwall 2 AC Installation Manual.
Step 1. Prepare for Installation
1. Turn off the first (previously installed) Powerwall by setting its On/Off switch to the OFF
position.
Figure 2: Switching Powerwall Off
2. Turn off the AC circuit breaker for the Powerwall.
3. Ensure that the second Powerwall is turned off by verifying that its On/Off switch is set to
the OFF position.
4. Remove both side covers from each Powerwall to be joined:
•On the first (previously installed) Powerwall, it may be necessary to remove the small
plastic insert at the bottom of the covers to help with removal.
Figure 3: Removing the Bottom Insert

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•For the right (LED) side covers, do not disconnect the switch and LED leads. Turn the
cover to one side and rest it against the Powerwall chassis.
Figure 4: Removing Powerwall Side Covers
5. Using a T20 Torx bit (provided with each Powerwall unit), remove the wiring compartment
covers from each Powerwall.
Figure 5: Removing Powerwall Wiring Compartment Covers

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Step 2: Choose a Wiring Option
In multi-Powerwall systems, communication wiring is daisy-chained between Powerwall units.
Power wiring is direct (home run) from each Powerwall to a dedicated circuit breaker in the
electrical panel. Wiring between Powerwalls can be concealed, or run externally.
Concealed Wiring
For concealed wiring, a hole is drilled from the front of the first Powerwall into its wiring
compartment and wires are run directly into it from the back port of the second Powerwall. To
use this wiring method, proceed to Step 3, “Prepare for Concealed Wiring.”
External Wiring
For external wiring, wires are run through conduit or raceway that spans the wiring
compartment ports on the side of each Powerwall. To use this wiring method, skip to Step 4,
“Join the Powerwall Units.”
Step 3: Prepare for Concealed Wiring
NOTE: If you are running wires between the wiring compartments through external conduit,
skip to Step 4, “Join the Powerwall Units.”
1. Disconnect all wiring from the wiring compartment of the first Powerwall.
2. Locate the wiring interface cover and peel back the film to expose the adhesive on the
cover gasket. With the gasket facing inward, place the cover over the interface board at the
back of the wiring compartment. The cover is intended to protect the circuit board and its
components from metal shavings while drilling into the wiring compartment.
Figure 6: Placing the Wiring Interface Cover in the Wiring Compartment

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3. Attach the included drill guide to the front of the first Powerwall by bracing the inside half
of the guide against the bottom of its wiring compartment.
Figure 7: Attaching the Inside Half of the Drill Guide
4. Clip the outside half of the drill guide to the inside half so that the guide engages the hem of
the Powerwall enclosure.
Figure 8: Attaching the Outside Half of the Drill Guide

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5. While holding the drill guide to make sure it conforms to the edge of the Powerwall chassis,
drill a 6 mm (1/4-inch) pilot hole using the small hole in the drill guide.
Figure 9: Drilling the Pilot Hole
6. Remove the drill guide.
7. Drill the full-size 35 mm (1-3/8 in) hole with a hole saw, using the pilot hole as a guide.
Figure 10: Drilling the Conduit Hole

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8. File the edges of the hole to remove any burrs.
9. Clear the wiring compartment of all metal shavings and debris.
10. Remove the protective cover from the wiring compartment.
11. If the first Powerwall still has its protective film, remove the film.
12. Peel back the protective film from the feet of the second Powerwall before moving it into
place.
13. Remove the plug from the back cable entry port of the second Powerwall and place it in
the side cable entry port of the same Powerwall.
Figure 11: Moving the Back Cable Entry Plug to the Side Cable Entry Port

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Step 4. Join the Powerwall Units
1. Orient the second Powerwall about 2 cm (1 in) in front of the first, with its back cable entry
port facing the hole you drilled in the front of the first Powerwall.
2. (Concealed wiring installations only) Do the following to bridge the gap between the
Powerwall wiring compartments:
•Locate the bridge piece, conduit nipple, two O-rings, and two insulation bushings.
Figure 12: Powerwall Bridge Assembly (Exploded View)
•Assemble the conduit nipple, bridge piece and O-rings. Center the bridge and O-rings
on the nipple.
NOTE: Orient the O-rings so that the sides with greater surface area (marked “Box Side”)
point to the outside, toward the Powerwall chassis.
Figure 13: Assembling the Conduit Nipple, Bridge and O-rings

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•Install the assembly between the two Powerwalls so it spans the two wiring
compartments.
Figure 14: Installing the Conduit Nipple, Bridge, and O-rings between the Powerwalls
•Thread an insulation bushing onto each end of the conduit nipple, but do not fully
tighten the bushings.
Figure 15: Placing Insulation Bushings on the Conduit Nipple

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3. (All installations) Locate a side clip, making sure the flange (with magnet) is positioned at
the top and that the cams are rotated vertically in relation to the clip.
Figure 16: Side Clip with Flange at Top and Cams Rotated Vertically
4. Slide the side clip into the gap between the two Powerwalls so that its flanges engage the
side hem of each enclosure.
Figure 17: Installing a Side Clip

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NOTE: The Powerwall enclosure hems have cutouts that mate with tabs in the clip.
Figure 18: Side Clip Tab Mated to Powerwall Enclosure Hem
5. Press the clip until it is flush with the sides of the Powerwalls.
6. Using the provided 6 mm Allen hex wrench, do the following:
•Turn the top cam 90 degrees clockwise until it clicks into place and stops rotating.
Figure 19: Turning the Top Cam

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•Turn the bottom cam toward the wall (toward the first Powerwall) so that the cam
indicator notch on the hex camshaft head points toward the wall, until the cam clicks
into place.
Figure 20: Cam Indicator Notch on Bottom Camshaft
NOTE: The top cam is symmetrical and can be rotated in either direction to secure the side
clip. The bottom cam must be rotated toward the first Powerwall so that its stepped side
(indicated by the notch on the hex camshaft head) engages the housing of one of the
Powerwalls.
7. Repeat steps 3-6 to install a side clip on the other side of the Powerwalls.
NOTE: If necessary, use a small rubber mallet or a hammer and wood block to gently tap the
side clips so that they are fully seated in the hem of the Powerwall.

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8. Position the top cover across the gap between the Powerwalls so that its flanges engage
the tops of each side clip. The cover is held in place by the magnets on the tops of the side
clips.
Figure 21: Installing the Top Cover
9. (Concealed wiring installations only) Tighten the insulation bushing on each side of the
conduit nipple to secure the bridge between the two Powerwall wiring compartments.

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10. Use the provided shims to ensure that the Powerwalls are level.
Figure 22: Leveling Powerwall with a Shim
NOTE: When joined, the units should be level within +/– 2 degrees side-to-side and within +/–
5 degrees front-to-back.

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Step 5. Wire the Powerwall Units
1. Connect the communication ports of the two Powerwalls by doing the following:
•Run the provided 5-conductor communication harness between the Powerwall wiring
compartments. The end with the shield/drain wire should be in the second Powerwall.
NOTE: The orange conductor is unused in Powerwall 2 AC installations.
•Attach the provided Phoenix connector to one end of the harness, and attach the extra
Phoenix connector that came with the Powerwall to the other end of the harness,
according to the following table and diagram.
Figure 23: Communication Connector Wiring
Communication Connector Wiring
Terminal
Connector Terminal Name
Recommended Wire Color
Wire Gauge
1
12V + (Logic +)
Brown
0.2–1.5 mm2(24–16 AWG)
2
GND (Logic –)
White
0.2–1.5 mm
2
(24–16 AWG)
3
CAN HI
Blue
0.2–1.5 mm2(24–16 AWG)
4
CAN LO
Yellow
0.2–1.5 mm2(24–16 AWG)
Cable Shield/Drain Wire
(Terminate at second Powerwall chassis ground lug)

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•Connect the communication OUT connector of the first Powerwall to the
communication IN connector of the second Powerwall.
•Insert the shield/drain wire in the second Powerwall chassis ground lug (Fig 24). The
ground lug is identified with the following symbol: . Tighten the screw in the ground
lug to 4.5 Nm (40 lb-in).
Figure 24: Connecting Powerwall Communication Ports
•In the last Powerwall in the communication chain, plug the 4-pin Phoenix connector
with the terminating 120-Ohm resistor into the top 4-pin socket (labeled “OUT”).
Figure 25: Connector with Terminating Resistor
Figure 26: Powerwall Communication Termination