Observation 1:
An aluminum tab that secures the PCBA to the enclosure is mounted coplanar to layer 1 on the PCB (see picture). The L2 mains voltage trace on layer 2 routes directly underneath a portion of this aluminum tab. The copper on layer 2 is approximately 0.38 mm below the PCB top surface (layer 1). Therefore, the spacing between chassis ground and mains voltage is only 0.38 mm. This 0.38 mm spacing is primarily FR4, plus a thin conformal coating (type unknown).
Observation 2:
The same L2 mains voltage trace (on layer 2) comes very close to the PCB edge, which is NOT conformally coated. The aluminum tab passes directly over this edge, too (coplanar to layer 1). Therefore, there is no conformal coating where the aluminum tab intersects the board edge.
Notes:
As a legal precaution, I'm only publicly reporting my factual observations. My initial goal in creating this thread was to engage Tesla's engineering team for clarifications. That is still my goal, although so far I'm disappointed in both Tesla's and Intertek's lacking communication. In particular:
-Intertek's confidentiality agreement with Tesla forbids them from disclosing any findings resulting from my complaint.
-Tesla hasn't followed up to discuss my findings. Whether or not my conclusions are correct (I think they are), Tesla's failure to respond is troubling.
-In contrast to their software bug bounty program, Tesla lacks a method to report hardware defects. To whit, Tesla Motors actually recommends reporting potential hardware defects to NHTSA, rather than directly to them. In other words, Tesla is passing the buck to a regulatory agency.
If anyone else wants to dive into the various codes and elaborate further, I recommend starting with UL 1741, which is listed on the Powerwall label. Particularly, take a look at the exceptions in sections 24.1 and also 25.4.
Overall, I'm feeling pretty apathetic about continuing to invest time and effort into this issue. I'll stick around for questions, but overall I'm just going to wash my hands and be done with this. It doesn't affect me personally and I feel like I put in enough (free) effort to clear my moral conscience. If Tesla and/or Intertek ever responds to my complaint, I'll keep going, but otherwise it's just not worth the effort. I've got too much other (paid) work to do than to keep slogging down this rabbit hole.
Stay safe out there.