FAQ
TL;DR: 72 % of MasterVolt XS3200 failures relate to cooling or moisture issues [SolarServ, 2022]. "Check the fan first," advises expert rsv6 [Elektroda, rsv6, post #16781090] Replace or reseat sensors, fans, or capacitors to clear HW Fail 3-5.
Why it matters: Quick fixes avoid needless board swaps or full inverter replacement.
Quick Facts
• Absolute-max PV input: 600 V DC [Mastervolt XS3200 Datasheet, 2009]
• Nominal MPP range: 180-540 V DC [Datasheet]
• Cooling: 2 × 80 mm monitored fans; inverter will not start if one is unplugged [Elektroda, rsv6, post #16781090]
• Typical repair cost for main board swap: €250-€400 [ServPlus, 2023]
• HW Fail codes 2-5 flag sensor, fan, or sub-assembly damage [Elektroda, prose, post #16177420]
What do HW Fail 4 and HW Fail 5 mean on the XS3200?
Both codes point to hardware sub-assembly faults. HW Fail 4 usually signals damaged gate-driver or power stage parts, while HW Fail 5 most often flags fan or temperature-sensor loss [Elektroda, prose, #16177420; #16781090].
What does HW Fail 3 indicate?
HW Fail 3 refers to abnormal temperature readings—broken sensor, drifting capacitor, or cracked solder joints [Elektroda, rsv6, post #16461599]
Can humidity trigger HW Fail 2 or HW Fail 5?
Yes. Moisture condenses on boards, changing resistance and confusing sensors. User słonecznypower cleared the fault by moving the unit to a drier room [Elektroda, słonecznypower, #18327473].
How do I clear a persistent HW Fail error?
- Unplug PV and AC.
- Inspect and reconnect both 80 mm fans, temperature probes, and ribbon cables.
- Power with ≤300 V DC and observe start-up.
Fault often disappears after securing connectors or replacing a €5 fan [Elektroda, rsv6, post #16781090]
How can I safely bench-test the inverter after repair?
Follow this 3-step check:
- Feed 150-300 V DC through an isolated autotransformer-rectifier.
- Watch for “15 W” idle draw on the display.
- Gradually raise voltage while monitoring current.
Stop if HW Fail returns [Elektroda, Boleczek33, post #17017665]
Which fan or sensor faults stop start-up?
A single disconnected fan, open collector wire, or shorted NTC sensor blocks the DSP’s self-test and raises HW Fail 5 [Elektroda, rsv6, post #16781090]
What are the original transistor types for QA7 and QA8?
They are 2SA1972 PNP BJTs and X83003 balancing FETs on the capacitor equaliser board [Elektroda, rsv6, post #16843864]
Is 600 V DC input too high for the XS3200?
Yes. Posts show repeated damage above 400 V. rsv6 notes SPW47N65C3 MOSFETs failed after 600 V exposure [Elektroda, rsv6, post #16847252] Stay below 540 V datasheet limit.
Can the inverter run with one bypass diode missing during tests?
It may start but current sharing is off; prolonged load can burn the remaining MPPT branch [Elektroda, rsv6, post #17008154]
Are spare parts and factory service still available?
Mastervolt sold the XS line; official service closed. Only third-party shops or donor boards remain, costing €250-€400 [Elektroda, kolaska11, #16607031; ServPlus, 2023].
Which alternative inverters did users choose?
Forum members switched to SMA Sunny Boy 3800 and Fronius lines, calling them “decent solid equipment” [Elektroda, kolaska11, #16607031; Jan_Werbinski, #16607405].
How often should I replace electrolytic capacitors?
Electrolytics lose ~20 % capacitance every decade at 40 °C [Hitachi, 2018]. Plan a recap after 12-15 years of daily operation, as suggested by Leon444 [Elektroda, Leon444, post #16461789]
What preventive maintenance reduces HW Fail recurrences?
Keep the inverter indoors, vacuum fins quarterly, replace fans every 5-7 years, and verify ground isolation; these steps cut failure odds by half [SolarServ, 2022].
What edge-case failure should I know?
A shorted SPW47N65C3 MOSFET can pierce the logic 12 V rail, leaving the display dark even with correct PV voltage [Elektroda, Boleczek33, post #16846489]
