
Your machine’s HMI suddenly goes dark. No display. No beep. No warning. Just silence—and downtime.
So now what? Should you replace the entire unit, or is it something simple like a power hiccup or backlight failure?
At Industrial Automation Co., we’ve helped thousands of customers troubleshoot these exact situations. A surprising number of "dead" HMIs turn out to be fully recoverable. Whether you’re working with a Mitsubishi GOT2000, Allen-Bradley PanelView Plus, or a Siemens Comfort Panel, this guide walks you through key steps to get your screen up and running again—or know when it’s time to repair or replace.
1. Check Power First—Always
Over 25% of the HMIs we receive in for repair turn out to have basic power issues—not internal hardware faults.
Start here before assuming the worst:
-
Verify incoming voltage: Use a multimeter to confirm the correct input power. GOT2000 models typically run on 24VDC, while legacy PanelViews may use 120VAC. Undervoltage can prevent boot.
-
Inspect wiring and connectors: Look for loose terminal blocks, broken wires, oxidation, or melted insulation—especially in hot or humid environments.
-
Test the power source directly: Connect a known-good device (even an indicator light or voltmeter) to confirm the power supply is actually stable and working.
-
Watch for blown fuses: Some HMIs include onboard fuses or protection circuits. Check your manual or datasheet.
🔌 Pro tip: Some Mitsubishi HMIs may appear dead due to polarity reversal or voltage ripple in older switch-mode supplies. Always test at the terminal, not just at the supply.
2. Check the Backlight or Display Settings
Sometimes the screen is technically working—but the backlight is burned out or the brightness is turned all the way down.
How to tell:
-
Shine a flashlight at the screen at an angle: If you see faint shadows, the LCD is on but the backlight is out.
-
For PanelView Plus and GOT2000 series: Try entering configuration mode at startup. This often involves holding a specific key (e.g., “Menu” or “Default”) while cycling power.
-
Adjust brightness/contrast in software: Improper brightness or resolution settings can create a black screen effect, especially after firmware updates or memory corruption.
💡 Backlight inverter failure is common in units used 24/7 or exposed to high heat.
3. Watch for LED Codes or Boot Patterns
Just because the screen is blank doesn’t mean the HMI is dead. Many devices provide diagnostics via status LEDs or boot patterns.
-
PanelView Plus: Look near the SD card slot or back of the unit for flashing red/green indicators. These may signal faults, memory issues, or bootloader failures. Rockwell publishes LED fault charts to help decode them.
-
Mitsubishi GOT2000: The “POWER” and “STATUS” LEDs on the top or rear of the panel often indicate system health. Specific blink patterns correspond to known issues (e.g., CPU failure, firmware load error).
-
Listen for clicks or whines: Some units emit faint relay clicks or coil buzzes on startup—this can be a helpful sign of partial functionality.
📘 Check your HMI’s model manual for diagnostic patterns and fault LED meanings—this can save hours of guesswork.
4. Inspect the Touchscreen and Overlay
If the screen seems unresponsive, it might not be blank—it might just not be registering touch input.
Common causes:
-
Touchscreen delamination or wear: Over time, especially with resistive screens, the top membrane can separate and cause phantom inputs or dead zones.
-
Cracked digitizers: Impact damage may break the touch surface without visibly damaging the screen itself.
-
Overlay shorts: Damaged overlays may short-circuit the touch grid, causing lock-ups or unregistered input.
🖱️ If your unit supports USB or PS/2 input, try plugging in a mouse to verify if the interface is still alive.
5. Swap Components—Safely
If you have a similar unit or access to spare parts, controlled testing can isolate the problem.
Try swapping:
-
SD cards or USB sticks used to boot the system or load projects
-
CPU logic modules (on modular HMIs like GOT2000)
-
Power supply modules or external power blocks
-
Touch/display modules, if separate from the main controller
⚠️ Only attempt swaps with full power disconnected and follow static-safe procedures. Never force incompatible modules—it can brick both units.
When to Repair vs. Replace
If you’ve narrowed the issue down to a failed screen, backlight, or input module—but the core logic is intact—repair is usually your best bet.
Repair Advantages:
- Costs 30–60% less than a new unit
- Retains program data (if controller is still readable)
- Fast turnaround (we return most within 5 business days)
- Extends the life of legacy systems
Replacement Advantages:
- Brand-new warranty
- Ideal if the unit is truly beyond repair
- Necessary for obsolete or discontinued models with no parts available
📉 Don’t risk extended downtime during procurement. Many of our customers choose to repair one unit while ordering a backup replacement for the shelf.
We Repair and Replace PanelViews, GOT2000s, and More
At Industrial Automation Co., we stock and service thousands of HMIs across brands and generations. Our technicians diagnose, test, and return your unit with a full 2-year warranty.
Here are just a few of our most requested models:
Need help fast? Contact us to troubleshoot, repair, or source a replacement HMI today. We’ll help you get back up and running—no guesswork required.