Is Your HMI Failing? How to Spot the Signs, Save Downtime, and Find th

Your HMI is a vital connection between operators and machines. When it begins to fail, the risk of downtime, errors, and production delays skyrockets.

Knowing the signs of HMI failure early can help you avoid major headaches.

In this guide, you’ll learn:

The top signs your HMI is failing
When to repair vs. replace
How to get a compatible replacement quickly
Installation and backup tips

⚠️ 5 Warning Signs Your HMI Is Failing

Don’t wait for total failure. These symptoms often appear first:

1. Touchscreen Issues: Delays, Dead Zones & Misfires

Slow or inaccurate response to touch
Non-functional areas of the screen
Wrong functions triggered by normal touches

🛠 Likely causes: Worn touch layers, voltage instability, or calibration issues.

2. Dim, Flickering, or Washed-Out Display

Weak backlight
Startup flickering
Low contrast or fading text

🛠 Common in CCFL-backlit screens after 30,000+ hours.

3. Frequent Freezing or Rebooting

Random shutdowns or restarts
Stuck splash screens
PLC communication drops

🛠 Often caused by memory failure, power issues, or corrupted firmware.

4. Lost Communication with PLC

Connection drops or fails entirely
Alarm messages: “Tag mismatch,” “No response,” “Data loss”
Appears functional but doesn’t sync

🛠 Check cables, but internal ports or logic board may be the real issue.

5. Physical Damage or Environmental Exposure

Cracked casing, worn buttons
Dust or water intrusion

🛠 Usually seen in HMIs without sealed enclosures.

🔧 Should You Repair or Replace Your HMI?

Here’s how to decide the best path forward:

Condition	Repairable?	Replace Recommended?
Dim backlight / touchscreen lag	✅ Yes	🚫 Not always necessary
Minor casing damage / loose terminals	✅ Yes	❌ Only if it affects function
Freezing / firmware issues	⚠️ Risky	✅ Safer to replace
End-of-life model / no OEM support	❌ No	✅ Strongly recommended
No display / no boot	⚠️ Hard to diagnose	✅ Replace

Tip: We offer fast-turnaround repair services and tested refurbished HMIs — all backed by warranty.

📦 Order Tip: Always Confirm Your Part Number

HMIs often have multiple versions within the same family. Watch for differences in:

Screen size and resolution
AC vs. DC power input
Communication type (EtherNet/IP, serial, DH+, etc.)
Firmware version or Series revision

Locate the part number on the rear label. Still unsure? Snap a photo and email it — we’ll confirm compatibility.

🔄 Replacing an HMI? Do This First:

Backup the project (e.g., .MER file for PanelView Plus)
Match software versions (FactoryTalk View ME, RSView32, etc.)
Check power requirements (24VDC vs. 110VAC)
Verify panel dimensions for correct fit
Consider ordering a spare for mission-critical applications