Pro face GP2000 Maintenance Guide

Pro face GP2000 series (GP-2400/2500/2600) human-machine interface: a complete engineering guide from installation, debugging to troubleshooting

Introduction: The Continuous Value of Classic HMI

In the field of industrial automation, the Pro face GP2000 series (including GP-2400, GP-2500, GP-2600) was once the benchmark product for medium to large human-machine interfaces. Despite the launch of more advanced models in the future, a large number of active equipment are still operating stably in production lines, packaging machinery, CNC machine tools, and other fields. For maintenance engineers, mastering the hardware specifications, installation points, offline settings, and common troubleshooting methods of the GP2000 series is a key skill to ensure production continuity.

This article is based on the GP2000 series user manual and extracts practical knowledge of the entire process from unboxing inspection to backlight replacement. It helps engineers quickly locate issues such as "screen failure", "inability to connect to PLC", "CF card read/write failure", and provides systematic maintenance recommendations.

Model Identification and Hardware Specification Quick Check

The GP2000 series consists of three sub series, with main differences in display screen size, resolution, and backlight type. Quickly identifying the model is crucial for selecting accessories.

Example of Series Models Display Screen Type Resolution Effective Display Area Backlight Model

GP-2400 GP-2400T-C41-24V TFT color LCD 640 × 480 149.8 × 112.3 mm PS400-BU00-MS

GP-2500 GP-2500L monochrome LCD 640 × 480 211.2 × 158.4 mm user non replaceable

GP-2500 GP-2500S STN color LCD 640 × 480 211.2 × 158.4 mm PS500S-BU00

GP-2500 GP-2500T-C41-24V/TC11 TFT color LCD 640 × 480 211.2 × 158.4 mm GP577RT-BL00-MS

GP-2600 GP-2600T-C41-24V/TC11 TFT color LCD 800 × 600 246.0 × 184.5 mm PS600-BU00

Key electrical parameters:

DC24V power supply model (suffix -24V): Input voltage range DC19.2V~28.8V, power consumption GP‑2400T ≤28W，GP‑2500/2600 ≤50W。

AC100V power supply model (TC11 and revision<3): rated AC100V, actual AC85-132V, power consumption ≤ 50VA.

AC100-240V wide range model (TC11 revision ≥ 3): rated AC100-240V, actual AC85-265V, power consumption ≤ 85VA at 240V.

Allowable instantaneous power outage time: 10ms for DC power supply model, 20ms for AC power supply model.

Insulation withstand voltage: DC power supply model AC1000V/1min, AC power supply model AC1500V/1min.

Environment and Structure:

The working temperature is 0-50 ℃, the storage temperature is -20-60 ℃, and the humidity is 10% -90% RH (without condensation).

Front panel protection level: equivalent to IP65f/NEMA 4X/12 (only when the front panel is tightly fitted with gaskets).

Vibration resistance: Complies with IEC61131-2.

Installation panel thickness: 1.6-10mm, recommended to use installation fasteners (GP070-AT01).

Installation and wiring: key steps determining long-term reliability

1. Inspection and installation of installation gaskets

The installation of gaskets (PS400-WP00-MS for GP-2400, GP570-WP10-MS for GP-2500/2600) is the core of achieving IP65 protection. Before installation, it is essential to:

Place the GP screen facing downwards on a flat surface and check if the gasket is fully embedded in its groove.

Gasket joints should not be placed in corners, only in straight sections, otherwise they are prone to tearing under long-term stress.

The surface of the gasket should be about 2mm higher than the groove. It needs to be replaced if it has been used for more than a year or if scratches or dirt appear.

2. Panel perforation and installation

Drill holes according to the dimensions specified in section 2.5.4 of the manual (GP-2400 approximately 215 × 170mm, GP-2500/2600 approximately 317 × 243mm).

Push GP into the front panel and secure it from the back using installation fasteners. Each GP should use at least 4 fasteners (GP-2500/2600 can accommodate up to 10).

The torque required to tighten the screws is only 0.5 N · m, excessive torque can damage the casing.

When the panel tilt angle exceeds 30 °, the upper limit of ambient temperature drops to 40 ° C, and forced air cooling may be required.

3. Power wiring (highest risk link)

Absolutely prohibit live wiring. The external power supply must be disconnected before wiring.

Use crimped ring terminals (with an inner diameter of approximately 3.2mm), and the exposed part of the terminal must be covered with an insulating sheath to prevent short circuits after loosening.

Wiring sequence: First connect the FG (ground) terminal, then connect the L (or+) and N (or -).

FG must be grounded separately, with a grounding resistance of ≤ 100 Ω and a wire cross-sectional area of ≥ 2mm ². Do not share grounding with other devices as it may cause common mode interference.

It is recommended to install a surge absorber (varistor) on the incoming side of the power supply, and its maximum circuit voltage should be greater than the peak voltage of the power supply.

4. Serial communication wiring (COM1/COM2)

COM1:25 pin female holder, supporting RS-232C or RS-422. If RS-422 is used, the following pins must be short circuited accordingly:

#18 (CSB)  ↔ # 19 (ERB) and # 21 (CSA) ↔ # 22 (ERA)

And install a 100 Ω terminal resistor between # 9 (TRMX) and # 10 (RDA) (only when using RS-422).

COM2: 9-pin male seat, only supports RS-232C. Please note that its fixing screws are imperial # 4-40UNC, which is different from the metric M2.6 of COM1.

Important warning: The serial port is not isolated, and the SG (signal ground) must be connected correctly, otherwise it may damage the RS-422 driver circuit. In addition, PIN14 (VCC) outputs DC5V/0.25A without protection, overloading is strictly prohibited.

5. Ethernet and tool connectors

The Ethernet interface is 10BASE-T and uses shielded RJ45 cables. If you directly connect to a PC and the network card does not support cross line adaptation, you need to go through a hub.

Tool Connector is used to download screen programs, cable model GPW-CB02. Power off and plugging are also required.

First startup and offline settings

After turning on the power, GP will load the Pro Designer Runtime. If the screen has not been downloaded yet or system parameters need to be modified, you can touch the top left corner of the screen within 10 seconds after startup, or touch the top right corner+bottom right corner+bottom left corner at the same time to enter the "Settings Menu".

This menu is divided into two tabs: Offline and System.

Offline settings:

Network: Set IP address, subnet mask, and default gateway. After modification, it must be restarted to take effect.

Buzzer: Touch buzzer mode. Optional "None" (off) or "Press Touch Object" (beeps when touched). Note that 'Press Anyway On Panel' is not applicable to the GP2000 series.

Backlight：

Brightness: 4-level brightness adjustment.

Wait: Set the backlight to automatically turn off after idle timeout (extending the lifespan of the lamp), default to OFF.

Enable Touch if Backlight is OFF: Allow touch operation when backlight burn is detected. Strongly recommend setting it to OFF to avoid accidental triggering.

Self Test: Enter the self diagnostic menu (see Chapter 5 for details).

System (system settings):

Date/Time: Use the pop-up numeric keypad to modify the date and time. The internal clock error is about+65 seconds/month at room temperature, and may drift to -380 to+90 seconds/month after long-term use, requiring regular calibration.

Language: Set the system menu language and user application language separately (supporting Chinese, Japanese, Korean, English, etc.).

Memory: Display the usage of application memory (8MB FLASH EPROM) and data backup memory (512KB SRAM).

Ver. Info: View Runtime version and project version number.

Restart: Soft restart GP.

The use of CF cards and data protection

The GP-2500/2600 series supports CF cards (16MB for GP077-CF20 and 32MB for GP077-CF30) for storing screen data, logs, or recipes. Pro Designer does not support extension unit interfaces and only supports CF cards.

Hardware dip switch (located at the bottom, under the cover):

Switch function ON (valid) OFF (invalid)

1 CF card startup control can be started from CF card but not from CF card

2-3 reservations must be kept OFF -

4. Forced closure of CF card cover detection. Forced closure (emergency use). Normal detection

The iron rule for correctly plugging and unplugging CF cards:

Before inserting, open the CF card cover and confirm the direction of the card (with the contacts facing downwards). Gently push in until the eject button pops out.

After closing the lid, the CF card access LED must light up, otherwise it cannot be read or written (closing the lid is a safety interlock).

It is absolutely forbidden to turn off the power, reset or unplug/insert the card when the LED is on, otherwise the data will be damaged or even the card will be scrapped.

Before unplugging, stop accessing the CF card through the screen program, confirm that the LED is off, and press the eject button to remove the card.

The erase life of a CF card is about 100000 times (assuming 500KB of data is overwritten each time), and important data must be backed up to a PC regularly.

Reading CF card on PC: Insert the CF card adapter (GP077-CFAD10) into the PC card slot or use a USB card reader. After testing, the CardDock CF/P (parallel port) of I-O DATA is compatible, but not all card readers are guaranteed to correctly read GP format data.

Troubleshooting and Self Diagnosis

1. The screen does not display at all (black screen)

Check in the following order:

Step check item handling method

Has Pro Designer been used to download the screen? If not downloaded, there may be no display on the first power up. Download any valid image.

Is the "Initial Screen ID" correct in Pro Designer 2? Set to the correct value and download again.

What color is the 3-state LED? Orange → Backlight burned out, replace backlight.

Is the input voltage within specifications? Measure the terminal voltage with a multimeter (for DC24V models, it should be between 19.2-28.8V; for AC100V models, it should be between 85-132V).

Is the wiring of the 5 power terminals correct and securely fastened? Check if L/+, N/-, FG correspond.

Is the power light on? If it doesn't light up, it may be a hardware power board malfunction.

Is the backlight on? Under the illumination of the flashlight, one can vaguely see the content of the image ->the backlight burns out; No display at all → motherboard/LCD malfunction.

2. Unable to communicate with PLC

Step check item handling method

Is the power supply normal and has GP been started?  —

Does the wiring of the communication cable comply with the pin definition of COM1/COM2? Especially RS-422 must be connected to terminal resistors and short circuited control lines (CSB-ERB, CSA-ERA).

Are the protocols and drivers for devices/PLCs in Pro Designer 3 correct? Reconfirm and download.

Are the communication parameters (baud rate, data bits, stop bits, parity check) consistent with the PLC? Adjust consistently.

If RS-232C is used, is SG connected? SG must be connected, otherwise the interface may be damaged.

3. Touch unresponsive or offset

Go to Offline → Self Test → Touch Panel, press each intersection point one by one, and check if each position can be correctly identified. If there is no response or significant displacement in certain areas, the touch screen may be damaged.

If the touch fails and the backlight is burned out, the "Enable Touch if Backlight is OFF" is set to OFF, and the touch is already disabled. This is normal protection.

Detailed explanation of Self Test function

Enter Offline → Self Test to perform five diagnostics:

The role of the test item is achieved through standard failure strategies

Char. Pattern check font ROM and Chinese character ROM display OK firmware damage, needs to be sent for repair

Disp Pattern check: The drawing function is displayed as OK, but there is a test pattern or LCD driver malfunction on the screen

Touch Panel touch screen matrix test highlights that the touch screen is broken when touching each grid and needs to be replaced

COM1/COM2 serial port circuit testing requires a dedicated loopback plug, and if it displays OK, check the wiring and driver chip

Video Memory: Video Memory Test OK. Video Memory: Bad, motherboard malfunction

Self made method for serial port loopback plug (for Self Test):

COM1 (25 pin female): Short circuit # 2 (SD) and # 3 (RD); #Short circuit between 4 (RS) and # 5 (CS); #20 (ER) and # 6 (DR) are short circuited.

COM2 (9-pin male): Short circuit # 2 (RD) and # 3 (SD); #Short circuit between 7 (RS) and # 8 (CS); #4 (ER) and # 6 (DR) are short circuited.

Please refer to section 5.2.2 of the manual for detailed illustrations.

Complete Guide for Backlight Replacement

When the status LED displays orange and "Enable Touch if Backlight is OFF" is set to OFF in Offline, the screen touch is disabled. At this point, the backlight must be replaced.

Security Warning:

Before replacement, the power cord must be unplugged and wait for at least 10 minutes for the lamp and inverter to cool down to prevent burns.

The backlight glass tube is fragile, do not touch the glass or pull the leads. If accidentally broken, be careful to clean the debris (containing mercury) and avoid inhalation or contact with the skin.

Backlight model comparison:

GP model backlight order number

GP‑2400T‑C41‑24V PS400‑BU00‑MS

GP‑2500SC‑41‑24V PS500S‑BU00

GP‑2500T‑C11 / GP‑2500T‑C41‑24V GP577RT‑BL00‑MS

GP‑2600T‑C11 / GP‑2600T‑C41‑24V PS600‑BU00

GP-2500L users are non replaceable and must contact an authorized service provider

Replacement steps (taking GP-2500T/2600T as an example):

Turn off the power, unplug all cables, remove the GP from the panel, and place the screen facing down on the soft cushion.

Use a Phillips screwdriver to remove the fixing screws of the back cover and take off the back cover.

Find the backlight tube assembly (usually located on the top, bottom, or left and right edges of the LCD panel). Unplug the high-voltage connection wire of the lamp (note: residual high voltage, it is best to wear insulated gloves).

Carefully remove the old lamp tube and clean the dust in the lamp tube slot.

Push the new lamp tube completely into the slot and reinsert the high-voltage wire.

Reinstall the back cover and tighten the screws (torque 0.5 N · m).

Power on test: The status LED turns green and the screen brightness returns to normal. If the LED is still orange, check the connection or tube direction.

Backlight lifespan: Design lifespan of 50000 hours (continuous illumination at 25 ℃ environment, brightness attenuation to initial 50%). The actual lifespan is affected by environmental temperature and switch frequency. It is recommended to replace it proactively after 5 years to avoid sudden failure and production line shutdown.

Regular maintenance checklist and battery precautions

Check every six months:

Whether the environmental temperature and humidity meet the specifications.

Is the power supply voltage within the allowable fluctuation range.

Are the communication cables and power terminals loose.

Is the installation of fasteners still secure.

Check for cracks, hardening, or warping in the installation gasket.

Lithium battery (for data backup):

The battery model is not provided in the manual, but it is stated that the battery life is 10 years below 40 ℃; 4.1 years below 50 ℃; 1.5 years below 60 ℃.

When fully charged, data can be retained for about 60 days; About 6 days in semi charged state.

Battery replacement must be operated by a Pro face authorized service provider, and users cannot replace it themselves, otherwise there is a risk of explosion.

9、 FAQ (based on on-site experience)

Q1: GP has been stopped on the startup screen since power on and does not enter the running mode.

A: Possible reasons: ① Failure to download valid projects; ② The CF card startup switch is turned on but there is no startup data in the card; ③ The application is damaged. Enter Offline mode, check Memory space, and download the screen again.

Q2: RS-422 communication often experiences packet loss or CRC errors.

A: ① Confirm whether CSB-ERB and CSA-ERA have been short circuited; ② Is the terminal resistor added with 100 Ω at the end station; ③ Is SG connected to the other SG; ④ Use shielded twisted pair cables, with the shielding layer grounded at one end.

Q3: The CF card can be inserted, but the ACCESS LED is not lit.

A: ① Confirm that the CF card cover is completely closed (press down the micro switch on the contact on the cover); ② Check if DIP switch 4 is in the OFF position; ③ Try another verified CF card (Digital original).

Q4: The sensitivity of some areas of the touch screen has decreased.

A: It may be due to aging of the surface protective film, dust, or aging of the liquid crystal. Clean the screen, if ineffective, replace the touch screen. Touch calibration can be performed in Pro Designer (offline calibration is not possible and requires system diagnosis or re downloading calibration data).

Q5: GP displays garbled characters or missing fonts.

A: Run Char. Pattern self-test. If it reports NG, the font ROM is damaged and the motherboard needs to be replaced. Additionally, check if the language settings are correct.