First: the 10-minute triage
Before anyone orders anything, work through this list. A surprising share of "dead panels" turn out to be something cheaper.
- Is the machine still running? If yes — the PLC is healthy and this is a visibility problem, not a control problem. Breathe.
- Panel power. Check the 24 VDC supply feeding the panel and its fuse. Panel power supplies fail far more often than panels.
- The flashlight test. Screen black but the power LED is on? Shine a flashlight at the screen at an angle. If you can faintly see the picture, the backlight is dead — the panel itself works, and a backlight/display repair is much cheaper than a replacement.
- Communications. If the panel boots but shows comm errors, check the Ethernet cable, the switch port and the PLC's link LEDs. The panel may be fine.
- One clean power cycle. Remove power for 30 seconds, restore it, let it boot fully. Firmware lockups happen; one restart is diagnosis, not superstition.
Still dead after all five? Now it's a real panel failure. Here are your options, honestly.
Your real options (with honest timelines)
| Option | Typical cost | Typical time | Watch out for |
|---|---|---|---|
| Repair service (backlight, touch, PSU) | $300–$1,000 | 1–2 weeks + shipping | Line is dark the whole time |
| Used unit (eBay etc.) | $500–$2,500 | Days, if you're lucky | No warranty, unknown hours, config transfer still needed |
| New replacement panel | $1,500–$4,000 | 2–6 weeks lead time | Plus converting & downloading the panel project |
| Bridge device (keep producing meanwhile) | $1,290 one-time (founders' price) | First batch — line-down requests get the first units + a free triage call now | Minimal by design — key values and buttons, not full HMI graphics |
These paths combine. The plants that lose the least money usually order the proper repair or replacement and bridge the gap so the line produces while they wait.
How the bridge works
LineKeeper is a self-contained 7″ touchscreen that plugs into the same network as your Allen-Bradley ControlLogix or CompactLogix. It reads the controller directly — the PLC program is never modified.
- Plug in — power + Ethernet into the machine network.
- Type the PLC's IP address — every tag appears automatically, live, twice a second.
- Assemble the operator screen — drag-and-drop the start/stop buttons, indicators and setpoints your operator needs. No programming, no licensed engineering software.
Afterwards it stays useful: data logging, dashboards, and diagnostics for the machine — many plants keep it running next to the new panel. See the full product tour →