Pro-face GP4000 to GP6000 Replacement: Cutouts, Cables and Project Conversion

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Replacing a Pro-face GP4000 with a GP6000 requires three separate checks: whether the new panel fits, whether the existing connections remain suitable, and whether the converted project behaves correctly.

Several GP6000 Standard models retain the mounting cutouts of their documented GP4000 predecessors. However, matching cutouts do not establish complete compatibility. Mounting hardware, transfer cables, display resolution, and software requirements can still change.

This guide focuses on documented GP4000-to-GP6000 Standard replacement paths. GP6000 Advanced has separate replacement guidance; do not apply Standard dimensions or interface assumptions to an Advanced model. Pro-face GP6000 Advanced replacement guide

Start with the Complete Model Number

Photograph the existing HMI nameplate before requesting a replacement. Record the full part number, power supply, connected ports, and any special coating or application requirements.

Examples from Pro-face’s replacement guides include:

Existing GP4000	Documented GP6000 Standard substitute	Nominal mounting cutout, W × H
PFXGP4301TAD	PFXGP6300TAD	156 × 123.5 mm
PFXGP4401TAD	PFXGP6400TAD	204.5 × 159.5 mm
PFXGP4501TAA	PFXGP6500TAA	259 × 201 mm
PFXGP4501TAD	PFXGP6500TAD	259 × 201 mm

These are selected replacement paths, not a complete interchangeability table. Coated, MPI, rear-mount, modular, handheld, and other variants require their own checks.

Sources: Pro-face 5.7-inch replacement guide, 7-inch replacement guide, and 10-inch replacement guide.

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Check the Cutout and the Space Behind It

For the selected paths above, the published cutout tolerance is +1/−0 mm on both dimensions, with an installation panel thickness of 1.6–5 mm. Measure the actual opening before deciding that no panel work is necessary. GP6000 Standard panel cut dimensions

Check four physical conditions:

Opening: Width, height, corner geometry, and evidence of previous modification.
Panel surface: Flatness, damage, and a continuous sealing surface around the opening.
Rear clearance: Space for the housing, connectors, cable bends, and servicing.
Mounting hardware: Correct gasket and fasteners for the replacement.

For the documented 10-inch path, housing depth increases from 57 mm to 58.5 mm. The same guide states that GP4000 fasteners PFXZCBAF1 cannot be reused; GP6000 uses PFXZC3AT1.

A shallow cabinet can therefore require attention even when the opening remains unchanged. Prepare the correct hardware before the shutdown rather than relying on parts removed from the old panel.

Separate PLC Cables from Project Transfer Cables

The cable connecting the HMI to its PLC serves a different purpose from the cable connecting an engineering computer to the HMI. Check both.

USB project transfer changes

The documented Standard migration replaces the older USB mini-B transfer connection with USB micro-B. Pro-face identifies PFXZUSCBMB2, or a suitable commercial micro-B data cable, for the new connection.

The old PFXZC3CBUSA1 / CA3-USBCB-01 Type-A-to-Type-A transfer arrangement is not supported for direct PC screen transfer on the new panel. Ethernet is another documented transfer route.

Include any cabinet-mounted USB extension in this inspection. An accessible front socket is useful only if its internal connection suits the replacement.

Verify serial cables against the actual driver

Before reusing a serial cable, record:

PLC manufacturer, CPU, and communication module
GP-Pro EX Device/PLC driver
HMI port assignment
RS-232C or RS-422/485 interface
Connector pinout, signal ground, shielding, and termination requirements
Station number, baud rate, parity, and other communication settings

For the documented PFXGP4401TAD-to-PFXGP6400TAD path, the guide lists RS-232C on COM1 and RS-422/485 on COM2. Cable suitability still requires the applicable Device/PLC connection instructions.

Treat an MPI installation as a separate compatibility decision. Confirm support for the exact PLC, interface arrangement, and installed software version before ordering adapters.

Record Ethernet settings before disconnecting anything

Photograph cable destinations and document the HMI’s network settings. During commissioning, confirm which interface the converted project uses.

Keep the replacement isolated from the production network while preparing it. Connecting old and new panels with duplicate addresses can introduce a new fault during the migration.

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Back Up the Installed Application Before Conversion

Preserve the original engineering project and obtain a current backup from the operating HMI where necessary.

Pro-face’s replacement procedure uses Receive Project to retrieve screen data. The HMI enters transfer mode and communication with the connected PLC is interrupted, so arrange a controlled maintenance window.

Build a recovery package containing:

Original project and a separately named conversion copy
Required SD-card or USB files
Relevant recipes and retained operating data
Communication settings and cable photographs
Software version and authorized access information
A rollback plan for the existing panel

Assign someone to verify the package before removal. A file that exists but cannot be opened is not a dependable starting point.

Convert the Project in GP-Pro EX

The Standard replacement documentation specifies GP-Pro EX 5.00.000 or later. It also identifies a software-license requirement for project transfer. Confirm that the engineering computer supports the exact target and required features before the shutdown.

Work on a copy of the original project:

Open the project in the supported engineering environment.
Select the replacement through Project → System Settings → Display → Change Display.
Choose the correct GP6000 Standard target.
Evaluate Convert Resolution.
Review the resulting screens and project checks before transfer.

For the documented 10-inch migration, resolution changes from 640 × 480 to 800 × 600. Physical mounting compatibility therefore does not preserve the original pixel layout.

Review more than the main screen

GP-Pro EX can adjust object positions, sizes, and text during resolution conversion, but the result can require manual correction. Registered keypads and certain special windows are not resized in the same way. A change in resolution, display colors, or color levels can also remove registered start-screen settings. GP-Pro EX restrictions on changing models

Inspect:

Numeric-entry keypads and touch targets
Alarm lists, banners, and acknowledgment controls
Pop-up windows and overlapping objects
Multilingual text and font sizing
Trends, images, and navigation buttons
Startup behavior and screens opened indirectly by the PLC

Also compare the project’s required functions with current target-model support. Remote access, peripherals, scripts, and animation behavior deserve explicit checks. An older guide’s “future support” note is not evidence that a feature is available in the installed release.

Commission the Replacement in Stages

Use a written acceptance checklist rather than treating a successful download as completion.

Stage	Check	Evidence to retain
Preparation	Correct project, hardware, accessories, and rollback files	Approved replacement record
Mechanical installation	Fit, sealing, fasteners, and cable clearance	Installation inspection
Initial startup	System setup, screen navigation, and project loading	Startup results
Communication	Expected values update without persistent errors	Driver and network test results
Functional testing	Authorized commands, recipes, alarms, and permissions behave correctly	Application test record
Restart test	Required settings and data remain available	Recovery and restart results

Before removing or rewiring equipment, qualified personnel should isolate the relevant supplies and follow the site’s electrical-safety procedure. During functional testing, control hazardous motion and stored energy through the machine’s established commissioning process.

Keep the original panel and its unchanged project available until acceptance testing is complete.

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Frequently Asked Questions

Does the same cutout mean the GP6000 is a direct replacement?

It establishes only part of the mechanical fit. Rear clearance, fasteners, power, connections, and application behavior still need verification.

Can I keep the existing PLC communication cable?

Possibly. Reuse depends on the exact source and target interfaces, pin assignments, driver, and connection requirements. A matching connector alone is insufficient.

Should I choose Standard or Advanced?

Choose against the application requirements and the exact replacement guide. Pro-face publishes separate Advanced migration documentation; Standard model numbers and dimensions should not be extrapolated to that range.

Can I schedule the shutdown before completing project conversion?

It is better to convert and review the project first, then prepare the replacement as far as practical off-machine. This exposes software and accessory requirements while the original HMI remains available.

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What to Send with a Replacement Inquiry

A useful inquiry includes the complete old model number, nameplate photograph, supply voltage, measured cutout, PLC model, cable details, and the proposed GP6000 target.

Also state whether the project backup opens successfully and whether the machine depends on special interfaces, coatings, or software functions.

For hardware sourcing, browse Kwoco’s Pro-face HMI range and provide this information for a model-specific inquiry. Confirm project-conversion and commissioning responsibilities separately so they are included in the shutdown plan.

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Pro-face GP4000 to GP6000 Replacement: Cutouts, Cables and Project Conversion

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