Spent hours trying to work around the issue:
If both my projector and Mac mini 2018 are off, if I first switch on the Mac a minute or two before the projector, it’s as if the Mac HDMI output does not trigger/jog/activate the HDMI output signal.
The signal may not be being sent by the Mac, and/or’s not being picked up reliably by the projector.
If the projector is first switched on and given 1or2min to get to the No Source Found screen, and then the Mac mini is switched on, the Mac’s HDMI output signal triggers/jogs/activates and displays on the projector.
The only thing which works fairly reliably I’ve found is over the Mac mini’s Thunderbolt/USB-C port to HDMI input on the projector, instead of the HDMI both ends.
I’m trying to diagnose a new 2018 Mac mini I purchased from Apple new November (came with Catalina), outputting from the Mac Mini HDMI socket output is not reliable.
The HDMI output to an external display, is in my case a newly bought (end of 2019) Optoma UHD40 projector which otherwise is no problem, it works -I’m using to type this on.
At Apple support’s guidance, I’ve reset the PRAM/NVRAM with Command+Option+P+R right at startup, and reset the SMC. Didn’t help.
I followed Apple phone instructions to partition, actually we had to add a new volume called ‘Test’ on the internal Mac mini SSD.
Catalina download from the App Store said Gateway error, actually we had to startup in the Test partition to successfully download Catalina.
I created a new user account on this new Test partition of the internal SSD, but the HDMI external display issue still remains probably a software/firmware issue introduced with Catalina.
I’d try installing Mojave to check, but getting the download to work it just sits there, maybe too busy.
It would restore confidence in the quality of macOS if Apple got to the bottom of this issue at least before/for the next major release of macOS.
Duet, SideCar to an iPad don’t solve my underlying problem but may help get out of a bind once logged in if the screen goes blank.
In the meantime I’ve gone to Energy Saver system pref and ticked ‘Prevent computer from sleeping automatically when display is off’ which reduces the chances of having unsaved work left open which I can’t see and have to force power-off if the screen doesn’t back come on.
Thank you