EVO800 Redundant PLC System: Uninterrupted Control for Heavy-Duty
Industrial Automation
The EVO800 Series is a high-performance large-scale redundant control system
meticulously engineered by Inovance Technology, drawing on decades
of profound expertise in controller R&D. Developed in
accordance with automotive-grade high-reliability standards and compliant with IEC specifications, it boasts core features including strong compatibility, easy migration, robust protection, and full
autonomy.
This PLC supports three operating modes: standalone mode, multi-CPU
single-chassis mode, and redundant mode. When paired with the
high-reliability Hi80 series I/O modules and matched switches, it
enables flexible system networking. Software programming is based
on the full-scenario intelligent iFA Evolution platform.
Widely applicable to large-scale production lines in industries
such as metallurgy, automotive manufacturing, municipal
engineering, water conservancy, petroleum, mining, ports,
chemicals, and power generation, the EVO800 Series facilitates
production line transformation and drives digital and intelligent
upgrading.
Core Product Features
Automotive-Grade High-Reliability Design with Full Compliance
- Engineered to automotive-grade high-reliability standards, its core
components and system architecture undergo rigorous testing to
ensure 24/7 continuous and stable operation
- Fully compliant with IEC international specifications as well as
relevant EMC and LVD standards, with insulation resistance,
anti-electromagnetic interference and other indicators meeting
requirements, enabling seamless access to overseas markets
- Supports multi-dimensional redundant configurations for
controllers, power supplies, and communications, with seamless
switchover in case of faults, significantly reducing the risk of
unplanned downtime
Diversified Operating Modes for Flexible Networking
- Compatible with three operating modes: standalone mode, multi-CPU
single-chassis mode, and redundant mode, allowing free selection of
deployment schemes based on production line scale
- Paired with high-reliability Hi80 series I/O modules and matched
switches, it supports multiple networking methods including single
ring network, dual ring network, and star network, adapting to
complex industrial layouts
- Features strong compatibility, supporting mainstream industrial
protocols such as Modbus and Profinet, enabling seamless connection
with existing equipment and reducing transformation difficulty
Full Autonomous Intelligence for Efficient Operation & Maintenance
- Based on the full-scenario intelligent iFA Evolution platform, it
realizes parameterized programming and visual operation,
simplifying project development and debugging processes
- Core features include easy migration, high protection, and full
autonomy. Programs can be quickly adapted to different production
line requirements, eliminating the need for extensive underlying
code modifications when switching product models
- Built-in intelligent diagnostic function monitors equipment
operating status in real time, accurately locates fault points and
saves key data, shortening troubleshooting time
Wide Industry Adaptability for Digital & Intelligent Upgrading
- Widely applicable to nine major industrial sectors including
metallurgy, automotive, municipal engineering, petroleum, and
power, meeting the complex control needs of large-scale production
lines
- Supports integration with MES, ERP systems and industrial internet
platforms, realizing real-time data upload and remote monitoring,
providing support for digital twins and predictive maintenance
- Empowers the automation transformation and intelligent upgrading of
traditional production lines, improving production efficiency and
equipment utilization rates
EVO800 Series Core Technical Parameters
| Parameter Category | Specifications |
|---|
| Basic Performance | - CPU: High-performance multi-core processor with nanosecond-level
instruction processing speed
- Program Memory: 128MB
- Data Memory: 128MB (including 512KB power-fail protected storage
area)
- Instruction Execution Speed: 0.9ns for bit operations; 2.5ns for
floating-point operations
|
| Operating Modes | Supports three modes: Standalone Mode, Multi-CPU Single-Chassis
Mode, Redundant Mode (1:1 redundancy configuration for controller,
power supply, communication) |
| I/O Configuration | - Matching Module: High-reliability Hi80 series I/O modules
- Digital Input/Output: Configurable via expansion modules,
supporting high-speed I/O (200kHz)
- Analog Input/Output: Supports thermocouple, thermistor, voltage
(0~10V, 4~20mA) signals, resolution up to 0.01℃ for temperature
measurement
|
| Communication Capabilities | - Network Interfaces: Ethernet (10/100/1000Mbps adaptive), EtherCAT,
RS485
- Supported Protocols: Modbus TCP, EtherNet/IP, PROFINET, OPC UA, CAN
bus
- Networking Topologies: Single ring network, dual ring network, star
network
- EtherCAT Capacity: Supports up to 256 slave stations; 1ms cycle
synchronization for 64 axes
|
| Power Supply | - Input Voltage: DC24V ±10% or AC220V (optional)
- Protection Features: Short-circuit protection, reverse polarity
protection
- Power Consumption: <5W (basic configuration)
|
| Environmental Adaptability | - Operating Temperature: -20℃ ~ 70℃
- Storage Temperature: -40℃ ~ 85℃
- Relative Humidity: 10% ~ 95% RH (non-condensing)
- Anti-interference: Complies with EMC Level 3 standard;
electrostatic discharge (air 8KV, contact 4KV); surge protection
±1KV
|
| Compliance & Certification | - Standards: IEC 61131-3, EN 61010-1, EN 61131-2
- Certifications: CE, UL/cUL, RoHS, EAC, KCC, UKCA
|
| Software & Programming | - Development Platform: iFA Evolution (supports ST, LD, SFC, CFC
programming languages)
- Intelligent Features: Parameterized programming, visual debugging,
real-time fault diagnosis (diagnostic coverage >90%)
- Expansion Capacity: Supports up to 32 local expansion modules
|
EVO800 Series Model Specifications
| Product Category | Model No. | Order No. | Core Configuration & Functions | Application Scenarios | International Certifications |
|---|
| CPU Modules | EVO800-CPU-100S | INO-E8C-100S-0001 | Standalone mode, high-performance single-core processor, 128MB
program memory & 128MB data memory, supports basic industrial
protocols (Modbus TCP) | Independent control scenarios for small-to-medium production lines | CE, UL/cUL, RoHS |
| CPU Modules | EVO800-CPU-200M | INO-E8C-200M-0002 | Multi-CPU single-chassis mode (supports 2-way CPU parallel
operation), multi-core processor, memory expanded to 256MB,
supports PROFINET | Distributed control for medium-to-large production lines | CE, UL/cUL, RoHS, EAC |
| CPU Modules | EVO800-CPU-300R | INO-E8C-300R-0003 | Redundant mode (1:1 controller redundancy), seamless fault
switching, supports OPC UA, diagnostic coverage rate >90% | Critical production lines with high reliability requirements
(petroleum, power) | CE, UL/cUL, RoHS, UKCA, KCC |
| Power Modules | EVO800-PWR-24DC | INO-E8P-24DC-0004 | Input DC24V±10%, output power 50W, short-circuit/reverse polarity
protection, supports redundant parallel connection | Power supply for all EVO800 series systems | CE, UL/cUL, EN 61010-1 |
| Power Modules | EVO800-PWR-220AC | INO-E8P-220AC-0005 | Input AC220V±10%, output power 100W, wide temperature adaptability
(-20℃~70℃), redundant power supply design | Direct power supply scenarios from industrial power grids | CE, UL/cUL, EN 61010-1, LVD |
| I/O Modules (Digital) | Hi80-DI-16DO-16 | INO-H8I-DO32-0006 | 16-channel digital input + 16-channel digital output, supports
high-speed I/O (200kHz), compatible with NPN/PNP signals | General discrete control (automotive assembly, port machinery) | CE, RoHS, EMC Level 3 |
| I/O Modules (Analog) | Hi80-AI-8AO-4 | INO-H8I-AO12-0007 | 8-channel analog input (4~20mA/0~10V), 4-channel analog output,
temperature measurement resolution 0.01℃ | Process control scenarios (chemical, metallurgical temperature
control) | CE, RoHS, EN 61131-2 |
| I/O Modules (Special Function) | Hi80-TC-8 | INO-H8I-TC08-0008 | 8-channel thermocouple input, supports J/K/S type thermocouples,
built-in cold junction compensation | High-temperature monitoring scenarios (power, chemical reactors) | CE, RoHS, EMC Level 3 |
| Communication Modules | EVO800-COM-EtherCAT | INO-E8C-ETHC-0009 | EtherCAT master interface, supports 256 slave stations, 1ms
synchronization cycle | High-precision motion control scenarios (automated production
lines) | CE, RoHS, EN 61000-3-3 |
| Communication Modules | EVO800-COM-CAN | INO-E8C-CAN01-0010 | CAN bus interface, supports CANopen protocol, suitable for
long-distance communication | Municipal, water conservancy remote monitoring scenarios | CE, RoHS, UL/cUL |
| Racks | EVO800-RACK-10 | INO-E8R-R10-0011 | 10-slot rack, single rack supports multi-CPU expansion, metal shell
for anti-electromagnetic interference | Centralized deployment of small-to-medium systems | CE, RoHS |
| Racks | EVO800-RACK-16 | INO-E8R-R16-0012 | 16-slot rack, supports full-module redundant configuration,
compatible with all Hi80 series I/O modules | Expansion of large-scale redundant systems | CE, RoHS, EN 61010-2-201 |
Industry Application Scenarios
Metallurgy (Blast Furnace & Rolling Mills)
Application Scenario: Blast furnace temperature control, rolling
mill speed synchronization, continuous casting production line
monitoring.
Why EVO800: Redundant mode ensures zero downtime during molten
steel smelting; multi-CPU parallel processing handles high-density
I/O signals from hundreds of sensors; Hi80 TC modules achieve 0.01℃
temperature measurement accuracy for precise heating control.
Automotive Manufacturing (Assembly & Stamping Lines)
Application Scenario: Robot arm coordination, body welding process
control, automated logistics conveying systems.
Why EVO800: Supports EtherCAT 1ms synchronization for seamless
robot collaboration; easy migration feature allows quick program
adjustment when switching car models; high protection design
resists electromagnetic interference from welding equipment.
Petroleum & Chemical (Refineries & Chemical Plants)
Application Scenario: Oil pipeline pressure regulation, chemical
reactor temperature/pressure closed-loop control, hazardous area
equipment monitoring.
Why EVO800: 1:1 controller redundancy prevents production
interruptions caused by equipment failures; compliance with IEC
standards meets explosion-proof area safety requirements; OPC UA
protocol enables data sharing with MES systems for real-time
process tracking.
Power Generation (Thermal & Hydropower Plants)
Application Scenario: Turbine speed control, boiler combustion
optimization, substation equipment status monitoring.
Why EVO800: Wide temperature adaptability (-20℃~70℃) works in harsh
power plant environments; redundant power supply modules avoid
sudden power outages; intelligent diagnostic functions predict
equipment faults in advance, reducing maintenance costs.
Mining (Open-Pit & Underground Mines)
Application Scenario: Conveyor belt speed control, mine hoist
safety protection, underground ventilation system regulation.
Why EVO800: Strong anti-interference performance resists vibration
and electromagnetic noise in mines; flexible networking supports
remote monitoring of underground equipment; standalone mode is
suitable for small pumping stations, while redundant mode protects
critical hoisting systems.
Port & Logistics (Container Terminals & Bulk Cargo Ports)
Application Scenario: Gantry crane positioning control, container
loading/unloading coordination, automated storage and retrieval
systems (AS/RS).
Why EVO800: Multi-CPU single-chassis mode handles simultaneous
control of multiple cranes; high-speed I/O modules respond to
position sensors in milliseconds; compatibility with Profinet
enables connection to port management systems.
Municipal Engineering (Water Treatment & Wastewater Plants)
Application Scenario: Water purification process control, sewage
treatment aeration system regulation, pipeline leakage monitoring.
Why EVO800: CAN bus long-distance communication supports remote
monitoring of scattered water plants; low power consumption reduces
operation costs; analog I/O modules accurately control chemical
dosing amounts for water quality optimization.
Water Conservancy (Dams & Irrigation Systems)
Application Scenario: Dam gate opening/closing control, irrigation
canal flow regulation, flood control monitoring systems.
Why EVO800: Stable operation in outdoor harsh environments;
redundant communication ensures no signal loss during flood
seasons; easy program migration allows quick adjustment of
irrigation plans according to weather changes.
Common Questions & Answers
Q1: The on-site power grid voltage is unstable with frequent
fluctuations during overseas installation. Will this damage the
PLC? How to solve it?
A: It won't cause damage easily, but long-term fluctuations will
affect the service life. The power module of EVO800 supports wide
voltage input (DC24V±10%/AC220V±10%), which can withstand minor
fluctuations on its own. If the on-site voltage fluctuation exceeds
this range, it is recommended to install an industrial-grade voltage stabilizer or surge protector. In addition, redundant power modules can be used in parallel;
even if one power supply fails, the other can switch seamlessly
without affecting system operation.
Q2: During commissioning at overseas factories, we find that the
PLC cannot communicate with on-site third-party devices (such as
Siemens frequency converters, AB sensors). How to handle this?
A: First, check two core points: one is protocol matching. The EVO800 supports mainstream protocols such as Modbus,
PROFINET, and EtherCAT. Confirm whether the communication protocol,
baud rate, station number and other parameters of the third-party
device are consistent with those of the PLC. The second is hardware wiring. Especially, do not reverse the A/B lines of RS485 communication,
and ensure that the IP addresses are in the same network segment
for Ethernet communication. If the connection still fails, use the communication diagnosis function of the iFA Evolution platform to directly view the data sending
and receiving status, and locate whether the problem is on the
device side or the PLC side.
Q3: In high-temperature/high-humidity working conditions overseas
(such as rubber factories in Southeast Asia and oil refineries in
the Middle East), the PLC alarms after running for a period of
time. How to solve it?
A: This is a common problem of environmental adaptation. The
operating temperature range of EVO800 is -20℃~70℃, and humidity is
10%~95% RH (non-condensing), but the superposition of high
temperature and high humidity will trigger overheating or
insulation alarms. Solutions: First, install heat dissipation measures, add axial fans or air conditioners in the control cabinet, and
avoid placing the PLC too close to high-power heating equipment
(such as contactors). Second, take good moisture-proof measures, put desiccants in the control cabinet, and install sealing strips
on the cabinet door to prevent humid air from entering. Third,
enable the overheating protection function of the PLC; when the temperature exceeds the threshold, it will
automatically reduce the load to run to avoid direct shutdown.
Q4: Will the program be lost after PLC switching in redundant mode?
How to confirm whether the switching is normal?
A: The program will not be lost. The 1:1 redundant configuration of
EVO800 realizes real-time data synchronization; the program and
running status of the master CPU will be backed up to the standby
CPU in real time, and the switching is completed in milliseconds
without interrupting production. There are two simple ways to
confirm normal switching: one is to check the panel indicator light --the master CPU has a green running light on, and the standby CPU
has a yellow standby light on; after switching, the standby CPU
will turn to green, and the original master CPU will have a red
alarm light on if it fails. The second is to check the redundancy status monitoring interface on the iFA Evolution platform, which can directly display the
switching reason and time, facilitating subsequent troubleshooting.
Q5: Overseas customers require the PLC system to comply with local
safety certifications (such as CE in the EU and UL in North
America). How to provide relevant documents?
A: First of all, the entire EVO800 series comes with international
certifications such as CE, UL/cUL, and RoHS ex-factory. You can
request the manufacturer to provide copies of certification certificates and Declaration of Conformity (DoC) when placing an order. In addition, for special regions (such as
EAC in Russia and KCC in South Korea), you need to inform the
manufacturer in advance, and the manufacturer will provide
certification documents corresponding to the region. Note that
during installation, ensure that the wiring complies with local
standards (such as EN 60204 in the EU); otherwise, even with
certificates, it may fail to pass local third-party testing.
Q6: On-site operators do not understand Chinese. How to quickly get
started with commissioning and maintenance?
A: The iFA Evolution platform supports multi-language switching. You can directly switch to commonly used overseas languages such
as English, Spanish, and French in the settings, and the interface
and operation manual will switch synchronously. In addition, the overseas version of the maintenance manual provided by the manufacturer is in full English, which includes
troubleshooting flow charts for common faults; operators can solve
problems step by step according to the procedures. For complex
problems, the remote debugging function of the platform can be used to allow domestic technical personnel
to provide direct assistance without sending people to the site.
Q7: In remote overseas areas (such as mines in Africa and
hydropower stations in South America), the supply of spare parts is
slow when the PLC fails. How to reduce downtime?
A: There are two practical methods: one is stock up in advance. According to the project scale, ask the customer to purchase 1-2
sets of core spare parts (such as CPU modules and power modules)
and store them in the on-site warehouse; when a failure occurs,
they can be replaced directly. The second is use standalone mode for emergency. If one CPU of the redundant system fails and the spare parts have
not arrived, the system can be switched to standalone mode to meet
basic production needs, and then the redundant configuration can be
restored when the spare parts arrive. In addition, the modules of
EVO800 feature hot-swappable design, so replacement can be done without powering off, without
affecting the operation of other equipment.
Product Certification & Quality Assurance
Full-Process International Certifications for Global Market Access
From R&D to mass production, the EVO800 Series is fully aligned
with international industrial standards and has obtained
certifications for mainstream global markets, enabling direct
market entry without additional testing:
- EU Market: CE certification (compliant with EN 61131-3 programmable
controller standards, EN 61010-1 electrical safety standards, and
EMC electromagnetic compatibility standards) and RoHS environmental
certification. It meets the requirements of the EU CE Marking
Directive and can circulate freely in 27 EU member states and the
European Free Trade Area.
- North American Market: UL/cUL certification (compliant with UL 508 industrial control
equipment safety standards). It has passed rigorous electrical
safety tests in North America and complies with installation and
operation specifications in the US and Canadian markets.
- Emerging Markets: EAC Customs Union certification (covering Russia, Kazakhstan and
other CIS countries), KCC certification (for South Korean market
access), and UKCA certification (exclusive certification for the UK
market). These certifications remove market access barriers in
emerging regions.
- Industry-Specific Certifications: Compliant with IEC 61131-2 environmental adaptability standards,
it has passed multiple industrial-grade reliability tests including
high temperature, low temperature, vibration, and electromagnetic
interference resistance, meeting the operational requirements of
high-risk industries such as metallurgy and chemicals.
Full-Lifecycle Quality Assurance - Closed-Loop Control from R&D
to After-Sales
R&D Phase
- Adheres to automotive-grade design standards, with core components sourced from leading international brands
(e.g., Infineon). Key chips undergo strict aging tests to ensure
stability under extreme working conditions.
- Adopts a redundant architecture verification system, conducting over 100,000 switching tests on redundant modules
(controllers, power supplies, communications). Fault switching time
is controlled within milliseconds to eliminate switching failure
risks.
Production Phase
- Assembled on fully automated production lines, with critical
processes inspected by machine vision to avoid human errors. Every
device undergoes a 72-hour high-temperature aging test before
delivery to eliminate early failure products.
- Establishes a product traceability system, with each module assigned a unique serial number. This enables
tracking of full-process information including production batch,
component batch, and test data, facilitating quick fault location
and quality tracing.
After-Sales Phase
- Offers global unified warranty service: 2-year warranty for core modules (CPU, power supply) and 1-year
warranty for I/O modules and accessories, supporting free repair or
replacement worldwide.
