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.
