TWK Elektronik IO-Link NOCIO User manual

TWK-ELEKTRONIK GmbH 40210 Düsseldorf [e-mail]
Bismarckstraße 108 Tel.: [phone] visit us at | twk.de
Document no.: NOC 15597 EE
Date: 16 Mar 2022
Switching cam encoder NOCIO with IO-Link interface
Data sheet NOC 15893
User manual

Date: 16 Mar 2022 Page 2 of 38 Document no. NOC 15597 EE
NOCIO - Cam encoder with IO-Link interface
COPYRIGHT: The Operating Instructions NOC 15597
is owned by TWK-ELEKTRONIK GMBH and is
protected by copyright laws and international treaty provisions.
© 2020 by TWK-ELEKTRONIK GMBH
POB 10 50 63 ■ 40041 Düsseldorf ■ Germany
Tel. [phone] ■ Fax [phone]
[email protected] ■www.twk.de

Date: 16 Mar 2022 Page 3 of 38 Document no. NOC 15597 EE
NOCIO - Cam encoder with IO-Link interface
Table of contents
1 Safety instructions ........................................................................................................................... 4
1.1 Scope ......................................................................................................................................................... 4
1.2 Documentation ........................................................................................................................................... 4
1.3 Proper use .................................................................................................................................................. 4
1.4 Commissioning ........................................................................................................................................... 4
2 General information .........................................................................................................................5
3 Installation instructions...................................................................................................................6
3.1 General....................................................................................................................................................... 6
3.2 Electrical connection .................................................................................................................................. 6
3.3 Status LEDs ............................................................................................................................................... 7
3.4 IODD le.....................................................................................................................................................7
4 System description .........................................................................................................................8
4.1 Principle function diagram of cams and relays...........................................................................................8
4.2 Cam setting for position trip...................................................................................................................... 10
4.3 Speed and acceleration calculation.......................................................................................................... 12
4.4 Cam setting for speed and acceleration trip.............................................................................................17
4.5 Slewing ring functionality..........................................................................................................................19
4.6 Block diagram for scaling factors .............................................................................................................20
5 Process data exchange ................................................................................................................. 21
5.1 Overview .................................................................................................................................................. 21
5.2 Input data ................................................................................................................................................. 21
5.2.1 Position data format .........................................................................................................................21
5.2.2 Speed data format............................................................................................................................21
5.2.3 Acceleration data format...................................................................................................................22
5.2.4 Temperature data format ..................................................................................................................22
5.2.5 Status data format ............................................................................................................................22
5.3 Output data............................................................................................................................................... 23
5.3.1 Control byte data format...................................................................................................................23
5.3.2 Position preset..................................................................................................................................24
5.3.3 Reset options ...................................................................................................................................24
5.3.4 Firmware update ..............................................................................................................................24
6 Setting-up operation ......................................................................................................................25
6.1 Prerequisites ............................................................................................................................................ 25
6.2 Inserting the NOCIO................................................................................................................................. 25
6.3 Changing parameters .............................................................................................................................. 26
7 Encoder and cam parameters .......................................................................................................29
8 Diagnosis overview........................................................................................................................36
8.1 Error types ................................................................................................................................................ 36
8.1.1 Device error .....................................................................................................................................36
8.1.2 Critical (hard) error: ..........................................................................................................................36
8.2 Error register 0x1003................................................................................................................................ 36
8.3 LED ashing code .................................................................................................................................... 37
Appendix ............................................................................................................................................ 38
A.1 Calculation of the cam and encoder checksums .....................................................................................38

Date: 16 Mar 2022 Page 4 of 38 Document no. NOC 15597 EE
NOCIO - Cam encoder with IO-Link interface
1 Safety instructions
1.1 Scope
This user manual is valid exclusively for the following absolute switching cam encoder with IO-Link interface:
• NOCIO79-xxxx-xxxxRxxxxSxxxLxx
1.2 Documentation
The following documents must be observed:
• The owner's system-specic operating instructions
• This user manual
• Data sheet number 15893
• The connection assignment enclosed with the device
• Assembly instructions number 16169 available on our homepage
1.3 Proper use
The TWK-ELEKTRONIK GmbH absolute encoders and linear transducers are used to register angular or linear
positions and make their measured value available in the form of an electrical output signal. As part of a system,
they have to be connected to the downstream electronics and must only be used for this purpose.
1.4 Commissioning
• The relevant device may only be set up and operated in combination with this manual and the
•documentation specied under point 1.2.
• The product is intended for use in industrial machinery applications as dened in the Electrical Standard
•for Industrial Machinery, NFPA 79 and EN 60204-1
• Protect the device against mechanical damage during installation and operation.
• Device commissioning and operation may only be undertaken by a specialist electrician.
• Do not operate the device outside of the limit values specied in the data sheet.
• Do not update the rmware while device is in operation in the application. Customer has to ensure that the
•safety contacts are open in the safety chain.
• Check all electrical connections before commissioning the system.
• If the equipment is used in a manner not specied by the manufacturer, the protection provided by the
•equipment may be impaired.

Date: 16 Mar 2022 Page 5 of 38 Document no. NOC 15597 EE
NOCIO - Cam encoder with IO-Link interface
2 General information
General functional principle
NOCIO is a backlash-free electronic switching cam encoder
withup totwo galvanicallyseparated safety switchingoutputs.
The NOCIO is a safety device and certied according to IEC
61508 (SIL2) and ISO 13849 (PLd).
A congurable multiturn absolute encoder with IO-Link
interface and switching cams with separate controller are
integrated in the compact housing. The supply voltage, IO-
Link signal and safety switching contact are each galvanically
separated from each other.
Encoder and cam parameters can be accessed and changed
via the IO-Link interface.
A special shaft design appropriate to the play-compensating
measurement gear ZRS is available.
NOCIO has a number of error detection procedures and self
diagnosis functions as required by a safety design. Any
detected error (at encoder and cams) is indicated by
transmitting an error message via IO-Link and by opening
the safety contact. Errors are recorded in a device error
history object (0x1003) for diagnosis.
To avoid parameter changes during normal operation, the
parameters can only be amended when the rotating speed
of the encoder shaft vsis approximately zero. Otherwise,
the new parameters are not accepted and the valid ags
0xXXFEcannotbesetto0xA5.Anerrormessageisgenerated.
Rotary encoder
The rotary encoder has a standard IO-Link interface (no
safety protocol). The position signal has a resolution of up
to 15(16) bits per revolution with a measuring range of 4096
revolutions. The resolution can be reduced on customer
request. The position reading can be referenced / preset
using IO-Link protocol. The signal path (CW/CCW) can be
set.
The NOCIO also provides a speed and acceleration signal
via the cyclic IO-Link data. The switching outputs can be
triggered by position, speed and/or acceleration.
Switching outputs (→cams)
Thesafetyswitchingoutputsarepotential-freeandgalvanically
separated. They are controlled by electronic cams which
can be congured according to the customers application.
Switching outputs are implemented using forcibly driven
safety relays with a long service life. Each safety contact
consist of two relays connected in series. These two relays
switch with a brief oset (in the millisecond range). This
guarantees reliable contact separation - even when switching
high external voltages and/or currents. A separate controller
unit monitors the function of the switching outputs. If incorrect
switching is detected, an error will be output and the relays
open.
The switching contacts are normally open contacts. In normal
operating the contact is closed and the relay coils are
powered. They open when the position / speed / acceleration
limits are reached, a fault is detected, the supply voltage is
too low or when the NOCIO is shut o completely.
The triggering limits (low and high limits) can be congured
via IO-Link. Customer-specic switching procedures can
also be implemented in the factory.
The switching information for the cams/relays is taken from
the rotary encoder. The switching outputs are activated and
deactivated without backlash, electronically and wear-free
in contrast to a mechanical switching cam encoder. A small
hysteresis can be activated to avoid contact ickering.
Direct and alternating voltage can be switched.
Alternative connector assignments can be realised on
customer's request.

Date: 16 Mar 2022 Page 6 of 38 Document no. NOC 15597 EE
NOCIO - Cam encoder with IO-Link interface
3 Installation instructions
3.1 General
For the planning of the cabling and installation please note the "IO-Link Design Guideline, Order No. 10.912"
from the IO-Link community (https://io-link.com/en/).
3.2 Electrical connection
The NOCIO79 has two connectors M12 A-coded:
The IO-Link port is a class A type. This means a three-core unshielded control line is sucient for cabling. Four
core cables are permissible because the Pin 2 of the NOCIO is not connected. The switching contacts are nor-
mally open contacts. For the detailed connection diagram please refer to the data sheet no. NOC15893.
Connection name connector
IO-Link S1 M12x4 A-coded pins
Switching outputs S2 M12x5 A-coded socket
Switching outputs IO-Link

Date: 16 Mar 2022 Page 7 of 38 Document no. NOC 15597 EE
NOCIO - Cam encoder with IO-Link interface
3.3 Status LEDs
The NOCIO is equipped with one bi-colour device status LED, and up to two LEDs for the relay status (yellow
LED for safety contacts, green for non-safety contacts).
A preset command is acknowledged by the device LED with 2s of ashing at 5 Hz. If the command has been
carried out successful, the LED ashes green. If the command is not accepted (e.g. due to inappropriate cam
states) the LED ashes red.
3.4 IODD le
An IODD le to integrate the switching cam encoder into a IO-Link master software is available for download on
our website www.twk.de. This describes the features of the IO-Link subscriber in the standardised XML format.
Every NOCIO variant has its own IODD le for exact identication.
Device
LED
Relay 2
LED
Relay 1
(safety)
LED
Description
green / red green or yellow yellow
green on Operating voltage available
green ashing Encoder exchanges data with master
Short term: preset acknowledge (see below)
red on Encoder error (see handbook for details)
red ashing Hard error (ashing codes see handbook)
Short term: preset acknowledge (see below)
on Relay 1 (safety) contact is in condition TRUE
(contact is closed)
on Relay 2 (only if installed) contact is in condition TRUE
(contact is closed)
3 Installation instructions

Date: 16 Mar 2022 Page 8 of 38 Document no. NOC 15597 EE
NOCIO - Cam encoder with IO-Link interface
4 System description
Singleturn
Multiturn
Speed
Accele-
ration
Input-source for cams
Cam 1-4
specications
13x0
-source
-low limit
-high limit
-hysteresis
-enable
-polarity
Cam
state
1300
Cam
statusbit
0,1,2,3
Relay1/2
assign
30x0
-cam 1
-cam 2
-cam 3
-cam 4
Relay
acknowledge
control bits or 30FC
Cam
FALSE f.
30FD
Relay
statusbit
4/5
Relay
1
Relay
2
Cam control Relay control
Cam 1
Cam 2
Cam 3
Cam 4
TRUE / FALSE
TRUE / FALSE
Code path 1100
Reference 1100
Gate time 1100
Multiplier 1100
Divider 1100
Relay1/2
acknow. cong
30x0
-acknowledge
-automatic
Process
data output
Gear module
1100
-inactive
-active:
-gear numerator
-gear denomin.
-resolut. Rrim
Position
specications
Position control
-resolution 64
-Nbr. steps 65
-genuine resolut.
(15/16 Bit)
4.1 Principle function diagram of cams and relays
NOCIO provides 4 cams. A cam is a software module which compares the input signal (source) with limits which are deposit
as a parameter set for each cam. For each dierent source (e.g. position, speed and acceleration) a set of limits is valid.
Therefore these limits have to be adapted to the chosen source. The other cam parameters as well.
If no limit is exceeded the cam is in the TRUE state. If a limit is exceeded, the cam changes to the FALSE state. But this is
only when the related cam is enabled via Cam enable (13x0/05). If not enabled the cam is always in the FALSE state, even
it is inverted.
When a cam is inverted via Cam polarity (13x0/06) the TRUE and FALSE states are swapped. The actual state (limit exceeded
or not) of each cam can be read out via Cam state (1300). In addition the state of each cam is displayed in the status word
(bits 0 to 3). Cam = TRUE means status-bit = 1.The status bits and the status in object 1300 display always the actual state
of the cams without regarding the Acknowledge command (30FC or bits 0/1 in control byte - see below), because the
acknowledge command refers to the relay status only (set TRUE).
The relay outputs can be assigned to any cam (1 to 4) and to more than one cam simultaneously. This is done via object Relay
assign (30x0/01). Therefore the relays can react to several cam limits and to several sources. The particular relay contact is
closed (TRUE) when no limit is exceeded and therefore the cam(s) is (are) TRUE as well. It changes to the FALSE state when
limits are exceeded, which is indicated by the cams (FALSE). Therefore we have: cam = TRUE means relay = TRUE and vice
versa. If a cam is inverted by 13x0/06 (cam polarity) the cam is FALSE when no limit is exceeded and TRUE when source value
is outside the limits.
If a relay is assigned to more than one cam, the cams are combined with logical "and" (&) → relay = TRUE when cam1 &
cam2 & ... = TRUE.
The state of each relay can be supervised by status bit 4 (relay 1) and status bit 5 (realy 2) in the status word. In addition the
reset behaviour of a relay can be determined via object 30x0/02: Automatic or Acknowledge. At automatic the relay changes
to the state TRUE as soon as no limit of the assigned cams is exceeded any more (related cam = TRUE. Be aware of cam
polarity). At acknowledge the user has to send the acknowledge command (via 30FC or bit 0/1 in control byte) to set relays
TRUE again. But the relay(s) change(s) to the state TRUE only when all related cams = TRUE.
If 30x0/02 is set to "1" (=acknowledge) after boot up of NOCIO the acknowledge command has to be sent to NOCIO once to
set the relay to condition TRUE (NOCIO = "operational").
The relays can be tested at any time (and state of NOCIO) via object Cam FALSE forcing (30FD). The PLC or safety chain
has to ignore the relay trip in case of test. This object has no inuence on the relays directly but on the cams. To do the test,
the relay(s) have to be TRUE – means the relays are assigned to one/more cams with are (all) TRUE and valid ags are set
“A5”. With 30FD the cam(s) are set to FALSE by force (input “1” for related cam(s)). Therefore the relay goes into condition
FALSE and the user can see that the contact opens properly. After that the user inputs “0” for the related cam(s) (at any time
later) for setting the cam(s) TRUE again. Relay closes again after acknowledge command (if ackn. = active) and test is done.
With the gear module (1100/09/A/B) the user has the possibility to calibrate the output signals (position/speed/acceleration)
to the rim of a gearbox (rim / pinion) to which the shaft (pinion) of the NOCIO is mechanical connected to. The number of teeth
of rim and pinion and the desired output resolution has to be inserted in the gear module. It can be activated / deactivated.
See handbook 15597 for the full list of parameters and the safety parameterization process (CRC checksums, etc.)

Date: 16 Mar 2022 Page 9 of 38 Document no. NOC 15597 EE
NOCIO - Cam encoder with IO-Link interface
4 System description
Function
The function of the switching outputs is implemented by means of relays. Each relay (safety or non-safety) provides a normally
open (NO) contact. It is open when NOCIO is not under power or in the error state (error detected due to internal diagnosis
routines). The safety contact provides a "forcibly driven" safety relay. Its control contact is used for detection of the proper
function of the main contact. The customer contact is internally build by two contacts (relays) connected in series due to one
operational relay (the forcibly driven one) and one additional redundant relay (normal relay). So reliable contact separation is
provided. The non-safety switching contact is designed with a standard relay with high reliability (but not PL d capable).
All switching outputs are galvanically separated in terms of operating voltage and IO-Link. The whole PCB electronic is
separated to the housing due to the recommendation of IO-Link specications.
The NOCIO's absolute encoder sends the shaft position data (position / speed / acceleration) to the main controller. The main
controller informs the relay controller when to open / close which relay (see diagram above). The exact position of the switching
anks, i.e. calibration of the cams, can be carried out via parameterisation by IO-Link.
The relay can trigger on shaft position or shaft speed and shaft acceleration (parameter "cam source"). For every trigger
source there is an individual set of related limit parameters (see table above). Each relay output can be assigned to one or
more cams. Note, that the cam limits are both part of the TRUE state (see below)
If the relay contact has been triggered by position or speed / acceleration, it can be reset automatically when the related cam
limit is not exceeded any more. Or it has to be reset by an IO-Link command. Parameters: Relay acknowledge (30FC) or
appropriate bit in the control byte.
The proper operation of the relay contact can be tested within normal operation of NOCIO: parameter Cam FALSE forcing
(30FD).
The position switching anks of the switching output are set as follows in the factory as regards the angular position of the
shaft: see cam diagram below.
The switching output switching anks refer to the IO-Link output signal of the absolute encoder. If the position signal's
preset function is used (IO-Link output signal oset), the switching anks are also accordingly shifted with reference
to the shaft position.
To avoid undesired switching back and forth (utter) on the part of the relays as a result of slight bit changes on the switching
ank, a switching hysteresis of 10 digits is pre-programmed. This can be changed via IO-Link. Valid for function Automatic.
Else the contact remains open until acknowledgement.

Date: 16 Mar 2022 Page 10 of 38 Document no. NOC 15597 EE
NOCIO - Cam encoder with IO-Link interface
Cam diagram (for position triggering - linear presentation)
A possibility for realising limit switch with a detection possibility, whether the working are has been exceed in CW or CCW
direction by using two cams (here cam 1 & 2) is shown below.
Note, that the circle can be extended above the maximum position value. When the cam high limit is smaller than the cam
low limit, the cam is extended over the inverted pitch circle.
In this case the status bits 0 (cam1) and 1 (cam2) are used/active. Working area is outside low- and high-limits of cam1 and
cam2. Therefore, cams have to be inverted. Relay = TRUE when cam1 & cam2 = TRUE.
4.5 turns for the cam length is exemplary. It can be any other length.
Cam 1 high limit has to be set to cam 2 low limit in order to close the circle (see below).
5 System description
Relay assigned
to cam1 & cam2 TRUE
= middle of measuring
range (TMR/2)
= 2048 turns
Shaft position
CCW - shaft rotation
← increasing position values decreasing position values →
CW - shaft rotation
Cam1 High Limit Cam2 Low Limit
FALSEFALSE
FALSE
TRUE
TRUE
FALSE
4.5 turns
4.5 turns
autom.
acknow.acknow.
autom.
acknow. acknow.
Relay
Cam 1
(inverted)
Cam 2
(inverted)
Working area → outside cam limits
Cam2 High Limit
Cam1 Low Limit
Relay
TRUE
middle of measuring range (TMR/2) = 2048 turns
Shaft position
CCW -
shaft rotation
← increasing position values decreasing position values →
CW - shaft rotation
Cam1 Low Limit Cam1 High Limit
FALSEFALSE
Cam 1
(not inverted) FALSE
TRUE → Low limit ≤ value < High limit
FALSE
Working area → Low limit ≤ value < High limit
4.2 Cam setting for position trip
Cam diagram (for position triggering)
First possibility for realising limit switch in CW and CCW direction by using one cam (here cam1).
In this case only statusbit 0 (cam1) is used/active. Working area is within low- and high-limit. Alarm area is outside limits