Product Information

KCI 120 Dplus
Absolute Inductive Rotary
Encoder with Additional
Functionality:
Position measurementof output side

10/2021KCI 120 Dplus

Absolute inductive rotary encoder with additional functionality• Robust inductive scanning principle• Consisting of an AE scanning unit and two rotor units (disk/hub assembly)• Position measurement of output side

.3
0

65

 2.6
1

50

0.2


 0.08 A

B

1
5°

 d6
 0.05 A

 .7

 11.38  d580



Rz 6.3 - 16
B

A



a4

B
3:1

57

 d3

.2

 39)

 27±0.2

 25 h7)

 d1)

151°

30°

a2
7.5±0.2

Rz 6.3 - 16
 0.05 B.2 39)

31.5

66°

4

80

)
(6x
R2

28.5

)

10

65

.8)



3°
10

13

(27

  d4

10


M1

67°



3

  d2(2.9)

  41

M2

48°
87°



(a1)





30

R28.5

30

 4.5
 5.3

5°

10

 a3

1±0.3



B

62°

C

 0.2 AC

 0.2 B



146°



B

 7±0.2

A
4:1

53
11

B-B

.5



A

61

C

(2.7)

C-C
90°...120°


2x
 0.05 A

(2.7)

9

M2.5 (3x)

12



C
2:1

 30.1

 1±0.5

E 1.50.02

3x
 0.1 AE

 = Bearing of Rotor A = Bearing of Rotor B
 = Required mating dimensions
M1 = Measuring point for operating temperature
M2 = Vibration measuring point
1 = 15-pin PCB connector
2 = Shown with the customer side
3 = Rotor A mounting dimension: tolerance includes compensationof mounting tolerances and thermal expansion
4 = Rotor B mounting dimension: tolerance includes compensationof mounting tolerances and thermal expansion
5 = M2, 5x12 ISO 4762 or ISO 14583 – 8.8 – MKL * (3x)with spring washer: DIN 6796 – 2.5 – FSt (3x)and washer: ID1334909-01; tightening torque: 0.7 ±0.05 Nm;
pay attention to the installation position of the spring washer
6 = Chamfer at start of thread is obligatory for materially bondinganti-rotation lock
7 = Direction of rotation of both shafts for ascending position values
8 = Ensure installation space for cable
9 = Rounded transition
10 = Ensure space for electronics
11 = Avoid collision with the scanning unit
12 = Distance for air creepage >1 mm
13 = Permissible forces and torques at Hub A (bearing):– Axial force  60 N,– Radial force  60 N,– Torque  0.5 Nm
14 = Material characteristics of customer shafts:
2– Tensile strength  700 N/mm ,2– Yield point  490 N/mm ,– CTE = 10-12 ppm/K

2

FOROA1:
06A, 06B

FOROA1:
07A, 07B

a1

17.6

18.1

a2

4.3

4

a3

7.3

7.8

a4

5.2±0.2

5.7±0.2

d1

28

33

d2

30

35

d3

0
20 -0.020
25 -0.02

d4

18

21

d5

14

18

d6

0
16 -0.0140
20 -0.017

Product Information KCI 120 Dplus  10/2021* For instructions on using screws with material bonding anti-rotation lock as per DIN 267-27,
see “General mechanical information” in the Rotary Encoders brochure (these screws notincluded in delivery!)

Product Information KCI 120 Dplus  10/2021

3

General information

Position measurement

Specifications

KCI 120 Dplus

Specifications

KCI 120 Dplus singleturn
Output side (Encoder A)

KCI 120 Dplus singleturn
Motor side (Encoder B)

Interface

EnDat 2.2

Shaft

Ordering designation

EnDat22

Hubs with an inside diameter of 20 mm
and 16 mm

Hubs with an inside diameter of 25 mm
and 20 mm

Calculation time tcal
Clock frequency

 5 µs 16 MHz

Shaft speed 6000 rpm

 15 000 rpm

Electrical connection

15-pin PCB connector (radial); cable length  10 m

Moment of inertia of rotor

5.5 · 10–6 kg · m2 (without supporting ball bearing) 5.0 · 10–6 kg · m2

Supply voltage

DC 3.6 V to 14 V (for both axes together)

Axial motion1)±0.3 mm±0.5 mmPower consumption (max.)2)

At 3.6 V:  1.2 W
At 14 V:  1.4 W

Position values per revolution

1 048 576 (20 bits)

524 288 (19 bits)

System accuracy

±40”

±120”

Current consumption (typical)

At 5 V: 200 mA (without load)

Online compensation

No

Yes

Angular acceleration of rotors

 1 · 105 rad/s2

1)

Vibration 55 Hz to 2000 Hz3)
Shock 6 ms

AE scanning unit:  400 m/s ; rotors:  600 m/s (EN 60068-2-6)
 2000 m/s2 (EN 60068-2-27)

Operating temperature–40 °C to 115 °C

Trigger thresholdfor exceeded temperatureerror message

127 °C (measuring accuracy of the internal temperature sensor: ±1 K)

Relative humidity

 93 % (40 °C/21 d as per EN 60068-2-78), condensation excluded

Protection rating EN 60529

IP00 (read about insulation under Electrical safety in the Interfaces of HEIDENHAIN Encoders
brochure)Mass 0.065 kg (scanning unit and rotors)

ID number

Individual packaging:
ID 1348258-01 (AE scanning unit)
ID 1348267-01 (TKN: Encoder A, ¬ 20 mm)
ID 1348267-02 (TKN: Encoder A, ¬ 16 mm)
ID 1348268-01 (TKN: Encoder B, ¬ 25 mm)
ID 1348268-02 (TKN: Encoder B, ¬ 20 mm)

1)

2Including thermal linear expansion and mounting tolerance

2

Collective package:
ID 1348258-51 (AE scanning unit)
ID 1348267-51 (TKN: Encoder A, ¬ 20 mm)
ID 1348267-52 (TKN: Encoder A, ¬ 16 mm)
ID 1348268-51 (TKN: Encoder B, ¬ 25 mm)
ID 1348268-52 (TKN: Encoder B, ¬ 20 mm)

1)

See pin layout for encoder
See General electrical information in the Interfaces of HEIDENHAIN Encoders brochure, or visit www.heidenhain.com
3)	Scanning unit: 10 Hz to 55 Hz, 6.5 mm constant peak to peak
Rotors: 10 Hz to 55 Hz, 10 mm constant peak to peak
2)

4

Product Information KCI 120 Dplus  10/2021

Product Information KCI 120 Dplus  10/2021

5

Mounting
Mounting and protection rating

Mounting and protection rating
The KCI 120 Dplus is mounted by pressfitting the two disk/hub assemblies andattaching the scanning unit. The circularscales are press-fit onto the respective
shaft, and the scanning unit is mounted tothe mating surface with the help of thecentering pins. The press-fitting process
may be performed only once for each disk/
hub assembly. For the press-fit, comply
with the material properties and conditions
for the mating surfaces stated in the
documents relevant for proper use. These
requirements must be followed, evenwhen new disk/hub assemblies are pressfitted onto a customer shaft that has
already been used.

Once the lower limit of the press-fit force
has been exceeded, the press-fit force
being applied must remain within thespecified range for the rest of theprocedure until the final position isreached.
When the disk/hub assembly is press
fitted, force may be applied only to theintended surfaces by means of pressing
stamps (see mounting instructions).

More information:
To ensure proper operation, comply
with the measures in the General electrical information under Electromagnetic
compatibility in the Interfaces of
HEIDENHAIN Encoders brochure.

For the design of the fault exclusion,
the following material properties andconditions for the mating surfaces are
assumed.

Customer motor shaft

When using a supporting bearing in
conjunction with the hub of Encoder A, thestated forces and the torque must not be
exceeded:
Axial force  60 N
Radial force  60 N
Torque  0.5 Nm

Customer output shaft

Material

S45C steel as per DIN 1.1191

AluminumTensile strength Rm

 700 N/mm2

 220 N/mm2

Yield strength Rp0.2 oryield point Re 490 N/mm2

Not applicable

Shear strength τa 390 N/mm2

 130 N/mm2

Interface pressure pG

 660 N/mm

2

 250 N/mm

Modulus of elasticity E(at 20 °C)

210 kN/mm

Coefficient of thermal
expansion Þtherm (at 20 °C)

10 · 10

Surface roughness Rz

 6.3 ... 16 µm

Friction values

Lubrication at the joint surfaces is recommended.

2–6

K–1 to 12 · 10–6 K–1

Mounting temperature

Scanning unit

2

70 kN/mm2 to 75 kN/mm2
 25 · 10–6 K–1

Mounting surfaces must be
clean and free of grease.
Use screws and washers intheir condition as delivered.
Use a signal-emitting torquewrench as per DIN EN ISO 6789;
accuracy: ±6 %Tightening procedure

Disk/hub assembly (Encoder B)

Customer stator

15 °C to 35 °C

Mounting tool
To avoid damage to the cable, use themounting aid to disconnect the cable
assembly. Apply pulling force only to theconnector of the cable assembly and not to
the wires.
ID 1075573-01
Mounting accessories
Screws: M2.5 x 12 ISO 4762
or ISO 14583 - 8.8 - MKL andspring washers: DIN 6796 - 2.5 - FSt.
Washer: ID 1334909-01

Scanning unit (mounted)

6

Instructions for use: use screws withmaterial bonding anti-rotation lock as per
DIN 267 27 (see the General mechanicalinformation in the Rotary Encoders
brochure). Fastening screws and spring
washers must be ordered separately.

For more mounting information andmounting aids, see the Mounting
Instructions and the Encoders for Servo
Drives brochure. The mounting quality canbe checked with the PWM 21 and the ATS
software (see document ID 1082415).

Disk/hub assembly (Encoder A)

Product Information KCI 120 Dplus  10/2021

Product Information KCI 120 Dplus  10/2021

7

Integrated temperature evaluation

Testing and inspection devices, and diagnostics

Each axis of these rotary encoders features
an internal temperature sensor integrated
into the encoder electronics. The digitized
temperature value is transmitted purely
serially via the EnDat protocol.

HEIDENHAIN encoders provide all of
the information needed for initial setup,monitoring, and diagnostics. The type of
information available depends on whether
the encoder is incremental or absolute andon which interface is being used.

Regarding the internal temperature sensor,
the rotary encoder supports the two-stage
cascaded signaling of a temperature
exceedance. This consists of an EnDat
warning and an EnDat error message.
In accordance with the EnDat specification,
an EnDat warning (EnDat memory area
“Operating status,” word 1 “Warnings,”
bit 21 “Temperature exceeded”) is output
when the warning threshold for thetemperature exceedance of the internal
temperature sensor is reached. Thiswarning threshold for the internal
temperature sensor is stored in the EnDat
memory area “Operating parameters,”
word 6 “Trigger threshold warning bit forexcessive temperature” of each axis, andcan be individually adjusted.

A device-specific default value is saved
here before the encoder is shipped. The
temperature measured by the internal
temperature sensor is higher by a devicespecific and application-specific amountthan the temperature at the measuring
point, as shown in the dimension drawing.

Absolute encoders employ serial datatransmission. The signals are extensively
monitored within the encoder. The
monitoring results (particularly valuation
numbers) can be transmitted to thedownstream electronics along with theposition values via the serial interface(digital diagnostics interface). The
following information is available:• Error message: position value is notreliable• Warning: an internal functional limit of
the encoder has been reached• Valuation numbers:– Detailed information about theencoder’s function reserve– Identical scaling for all HEIDENHAIN
encoders– Cyclic reading capability

Each axis of the rotary encoders features afurther, albeit non-adjustable trigger
threshold for the “Temperature exceeded”
EnDat error message of the internal
temperature sensor. When this is reached,an EnDat error message is output (EnDat
memory area “Operating status,” word 0“Error messages,” bit 22 “Position” and in
additional data 2 “Operating status error
sources,” bit 26 “Temperature exceeded”).
This trigger threshold may vary dependingon the encoder and is stated in thespecifications.
HEIDENHAIN recommends adjusting thewarning threshold based on the applicationsuch that this threshold is sufficiently
below the trigger threshold for the“Temperature exceeded” EnDat error
message. Compliance with thetemperature at the measuring point isrequired for adherence to the encoder’sintended and proper use.

The downstream electronics are able toevaluate the current status of the encoderwith low resource expenditure, including inclosed-loop operation.
For the analysis of these encoders,
HEIDENHAIN offers the appropriate PWM
inspection devices and PWT testing
devices. Based on how these devices areintegrated, a distinction is made between
two types of diagnostics:• Encoder diagnostics: the encoder isconnected directly to the inspection or
testing device, thereby enabling adetailed analysis of encoder functions.

• Monitoring mode: the PWM inspection
device is inserted within the closed
control loop (via suitable testing adapters
as needed). This enables real-time
diagnosis of the machine or equipment
during operation. The available functions
depend on the interface.

Mounting accuracy with the PWM 21 and ATS software

Electrical resistancePWM 21The PWM 21 phase-angle measuring unit,
in conjunction with the included ATS
adjusting and testing software, serves as
an adjusting and testing package for the
diagnosis and adjustment of HEIDENHAIN
encoders.

PWM 21
Encoder input• EnDat 2.1, EnDat 2.2, or EnDat 3 (absolute value
with or without incremental signals)• DRIVE-CLiQ• Fanuc Serial Interface• Mitsubishi high speed interface• Yaskawa Serial Interface• Panasonic serial interface• SSI• 1 VPP/TTL/11 µAPP
• HTL (via signal adapter)

InterfaceUSB 2.0

Supply voltage

AC 100 V to 240 V or DC 24 V

Dimensions

258 mm × 154 mm × 55 mm

Check the electrical resistance between
the customer-side stator and bothcustomer-side shafts. Nominal value:< 1 ohm

For more information, see the PWM 21/ATS
Software Product Information document.

8

Product Information KCI 120 Dplus  10/2021

DRIVE-CLiQ is a registered trademark of Siemens AG.

Product Information KCI 120 Dplus  10/2021

9

Electrical connection

For connection to the PMW 21 diagnostic
and testing device, Encoder A (output side)and Encoder B (motor side) each require adifferent special testing cable.

Pin layout for the rotary encoder

HEIDENHAIN offers two testing cables forthis purpose. As a result, either a testing
cable for the output-side encoder or atesting cable for the motor-side encoder
can be connected to the PWM 21 asneeded.

15-pin PCB connector
15

Pin layout of the testing cables
Testing cable for connection to Encoder A: 1311046-xx
15-pin PCB connector
15Power supply

15

Serial data transmission(Encoder A)

14

12

13

11

7

8

9

10

0V

Sensor0V

UP

Sensor
UP

DATA
A

DATA
A

CLOCK
A

CLOCK
A

White/GreenWhite

Brown/Green

Blue

Gray

Pink

VioletYellow

Testing cable for connection to Encoder B: 1311047-xx
15-pin PCB connector

14

12

13

11

7

8

9

10

1

2

3

4

0V

Sensor0V

UP

Sensor
UP

DATA
A

DATA
A

CLOCK
A

CLOCK
A

DATA
B

DATA
B

CLOCK
B

CLOCK
B

Cable length > 0.5 m:
To prevent crosstalk, the two EnDat interfaces must be separately shielded fromeach other. The cable sold by the meterwith ID 1347450-xx (PUR,  3.7 mm) canbe used for this. Two cables must be attached to the PCB connector in order totransmit the EnDat signals separately. Only
one cable is used for the power supply.
When using the cable sold by the meterwith ID 1347450-xx, comply with the
General information in the Cables andConnectors brochure; use of the cables attemperatures of up to 100 °C is possible,
provided that the exposure to hydrolysis
and harmful media is low.

15

Power supply

Serial data transmission(Encoder B)

14

12

13

11

1

2

3

4

0V

Sensor0V

UP

Sensor
UP

DATA
B

DATA
B

CLOCK
B

CLOCK
B

White/GreenWhite

Brown/Green

Blue

Gray

Pink

VioletYellow

UP = Power supply
Vacant pins or wires must not be used!
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 

10

Serial data transmission(Encoder B)

UP = Power supply
Vacant pins or wires must not be used!
The subsequent electronics must have a common ground reference!

UP = Power supply
Vacant pins or wires must not be used!

15

Serial data transmission(Encoder A)

Power supply

Product Information KCI 120 Dplus  10/2021

1357726 · 00 · A · 02 · 10/2021 · PDF

Cable length ≤ 0.5 m:
When single wires with up to a maximum
length of 0.5 m are used, each data andclock wire combination must be implemented as a twisted wire pair in order toavoid coupled interference. As analternative, the cable with ID 605090-51(EPG,  4.5 mm) and a length of 0.3 m canbe used. The General information in the
Cables and Connectors brochure must be
noted.

This Product Information document supersedes all previous editions, which thereby
become invalid. The basis for ordering from HEIDENHAIN is always the Product
Information document edition valid when the order is placed.
More information:
Comply with the requirements described in the following documents to ensure correctand intended operation:• Brochure: Encoders for Servo Drives		208922-xx• Brochure: Interfaces of HEIDENHAIN Encoders		1078628-xx• Brochure: Cables and Connectors		1206103-xx• Mounting Instructions: KCI 120 Dplus		1363648-xx• Product Notes for JAE connecting element		 576762-xx(sheet 1)• Setup instructions		 1082415-xx