Product Information

KCI 120 Dplus
Absolute Inductive
Rotary Encoder withAdditional Functionality:
Position measurement
at the output side

01/2023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)• Additional position measurement at the output side

 9.5

 

 

M1

M1

(

Rzmax 16


5°

 


82



82

 

1

3) 3)
32. 32.
(36

 3 
 0.05 A 3  2

49.20.5 440.3

 480.3

2.90.3
2.90.3

  
0.1C0Z.1 CZ
4x 4x
 75 75



-0.5

M2

 
36

Z

M2


2
 2

33.4





60.5 60.5(13) (13)30.3

 0.2 A

Z
10:1

33.4
30.3



4





 10.530.3

6108° 108°

30.3

80.5

 12.7 12.7
14.3 14.3

 
A

 
7





 






  

 480.3

 38

 35 h7 590.5

A



Z
10:1
4
15.5

A




Rzmax 161

 5°

11.20.5

 = Bearing of mating shaft
 = Required mating dimensions
1 = Scanning unit (AE), separate; for mounting, see the respective mating dimensions.
2 = Rotor B mating dimension; tolerance includes compensation for the mounting tolerances and thermal expansion;
dynamic motion permitted over entire range
3 = On the fine track ( 42 mm to  48 mm), after press-fitting
4 = Rounded transition to the fit surface
5 = Required fit length on the mating shaft
6 = Bearing surface of scanning unit (AE)7 = Rotor A mating dimension; tolerance includes compensation for the mounting tolerances and thermal expansion;
dynamic motion permitted over entire range
8 = Axial runout after press-fitting
9 = A suitable support bearing is permissible but optional;
permissible forces and torques during operation:– Axial force: 40 N
– Radial force: 40 N
– Torque: 0.5 Nm

2

 

Z

 0.1 A

A-A A-A
3:1 3:1

(7)

10.3

 

 29 h6
 0.05 A

9.2
7.2

(7)

A

Product Information KCI 120 Dplus  01/2023

M1 = Measuring point for operating temperature;ensure electrical isolation for the mounted temperature sensor
M2 = Measuring point for vibration
1 = 15-pin PCB connector
2 = Cylinder head screw
DIN EN ISO 4762 – M2.5 x12 – 8.8 – MKL* or
DIN EN ISO 14583 – M2.5 x12 – 8.8 – MKL (ID 202264-61);
tightening torque: 0.7 Nm ±0.05 Nm, with spring washer: DIN 6796 – 2.5 – FSt,
and washer: ID 1334909-01
Pay attention to the mounting position of the spring washer!
3 = Ensure installation space for cable
4 = Direction of shaft rotation for ascending position values
5 = TKN for Rotor A, separate; for mounting, see the respective mating dimensions
6 = TKN for Rotor B, separate; for mounting, see the respective mating dimensions
7 = Holes as an option for aligning the scanning unit by means of a device;
0.2CZ
0.2 CZ
centered position relative to reference A after mounting: 
8 = Room for supporting flange for Rotor A; avoid collision with the scanning unit
9 = Ensure > 1 mm gap for air and creepage distances* Instructions for use: screw with material bonding anti-rotation lock as per DIN 267-27;
see General mechanical information in the Rotary Encoders brochure (screw not included in delivery!)

Product Information KCI 120 Dplus  01/2023

3

General information

K2



82

H6

K1

K3

  0.1 A
108°

A

A
Z
5:1

4x 90°
B



 75

.5

2.

5

9

4x
  0.1 A

C-C
2:1



4x
  0.1 A

4x  0.1 A2±90°...120°

KCI 120 Dplus

Interface

EnDat 2.2

Ordering designation

EnDat22

Calculation time tcal
Clock frequency

 5 µs 16 MHzElectrical connection

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

Supply voltage

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

Power consumption (max.)2)

At 3.6 V:  1.2 W
At 14 V:  1.4 W

Current consumption (typical)

At 5 V: 180 mA (without load)

Angular acceleration of rotors

 1 · 105 rad/s2

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

125 °C (measuring accuracy of the internal temperature sensor: ±1 K at 125 °C)

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 0.1 kg (scanning unit and rotors)

ID number

Individual packaging:
ID 1362008-01 (AE scanning unit)
ID 1362006-01 (disk/hub assembly: Encoder A)
ID 1362007-01 (disk/hub assembly: Encoder B)



3

0.

1

0.

M

9

6

9
(4x)

30°


4x
  0.1 B

C

B-B
2:1

 75

Z

5
1. .5
0

 75

9
(4x)

B

-0.5

A-A
2:1

4x 90°

C02

4x 90°

Specifications

K1

K2

K3





4x
 0.08 CZ A
Burr-free

1)

2

2

Collective package:
ID 1362008-51 (AE scanning unit)
ID 1362006-51 (disk/hub assembly: Encoder A)
ID 1362007-51 (disk/hub assembly: Encoder B)

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)

4.5



 = Bearing of mating shaft
K1 = 
Mating dimensions on the customer side;
mounting with centering collar
K2 = 
Mating dimension on the customer side;
mounting with cylindrical pins (not available as an accessory)
K3 = 

Customer-side mating dimensions;
mounting with mounting device (not available as an accessory)
1 = Ensure space for electronics; see also the mating dimension model
2 = Flange surface: ensure full-surface, burr-free contact!
3 = Chamfer at start of thread is obligatory for material bonding anti-rotation lock
K1
4 = For thread dimensions, see 

4Product Information KCI 120 Dplus  01/2023

Product Information KCI 120 Dplus  01/2023

5

Position measurement

Mounting
Mounting and protection rating

Specifications

KCI 120 Dplus singleturn
Output side (Encoder A)

KCI 120 Dplus singleturn
Motor side (Encoder B)

Shaft

Hub with an inside diameter of 29 mm

Hub with an inside diameter of 34 mm

Shaft speed 6000 rpm

 15 000 rpm

Moment of inertia of rotor

17 · 10–6 kgm2

15 · 10–6 kgm2

Axial motion1)±0.3 mm±0.5 mm

Position values per revolution

1 048 576 (20 bits)

524 288 (19 bits)

System accuracy

±40”

±120”

1)

6

Mounting and protection rating
Mounting the KCI 120 Dplus consists ofthe following: alignment and mounting of
the scanning unit, and press-fitting the two
disk/hub assemblies. The disk/hub
assemblies are press-fitted onto therespective shaft, and the scanning unit ismounted to the mating surface via the fourholes. Alignment can optionally be
performed with a centering collar, withcylindrical pins or with a mounting device.

The press-fitting process may be
performed only once for each disk/hub
assembly. For press-fitting, adhere to thematerial properties and the conditions forthe mating surfaces stated in the relevant
documents for use. These requirements
must be followed, even when new disk/
hub assemblies are press-fitted onto amating 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, including until the final position
is reached.

Mounting the disk/hub assembly (Encoder B)

Alignment with centering collar

Alignment with cylindrical pins

Alignment with mounting device

Mounting of scanning unit

Mounting of disk/hub assembly (Encoder A);
optionally with bearing

For more information:
Follow the measures for electromagnetic
compatibility described in the Generalelectrical information in the Interfaces of
HEIDENHAIN Encoders brochure toensure disturbance-free operation.

Including thermal linear expansion and mounting tolerance

Product Information KCI 120 Dplus  01/2023

Product Information KCI 120 Dplus  01/2023

7

Integrated temperature evaluation

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

Customer motor shaft

Customer output shaft

Customer stator

Material

Unalloyed hardened steel

Hardenable wrought
aluminum alloy

Tensile strength Rm

 600 N/mm2

 220 N/mm2

Yield strength Rp0.2 oryield point Re

 400 N/mm2

Not applicable

Shear strength τa 390 N/mm2

 130 N/mm2

Interface pressure pG

 660 N/mm2

 250 N/mm2

Modulus of elasticity E(at 20 °C)

200 kN/mm to 215 kN/mm

Coefficient of thermal
expansion Þtherm (at 20 °C)

10 · 10

Surface roughness Rz

 16 µm

Friction values

Lubrication at the joint surfaces is recommended.

Tightening procedure

Use a signal-emitting torque wrench as per DIN EN ISO 6789, with an accuracy of ±6 %Mounting temperature

15 °C to 35 °C

2

–6

2

K–1 to 12 · 10–6 K–1

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

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. Pleasebear in mind that this measurement andtransmission of the temperature is not safein terms of functional safety.
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.

Mounting surfaces must be clean
and free of grease.
Use screws and washers in theircondition as delivered.

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.
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.

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

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

8

Instructions for use: use screws withmaterial bonding anti-rotation lock as per
DIN 267 27 (see 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 tested with the PWM 21 and the ATS
software (see document ID 1082415).

Product Information KCI 120 Dplus  01/2023

Product Information KCI 120 Dplus  01/2023

9

Testing and inspection devices, and diagnostics

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.
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 diagnostic 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

This enables the downstream electronics
to evaluate the current status of theencoder with little effort, even in closedloop mode.
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 testing or
inspection 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.

Electrical connection

When a special testing cable is connectedto the PWM 21 diagnostic and testing
device, Encoder A (output side) isconnected. In order to connect Encoder B(motor side), a different special testing
cable must be used.

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.

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

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

Mounting accuracy with the PWM 21 and ATS software

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

PWM 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.

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

10

Power supply

Serial data transmission(Encoder B)

PWM 21
Encoder input• EnDat 2.1, EnDat 2.2, or EnDat 3 (absolute value with orwithout 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

15

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!

DRIVE-CLiQ is a registered trademark of Siemens AG.

Product Information KCI 120 Dplus  01/2023

Product Information KCI 120 Dplus  01/2023

11

Pin layout for the rotary encoder
15-pin PCB connector
15Power supply

Serial data transmission(Encoder A)

Serial data transmission(Encoder B)

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

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

Cable length > 0.5 m:
To prevent crosstalk, the two EnDatinterfaces must be separately shieldedfrom each other. The cable sold by themeter with ID 1347450-xx (PUR,
 3.7 mm) can be used for this. Two cables
must be attached to the PCB connector inorder to transmit 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 thegeneral 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.

DR. JOHANNES HEIDENHAIN GmbH
Dr.-Johannes-Heidenhain-Straße 583301 Traunreut, Germany +49 8669 31-0
 +49 8669 32-5061
info@heidenhain.dewww.heidenhain.com

1391327 · 00 · A · 02 · 01/2023 · 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 inorder to avoid coupled interferences. 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:• Operating Instructions: TKN KCI 120 Dplus					1375948-xx• Operating Instructions: AE KCI 120 Dplus					1381445-xx