Product Information

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

With additional measures:suitable for safety-related
applications with up to SIL 3

11/2022

General information

KCI 120 Dplus

62



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

127 °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 0.056 kg (scanning unit and rotors; 1 x steel hub)
 0.047 kg (scanning unit and rotors)

ID number

Individual packaging:
ID 1285758-03 (AE scanning unit)
ID 1289200-04 (disk/hub assembly: Encoder A)
ID 1289199-05 (disk/hub assembly: Encoder B)
ID 1369822-02 (disk with steel hub: Encoder B)



X
3.5
7.5
2.5

50
Y
0.3 ± 0.15

15 15
0.005
 15.7 h6
0.05 B

50

A

Y
5:1

13
90°...120°
 4.5 ± 0.1
M3
4x
30°

 13.512x, sharp edges
 0.1 AZ

Rz 6,3

3

Free of burrs

A

 11

1

R2.25 ± 0.05

5°3x120°

1

.3
R0
12

11

TKN
a

  16

R1

  21Rz 6.3

 = Bearing of motor shaft
 = Bearing of output shaft
 = Required mating dimensions
12
M = Measuring point for operating temperature and vibration
1 = 15-pin PCB connector
2 = Shown with customer side
3 = Encoder B mating dimension (motor-side):
Tolerance includes compensation of the mounting tolerances and thermal expansion
4 = Encoder A mating dimension (output side):
Tolerance includes compensation of mounting tolerances and thermal expansion
5 = Axial runout after press-fitting
6 = M3 ISO 4762 - 8.8 MKL (4x) with spring washer: DIN 6796 - 3 - FSt (4x);tightening torque: 1.0 Nm ±0.1 Nm
7 = Minimum engagement depth of screw 6 starting at surface of the scanning unit
8 = Direction of rotation of both shafts for ascending position values
9 = Ensure installation space for cable
10 = Ensure space for electronics; see also the mating dimension model
11 = Rounded transition
12 = Valid for mounting with an axial stop
13 = Chamfer at start of thread is obligatory for materially bonding anti-rotation lock
14 = Mounting without axial stop (Encoder B)
15 = Permissible inside diameter in the press-fit area

2

5:1

11

R1

4x
0.08 A



4
1.5

0.5

 5.1

B

10 4.2A 3.3 ± 0.1

2Z  12   14.2

6.8 ± 0.1

  14   17.2


 9 ± 0.2

≥ 5.5
1

+0.10

2:1

14  812.5

 4.7 –0.05

X

1.5

a



 22

57°



0.005
0.05 A

05
0.
5±
 x)
(4

81



Interface0.1 B

 9 ± 0.2
 0.2 A 4x5

 2 ± 0.0
4x

A-A
5:1

KCI 120 Dplus



34.5

 39

 39.5 26

31

29.5 ± 0.3
50 ± 0.05

 74

5Specifications

1 ± 0.3

 58





 17 ± 0.008

50 ± 0.05

 1 ± 0.5

(20)

≥ 36

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

5°

1)

2

2

Collective package:
ID 1285758-53 (AE scanning unit)
ID 1289200-54 (disk/hub assembly: Encoder A)
ID 1289199-55 (disk/hub assembly: Encoder B)
ID 1369822-52 (disk with steel hub: 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 peak2)

10B
(steel)TKN 03B (aluminum)
03B (Alu) 10B(Stahl)a 19 h6  19,2h6h6
¬ 19 h6¬ 19.2

Product Information KCI 120 Dplus  11/2022

Product Information KCI 120 Dplus  11/2022

3

Position measurement

Mounting
Mounting and protection rating

Specifications

KCI 120 Dplus singleturn
Output side (Encoder A)

KCI 120 Dplus singleturn
Motor side (Encoder B)

Functional safety
for applications with up to

As a single-encoder system for monitoring functions and control-loop functions:• SIL 2 as per EN 61508 (further basis for testing: IEC 61800-5-3)• Category 3, PL d, in accordance with EN ISO 13849-1:2015
With additional measures as per document 1000344, suitable for safety-related applications
with up to SIL 3 or Category 4, PL e
Safe in the singleturn range of both axes

PFH (each encoder)

SIL 2: ≤ 15 · 10–9 (probability of dangerous failure per hour)
SIL 3: ≤ 2 · 10–9

Safe position1)

Encoder: ±0.44° (safety-related measuring step SM = 0.176°)
Mechanical coupling for shaft: 0° (fault exclusion for the loosening of the shaft coupling andstator coupling, designed for accelerations at the stator: ≤ 400 m/s2; at the rotor: ≤ 600 m/s2)

Shaft

Hub with an inside diameter of 15.7 mm

Hub with an inside diameter of 19 mm and19.2 mm (steel)

Shaft speed 6000 rpm

 15 000 rpm

Moment of inertia of rotor

5.5 · 10–6 kgm2 (without supporting ball bearing)

2.0 · 10–6 kgm2 (steel: 4.1 · 10–6 kgm2)

Axial motion2)±0.3 mm±0.5 mm

Position values per revolution

1 048 576 (20 bits)

524 288 (19 bits)

System accuracy

±40”

±120”

Mounting and protection rating
The KCI 120 Dplus is mounted by pressfitting the two disk/hub assemblies andattaching the scanning unit. The disk/hub
assemblies are press-fitted onto therespective shaft, and the scanning unit ismounted to the mating surface through thefour holes.
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 proper use. These
requirements must be followed, evenwhen new disk/hub assemblies are pressfitted onto a mating shaft that has alreadybeen used. Once the lower limit of thepress-fit force has been exceeded, thepress-fit force being applied must remain

within the specified range for the rest of theprocedure until the final position is reached.
The circular scale with a steel hub may bepress-fitted only onto a steel shaft, and thecircular scale with an aluminum hub may
be press-fitted only onto an aluminum
shaft.
If the application features functional safety,
then, after the mounting or installation of
the encoder onto the mating surface, thedevice must be protected from at least the
ingress of solid foreign objects inaccordance with an IP6x protection rating,as well as from the ingress of liquids (theprotection rating for liquids depends on theapplication, e.g., IPx5: protection fromwater jets). If exposure to contamination,such as dust and liquids, can be excluded,
then a protection rating of at least IP40
when mounted is sufficient.

More information:
Follow the measures forelectromagnetic compatibility describedin the General electrical information in
the Interfaces of HEIDENHAIN
Encoders brochure to ensure
disturbance-free operation.

1)	Further tolerances may arise in the downstream electronics after position value comparison(contact mfr. of the downstream electronics)
2)
Including thermal linear expansion and mounting tolerance

Disk/hub assembly (Encoder B)

Scanning unit

PCB connector

Disk/hub assembly (Encoder A)
Optional: press-fitting of a supporting ball bearing

4

Product Information KCI 120 Dplus  11/2022

Product Information KCI 120 Dplus  11/2022

Graduated disks and scanning unit (mounted)

5

Mechanical fault exclusion

Customer motor shaft

Customer output shaft

Customer stator

Material

Hardenable wrought aluminumalloy(steel: alloyed hardened steel)

Hardenable wrought aluminumalloy

AluminumTensile strength Rm

 260 N/mm2(steel:  800 N/mm2)

 215 N/mm

2

 220 N/mm2

Yield strength Rp0.2 oryield point Re

 240 N/mm2(steel:  550 N/mm2)

 160 N/mm

2

Not applicable

Shear strength τa

Not applicableNot applicable 130 N/mm

Interface pressure pG

Not applicableNot applicable 250 N/mm2

Modulus of elasticity E(at 20 °C)

69 kN/mm to 71 kN/mm(steel: 190 to 215 kN/mm2)

69 kN/mm to 71 kN/mm

70 kN/mm2 to 75 kN/mm2

Coefficient of thermal
expansion Þtherm (at 20 °C)

–6 –1
–6 –1
23 · 10 K to 24 · 10 K
–6 –1
(steel: 10 · 10 K to
12 · 10–6 K–1)

–6 –1
23 · 10 K to
24 · 10–6K–1

 25 · 10–6 K–1

Surface

Anodized coating permissible(steel: not relevant)Anodized coating permissible

Surface roughness Rz

 6.3 µm
(steel:  12.5 µm)

 6.3 µm

Friction values

Lubrication at the joint surfaces is recommended.

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

Tightening procedure–

Use a signal-emitting torquewrench as per DIN EN ISO 6789.
accuracy: ±6 %Mounting temperature

15 °C to 35 °C

Z

 

 1.5
Z



 10 /  15



4:1

Faxial = 15 N
Flateral = 33 N

1 =	Supporting flange for stator connection;
type of material in accordance with the “Customer stator” column in the table;
Maximum permissible overall mass (including additional components): 0.130 kg
Surface roughness in the area of the joints: Rz  16 μm
2 =	Spring washer: DIN 6796 – 3 – FSt (4x)Ensure correct positioning with the convex side facing the screw head
3 =	Screw: M3 ISO 4762 – 8.8 – MKL (4x)Tightening torque: 1.0 Nm ±0.1 Nm
4 =	Minimum engagement depth starting at the surface of the scanning unit;
see also the dimension drawing
5 = Board thickness at screw connection
6 =	Optional supporting ball bearing for measured shaft;
Service life and permissible bearing load must not be exceeded;
The ball bearing must not be blocked
7 =	Maximum permissible forces acting on the screw connection
		 – To be applied to at least two diagonally opposing screws with a spring washer, which must
immediately adjoin the supporting flange 1
		 – Valid for all operating conditions. Additionally arising forces (e.g., from a vibration load andtorque) must be taken into account:
Flateral = 33 N
Faxial = 15 N

6

Rotary encoders may exert a torque of up
to 1 Nm on the mating shaft. The customerside mechanical design must be made forthis load.

The following material properties andconditions for the mating surfaces are
assumed for the fault exclusion design forfunctional safety.

2

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

Product Information KCI 120 Dplus  11/2022

2

2

Mounting accessories
Screws: M3 ISO 4762 – 8.8 MKL, andspring washers: DIN 6796 - 3 - FSt.
Instructions for use: use screws withmaterial bonding anti-rotation lock as per
DIN 267 27 (see the Rotary Encoders
brochure, under General mechanicalinformation). Fastening screws and spring
washers must be ordered separately.

Product Information KCI 120 Dplus  11/2022

22

 16 µm

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

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. Please bearin mind that this measurement andtransmission of the temperature is not safein terms of functional safety.

HEIDENHAIN encoders provide all of theinformation 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 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

Each axis of the rotary encoders features
a further, 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.

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.

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 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

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  11/2022

DRIVE-CLiQ is a registered trademark of Siemens AG.

Product Information KCI 120 Dplus  11/2022

9

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.

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

Power supply

Testing cable for connection to Encoder A: 1311046-xx
15-pin PCB connector
15Power supply

15

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!

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 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.

15

15

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

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

www.heidenhain.com

10

Serial data transmission(Encoder B)

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

Serial data transmission(Encoder A)

Power supply

Serial data transmission(Encoder A)

Product Information KCI 120 Dplus  11/2022

1335409 · 02 · B · 02 · 11/2022 · 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:• Brochure: Encoders for Servo Drives					 208922-xx• Operating Instructions							1364844-xx• Product notes for JAE connecting element				  576762-xx										 (Sheet 1)• Technical Information: Safety-Related Position Measuring Systems
596632-xx• For implementation in a functionally safe control or inverter:
Specification:								 533095-xx
Specification Supplementary Catalog of Measures (SIL 3, PLe)		
1000344-xx• Setup instructions								 1082415-xx