Product Information

KCI 120 Dplus

Absolute Inductive Rotary
Encoder with Additional
Functionality:

Position measurement of
output side

With additional measures:

suitable for safety-related
applications with up to SIL 3

05/2021
KCI 120 Dplus General information
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

62  1 ± 0.5 Specifications KCI 120 Dplus

50 ± 0.05 (20) 1 ± 0.3 
 5 Interface EnDat 2.2

 17 ± 0.008

  Ordering designation EnDat22

 15.7
29.5 ± 0.3

37 ± 1
31
Calculation time tcal  5 µs
50 ± 0.05 Clock frequency  16 MHz

 39.5
 26
 19

 39
 58
 1)
 74 0.1 B Electrical connection 15-pin PCB connector (radial); cable length  10 m
34.5

5
 2 ± 0.0 Supply voltage DC 3.6 V to 14 V (for both axes together)
4x X 
 x)

3.5 Power consumption (max.)2) At 3.6 V:  1.2 W

5±
(4

57° 7.5 1.5  At 14 V:  1.4 W

0.


05
81

2.5 14  8


 0.2 A 4x
Current consumption (typical) At 5 V: 180 mA (without load)

 9 ± 0.2
12.5 5.5

+0.10
 4.7 –0.05
X
 22

1
2:1
Angular acceleration of rotors  1 · 105 rad/s2

 9 ± 0.2
50

Vibration 55 Hz to 2000 Hz3) 2 2

AE scanning unit:  400 m/s ; rotors:  600 m/s (EN 60068-2-6)
Y
 Shock 6 ms  2000 m/s2 (EN 60068-2-27)
0.3 ± 0.15 Z 2
6.8 ± 0.1 Operating temperature –40 °C to 115 °C
A B

 15.7 h6
  14.2
  17.2

 19 h6
Trigger threshold 127 °C (measuring accuracy of the internal temperature sensor: ±1 K at 125 °C)
50

for exceeded temperature error

message

0.02 A
0.05 B
A-A Relative humidity  93 % (40 °C/21 d as per EN 60068-2-78), without condensation

0.005
0.005
5:1 Y
13
5:1
90°...120° Protection EN 60529 IP00 (read about insulation under Electrical safety in the Interfaces of HEIDENHAIN Encoders brochure)
 4.5 ± 0.1 A 10 4.2
 3.3 ± 0.1  13.5 Mass  0.047 kg (scanning unit and rotors)
12x, sharp edges
M3  0.1 A
4x  5.1 ID number Individual packaging: Collective package:
30° ID 1285758-03 (AE scanning unit) ID 1285758-53 (AE scanning unit)
ID 1289200-04 (disk/hub assembly: Encoder A) ID 1289200-54 (disk/hub assembly: Encoder A)
0.5

Z ID 1289199-05 (disk/hub assembly: Encoder B) ID 1289199-55 (disk/hub assembly: Encoder B)

5:1


4x
4

Rz 6.3
3

0.08 A 1)
1.5

A  11
See pin layout for encoder
Free of burrs 1 2)
See General electrical information in the Interfaces of HEIDENHAIN Encoders brochure or at www.heidenhain.com
R2.25 ± 0.05
5° 1 3)
Scanning unit: 10 Hz to 55 Hz, 6.5 mm constant peak to peak
3x120° Rz 6.3 Rotors: 10 Hz to 55 Hz, 10 mm constant peak to peak
. 3
  21

R0
 11 11 5°
  16
R1

R1

12
12
 = Bearing of motor shaft
 = Bearing of output shaft
 = Required mating dimensions
M = Measuring point for operating temperature and vibration
1 = 15-pin PCB connector
2 = Shown with the customer side
3 = Mating dimension: Encoder B (motor side); the tolerance includes compensation of mounting tolerances and thermal expansion
4 = Mating dimension: Encoder A (output side); the 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)

2 Product Information KCI 120 Dplus  05/2021 Product Information KCI 120 Dplus  05/2021 3
Position measurement Mounting
Mounting and protection rating

Specifications KCI 120 Dplus singleturn KCI 120 Dplus singleturn Mounting and protection rating If the application features functional safety,
Output side (Encoder A) Motor side (Encoder B) The KCI 120 Dplus is mounted by press- then, after the mounting or installation of Further information:
fitting the two disk/hub assemblies and the encoder onto the mating surface, the
attaching the scanning unit. The disk/hub device must be protected from at least the Follow the measures for electromagnetic
Functional safety As a single-encoder system for monitoring and control-loop functions:
assemblies are press-fit onto the ingress of solid foreign objects in compatibility described in the General
for applications with up to • SIL 2 as per EN 61508 (further basis for testing: EN 61800-5-2)
respective shaft, and the scanning unit is accordance with an IP6x protection rating, electrical information in the Interfaces
• Category 3, PL d as per EN ISO 13849-1:2015
mounted to the mating surface through the as well as from the ingress of liquids (the of HEIDENHAIN Encoders brochure to
four holes. protection rating for liquids depends on the ensure disturbance-free operation.
With additional measures as per document 1000344, suitable for safety-related applications with up to
SIL 3 or Category 4, PL e The press-fitting process may be application, e.g., IPx5: protection from
Safe in the singleturn range of both axes performed only once for each disk/hub water jets). If exposure to contamination,
assembly. When press-fitting onto the such as dust and liquids, can be excluded,
PFH (each encoder) SIL 2: ≤ 15 · 10–9 (probability of dangerous failure per hour) shafts, the material properties and the then a protection rating of at least IP40
SIL 3: ≤ 2 · 10–9 conditions for the customer's mating when mounted is sufficient.
surfaces stated in the relevant documents
Safe position1) Device: ±0.44° (safety-related measuring step SM = 0.176°) must be adhered to for the intended
Mechanical coupling for shaft: 0° (fault exclusion for the loosening of the shaft coupling and stator purposes. These requirements must also
coupling; designed for accelerations at the stator of ≤ 400 m/s2; at the rotor: ≤ 600 m/s2) be followed when press-fitting new disk/
hub assemblies onto customer shafts that
Shaft Hub with an inside diameter of 15.7 mm Hub with an inside diameter of 19 mm have already been used. Once the lower
limit of the press-fit force has been
Shaft speed  6000 rpm  15 000 rpm exceeded, the press-fit force being applied
must remain within the specified range for
Moment of inertia of rotor 5.5 · 10–6 kgm2 (without supporting ball bearing) 2.0 · 10–6 kgm2 the rest of the procedure, including until
the end position is reached.
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”

1)
Further tolerances may arise in the subsequent electronics after position value comparison (contact mfr. of subsequent 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 Graduated disks and scanning unit (mounted)
4 Product Information KCI 120 Dplus  05/2021 Product Information KCI 120 Dplus  05/2021 5
Mechanical fault exclusion

For the fault exclusion design for functional Rotary encoders may exert a torque of up
safety, the following material properties to 1 Nm on the mating shaft. The customer-
and conditions for the mating surfaces are side mechanical design must be made for
assumed. this load.


Customer motor shaft Customer output shaft Customer stator

Z Material Hardenable wrought aluminum alloy Aluminum

   Tensile strength Rm  260 N/mm2  215 N/mm2  220 N/mm2

Yield strength Rp0.2 or  240 N/mm2  160 N/mm2 Not applicable

yield point Re

Shear strength τa Not applicable  130 N/mm2

 1.5
2
 10 /  15 Interface pressure pG Not applicable  250 N/mm
Z  2 2
4:1 Modulus of elasticity E 69 kN/mm to 71 kN/mm 70 kN/mm2 to 75 kN/mm2
(at 20 °C)
–6
Faxial = 15 N Coefficient of thermal 23 · 10 K–1 to 24 · 10–6 K–1  25 · 10–6 K–1
expansion Þtherm (at 20 °C)

Surface Anodized coating permissible

 Surface roughness Rz  6.3 µm  16 µm
Flateral = 33 N
Friction values Lubrication at the joint surfaces is recommended. Mounting surfaces must be
clean and free of grease.
Use screws and washers in their
condition as delivered.

Tightening procedure Use a signal-emitting torque wrench as per DIN EN ISO 6789; accuracy: ±6 %

Mounting temperature 15 °C to 35 °C
1 = Supporting flange for the stator connection:
Material in accordance with the table at right (“Customer stator” column)
Maximum permissible total mass (including additional parts): 0.130 kg
Surface roughness at the joints: Rz  16 μm
2 = Spring washer: DIN 6796 – 3 – FSt (4x) Mounting tool
Ensure correct positioning with the convex side facing the screw head
To avoid damage to the cable, use the
3 = Screw: M3 ISO 4762 – 8.8 – MKL (4x)
Tightening torque: 1.0 Nm ±0.1 Nm mounting aid to disconnect the cable
4 = Minimum engagement depth starting at the surface of the scanning unit; see also the assembly. Apply pulling force only to the
dimension drawing connector of the cable assembly and not to
5 = Board thickness at screw connection the wires.
6 = Optional supporting ball bearing for measured shaft;
Service life and permissible bearing load must not be exceeded; ID 1075573-01
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 Mounting accessories
– Valid for all operating conditions. Additionally arising forces (e.g., from a vibration load and Screws: M3 ISO 4762 – 8.8 MKL and
torque) must be taken into account: spring washers: DIN 6796 - 3 - FSt.
Flateral = 33 N
Faxial = 15 N Instructions for use: use screws with For more mounting information and
material bonding anti-rotation lock as per mounting aids, see the Mounting
DIN 267 27 (see the Rotary Encoders Instructions and the Encoders for Servo
brochure, under General mechanical Drives brochure. The mounting quality can
information). Fastening screws and spring be tested with the PWM 21 and the ATS
washers must be ordered separately. software (see document ID 1082415).

6 Product Information KCI 120 Dplus  05/2021 Product Information KCI 120 Dplus  05/2021 7
Integrated temperature evaluation Diagnostics, inspection, and testing devices

Each axis of these rotary encoders features A device-specific default value is saved HEIDENHAIN encoders provide all of the The subsequent electronics are able to • Monitoring mode: the PWM inspection
an internal temperature sensor integrated here before shipping. The temperature information needed for commissioning, evaluate the current status of the encoder device is interposed within the closed
into the encoder electronics. The digitized measured by the internal temperature monitoring, and diagnostics. The type of with low resource expenditure, including in control loop (via suitable testing adapters
temperature value is transmitted purely sensor is higher by a device-specific and information available depends on whether closed-loop operation. as needed). This enables real-time
serially via the EnDat protocol. Please bear application-specific amount than the the encoder is incremental or absolute and diagnosis of the machine or equipment
in mind that this measurement and temperature at the measuring point, as on which interface is being used. For the analysis of these encoders, during operation. The available functions
transmission of the temperature is not safe shown in the dimension drawing. HEIDENHAIN offers the appropriate PWM depend on the interface.
in terms of functional safety. Absolute encoders employ serial data inspection devices and PWT testing
Each axis of the rotary encoders features a transmission. The signals are extensively devices. Based on how these devices are
With regard to the internal temperature further non-adjustable trigger threshold for monitored within the encoder. The integrated, a distinction is made between
sensor, the rotary encoder supports the the “Temperature exceeded” EnDat error monitoring results (particularly valuation two types of diagnostics:
two-stage cascaded signaling of a message of the internal temperature numbers) can be transmitted to the • Encoder diagnostics: the encoder is
temperature exceedance. This consists of sensor. When this is reached, an EnDat subsequent electronics along with the connected directly to the testing or
an EnDat warning and an EnDat error error message is output (EnDat memory position values via the serial interface inspection device, thereby enabling a
message. area “Operating status,” word 0 “Error (digital diagnostics interface). The detailed analysis of encoder functions.
messages,” bit 22 “Position” and in following information is available:
In accordance with the EnDat specification, additional data 2 “Operating status error • Error message: position value is not
an EnDat warning (EnDat memory area sources,” bit 26 “Temperature exceeded”). reliable
“Operating status,” word 1 “Warnings,” bit This trigger threshold may vary depending • Warning: an internal functional limit of
21 “Temperature exceeded”) is output on the encoder and is stated in the the encoder has been reached
when the warning threshold for the specifications. • Valuation numbers:
temperature exceedance of the internal – Detailed information about the
temperature sensor is reached. This HEIDENHAIN recommends adjusting the encoder’s function reserve
warning threshold for the internal warning threshold based on the application – Identical scaling for all HEIDENHAIN
temperature sensor is stored in the EnDat such that this threshold is sufficiently encoders
memory area “Operating parameters,” below the trigger threshold for the – Cyclic reading capability
word 6 “Trigger threshold warning bit for “Temperature exceeded” EnDat error
excessive temperature” of each axis, and message. Compliance with the
can be individually adjusted. temperature at the measuring point is
required for adherence to the encoder’s
intended and proper use.

Mounting accuracy with the PWM 21 and the ATS software

Electrical resistance PWM 21

The PWM 21 phase-angle measuring unit,
PWM 21
in conjunction with the included ATS Encoder input • EnDat 2.1, EnDat 2.2, or EnDat 3 (absolute value with or
adjusting and testing software, serves as without incremental signals)
an adjusting and testing package for the • DRIVE-CLiQ
diagnosis and adjustment of HEIDENHAIN • Fanuc Serial Interface
encoders. • Mitsubishi high speed interface
• Yaskawa Serial Interface
Check the electrical resistance between • Panasonic serial interface
the customer-side stator and both • SSI
customer-side shafts. • 1 VPP/TTL/11 µAPP
Nominal value: < 1 ohm • HTL (via signal adapter)

Interface USB 2.0

Supply voltage AC 100 V to 240 V or DC 24 V

Dimensions 258 mm × 154 mm × 55 mm

For more information, see the PWM 21/
ATS Software Product Information DRIVE-CLiQ is a registered trademark of Siemens AG.
document.

8 Product Information KCI 120 Dplus  05/2021 Product Information KCI 120 Dplus  05/2021 9
Electrical connection

When a special testing cable is connected HEIDENHAIN offers two testing cables for Pin layout for the rotary encoder
to the PWM 21 diagnostic and testing this purpose. As a result, either a testing
device, Encoder A (output side) is cable for the output-side encoder or a
connected. In order to connect Encoder B testing cable for the motor-side encoder 15-pin PCB connector
(motor side), a different special testing can be connected to the PWM 21 as
cable must be used. needed.
15

Pin layout of the testing cables Serial data transmission Serial data transmission
Power supply (Encoder A) (Encoder B)
Testing cable for connection to Encoder A: 1311046-xx
15-pin PCB connector 14 12 13 11 7 8 9 10 1 2 3 4

Sensor UP Sensor DATA DATA CLOCK CLOCK DATA DATA CLOCK CLOCK
15 0V 0V UP A A A A B B B B

UP = Power supply
Power supply Serial data transmission Vacant pins or wires must not be used!
(Encoder A) The subsequent electronics must have a common ground reference!

15 14 12 13 11 7 8 9 10

0V Sensor UP Sensor DATA DATA CLOCK CLOCK

0V UP A A A A
Cable length > 0.5 m: Cable length ≤ 0.5 m:
White/Green White Brown/Green Blue Gray Pink Violet Yellow To prevent crosstalk, the two EnDat When single wires up to a maximum
interfaces must be separately shielded length of 0.5 m are used, each data and
UP = Power supply from each other. The cable sold by meter clock wire combination must be
Vacant pins or wires must not be used! with ID 1347450-xx (PUR,  3.7 mm) can implemented as a twisted wire pair in
be used for this. Two cables must be order to avoid coupled interferences. As an
attached to the PCB connector in order to alternative, the cable with ID 605090-51
transmit the EnDat signals separately. Only (EPG,  4.5 mm) and a length of 0.3 m can
Testing cable for connection to Encoder B: 1311047-xx one cable is used for the power supply. be used. The general information in the
When using the cable sold by meter with Cables and Connectors brochure must be
15-pin PCB connector ID 1347450-xx, the general information in noted.
the Cables and Connectors brochure must
be noted; use of the cables at temperatures
15
of up to 100 °C is possible provided that
the exposure to hydrolysis and media is
low.
Power supply Serial data transmission
(Encoder B)

14 12 13 11 1 2 3 4 This Product Information document supersedes all previous editions, which thereby
15
become invalid. The basis for ordering from HEIDENHAIN is always the Product
0V Sensor UP Sensor DATA DATA CLOCK CLOCK  Information document edition valid when the order is placed.
0V UP B B B B 
      
    Further information:
White/Green White Brown/Green Blue Gray Pink Violet Yellow
    

 Comply with the requirements described in the following documents to ensure correct
UP = Power supply


 and intended operation:
Vacant pins or wires must not be used!
• 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 1336024-xx
• Product Notes for JAE connecting element 576762-xx
(sheet 1)
• Technical Information: Safety-Related Position Measuring Systems 596632-xx
• For implementation in a safe control or frequency inverter:
Specification: 533095-xx
Specification: Supplementary Catalog of Measures (SIL 3, PLe) 1000344-xx
• Setup instructions 1082415-xx

10 Product Information KCI 120 Dplus  05/2021 1335409 · 01 · A · 02 · 05/2021 · PDF