Sympatec GmbH

System-Partikel-Technik

HELOS/R
Operating Instructions
(Translation of the original
instructions)
 Hint
Complete or partial duplication of this documentation and
associated software without written permission is prohib-
ited. Rights to the documentation and software are re-
served by Sympatec GmbH.

There is no guarantee for the accuracy of the content. Since

errors can never be entirely excluded in spite of the greatest
care, we are grateful for corresponding indications.

Clausthal-Zellerfeld, 28 June 2019.

HELOS/R
Copyright © 2019 Sympatec GmbH, System-Partikel-Technik,
Am Pulverhaus 1, D - 38678 Clausthal-Zellerfeld, Germany

Item No.: BM00010E.W

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Operating Instructions

Content
Page

1 Important Advice 9
1.1 Operating Instructions 9
1.2 Intended Use 9
1.3 Identification of Safety Alerts 9
1.4 Supplemental Directives 9
1.5 Overview of used Safety Alert Symbols 11
1.6 Used Safety Alert Warnings 11
1.7 Additional Hints and Symbols 12

2 Introduction 15
2.1 HELOS measuring range R1 … R8 16

3 Installation 19
3.1 Before Start-Up 19
3.2 Scope of Supply 20
3.3 Overview of Functional Parts 20
3.4 Execution of the Installation 24
3.4.1 Preparation of the Sensor 24
3.4.2 Installation and Connection of the Personal Computer 26
3.4.3 Installing a Lens Magazine Disc into HELOS/R Multi
Range 31
3.4.4 Installing a Measuring Range into HELOS/R-OM 34
3.4.5 Positioning of the Detector in HELOS/R-OM 38
3.4.5.1 Special Installation of R4 and R5 into HELOS/BR-
OM 40
3.4.6 Connecting Mains Supply to HELOS/R 41
3.4.7 Connecting a Dispersing Unit to HELOS 42
3.4.8 Special Notes for the Installation in the United States 42
3.5 Installation of HELOS-VARIO/KR 43
3.5.1 Installation 44
3.5.2 Adjusting the Width of the Measuring Zone 47
3.5.3 Installation of the blocking air nozzles (optional, ex
works only) 48
3.6 Remote Control Software 51

4 Operation 53
4.1 Panel for Manual Operation 53
4.1.1 Error During Initialisation 54
4.2 Starting the Remote Control Software 54
4.3 Initial Operation 54
4.3.1 Access Control of the Connection 56
4.3.2 Personal Area Network (PAN) as Option 56
4.3.3 Date and Time Settings 56
4.3.4 Password 56
4.4 Performing a Measurement 56
4.5 Changing the Measuring Range 57

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Operating Instructions

5 Maintenance and Care 59

5.1 Maintenance & Service Schedule 59
5.2 Cleaning the Lenses 60
5.2.1 Cleaning the Lenses with Cleaning Cloth 60
5.2.2 Cleaning the Lenses with Lens Cleaning Tissue 60
5.3 Maintenance of the Dust Protection Window 61
5.3.1 Cleaning the Dust Protection Window 61
5.3.2 Exchanging the Dust Protection Window 61
5.4 Factory Reset 62

6 Glossary 65

7 Technical Data 67
7.1 HELOS-OM 67
7.2 HELOS Multirange 72

8 Appendix 79
8.1 Optional Accessories 79
8.2 List of Spare Parts and Wearing Parts 81

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Operating Instructions

1 Important Advice
1.1 Operating Instructions

Read the operating instructions and safety instructions carefully before

using the machine and act accordingly. The operating instructions are di-
rectly connected to the instrument. Keep them readily available and
transfer them always together with the instrument.

1.2 Intended Use

The device is suitable for use in a laboratory. It is the centrepiece in a measuring

system together with a designated disperser and possibly supplemented by an addi-
tional dosing unit. The measuring system allows for particle size analysis (PSA) of
dispersed substances in gas or liquid regardless of whether the particles are solid,
liquid (droplets) or gaseous (bubbles).

The prescribed installation, operating and maintenance instructions in this manual

must be followed. For any other than the intended use, the safe operation of the
device is not guaranteed. The manufacturer is not liable for damages or harm re-
sulting from other than its intended use.

1.3 Identification of Safety Alerts

NOTICE
Is used to address practices not related to personal injury. E.g. to give
an important hint to protect the equipment from damage or malfunc-
tion.

CAUTION
Indicates a hazard with a low level of risk which, if not avoided, could
result in minor or moderate injury.

WARNING
Indicates a hazard with a medium level of risk which, if not avoided,
could result in death or serious injury.

1.4 Supplemental Directives

• For your own safety:

Only persons who are trained in the use and are authorised to use the in-
strument are allowed to operate the instrument.
The use of the unit is subject to valid national regulations.
Observe recognised regulations for safety and proper use besides the oper-
ating instructions and binding accident prevention regulations in the

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Operating Instructions

country of use.
Do not operate the unit in an unsafe operation method.

• Purpose of use:
Before starting work, the operating staff must be informed on use of the
instrument.

• Before start-up (Operation):

Check the power cord regularly against damages like cracking or ageing.
If the power cord is damaged it has to be changed by an electrician before
use of the unit is continued to avoid danger.

• Power supply socket:

The power supply socket has to be used for the purpose described in the
operating instructions only.
Switch off all the units before plugging in any appliance to the sockets.

WARNING
Power Supply is switched by the instrument.
Risk of an electric shock when connecting to the socket.
➢ Turn off the instrument before connecting any other device to
the power supply socket.
➢ Only connect devices which are applicable in accordance to the
supply specifications:
90-250VAC, 50-60Hz, 1400W max.
➢ Refer also to the safety advices in the operating instructions of
the additional device!
• Maintenance and cleaning:
Only carry out maintenance work described in the operating instructions.
Meet the given cycles.
Handle the unit in such a manner that there is no danger during maintenance
and cleaning of the unit to the maintenance or other personal.

• Accessories and spare parts:

Use only original accessories and spare parts. The use of other components
can adversely affect safety and functionality of the unit.

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1.5 Overview of used Safety Alert Symbols

General warning sign

Warning; Electricity

Warning; Laser beam

Warning; Falling objects

1.6 Used Safety Alert Warnings

WARNING
Power Supply is switched by the instrument.
Risk of an electric shock when connecting to the socket.
➢ Turn off the instrument before connecting any other device to
the power supply socket.
➢ Only connect devices which are applicable in accordance to the
supply specifications:
90-250VAC, 50-60Hz, 1400W max.
➢ Refer also to the safety advices in the operating instructions of
the additional device!

CAUTION
Weight of the unit is more than 25 kg!
If this is not observed when transporting, there is a risk of injury to the
back, extremities or other body parts.
➢ Do not transport the unit on your own. Ask a second person for
assistance.
➢ Take very special attention to the place and stability during
HELOS-VARIO installation.

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CAUTION
Laser beam when housing is open!
Laser beam may be released and harm to the eyes of persons standing
near the instrument.
➢ Never bridge the safety lock for releasing the laser shutter.

CAUTION
Crushing hazard by falling objects when setting the measurement zone
width!
If you loosen the fixing screws of HELOS-VARIO too much, the head
part may fall forward or backward or, additionally, the detector side will
tilt to the side.
➢ Loosen the screws only one turn before pushing.
➢ Don’t slide the detector side over the end of the rack that an
overweight arises.
➢ Use a modified measuring zone (H4Z010 or H4Z011), if the
adjustable distance appears to be too low.

1.7 Additional Hints and Symbols

If there should remain open questions after reading this documentation

do not hesitate to contact your local Sympatec partner or:

Sympatec GmbH
System-Partikel-Technik
Am Pulverhaus 1
D-38678 Clausthal-Zellerfeld

www.sympatec.com

Phone: 0700 Sympatec = 0700 7967 2832

or +49 (5323) 717-0
Fax: +49 (5323) 717-229
E-mail: [email protected]

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Operating Instructions

The machine described below corresponds in its design and construction,

as well as the version marketed by us, with the basic safety requirements
of the following EU directives:

Product: Particle sizing instrument

Type: HELOS/R

• 2006/42/EC (Machinery safety)

• 2014/35/EU (Low voltage)

• 2014/30/EU (Electromagnetic compatibility)

HELOS / R
499
90 - 250 V
17.12.2014

This product is classified as electrical and electronic equipment in ac-

cordance with Directive 2012/19/EU (WEEE). It must not be disposed
via the domestic waste but collected separately. Please ensure the dis-
posal of the equipment in accordance with the directive, or your local
legislation. If you have no more use for your instrument, you may return
it to Sympatec GmbH for recovery.

The device and all accessories are delivered in a special packaging. You
may return the packaging back to your Sympatec partner for disposal.
We recommend to store the packaging for future transport to ensure the
best protection for the instrument.

Gives information for a better or easier handling of the instrument or its

components.

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Operating Instructions

2 Introduction
We are pleased you decided in favour of the new Sympatec HELOS/R-System. You
acquire a powerful device for the determination of particle size distributions of sol-
ids, suspensions and sprays by using the physical principle of laser diffraction (LD).
It is designed on a modular basis and includes the following components:

LD Sensor The LD sensor called HELOS/R is the core of the measur-

ing device. It includes a laser-light source, a focusing lens, a
measuring zone, an optical system and a multi-component
photo detector with integrated auto-focus unit.
The laser light and the particles interact in the measuring
zone and the optical system converts the diffraction of the
laser light in the spectrum into an image that can be de-
tected by the photo detector.

Dispersing unit Since LD is analysing the dimensions of a cluster of adher-

ent particles as one particle, it needs to be ensured that the
sample is free of agglomerates. This needs to be done be-
fore the analysis is performed. Dispersing units are devel-
oped for this step of preparation. They are optimised for the
respective task. Depending on the media we distinguish be-
tween systems for gases (aero dispersion: RODOS or
GRADIS) and liquids (suspensions: SUCELL, QUIXEL,
CUVETTE and LIXELL) or so-called adaptive systems
(gas-liquid mixture: INHALER and SPRAYER).

Dosing unit The sample preparation for the LD sensors and/or dispers-
ing units normally requires the conditioning of the sample
in terms of concentration. The suspension dispersion sys-
tems are conditioning the sample through the sample vol-
ume whereas the aero dispersers are conditioning the
sample through the mass throughput that is held constant
during the analysis using the dosing unit.

Sample preparation The sample preparation includes the adaptation to the meas-
uring range and to the sample volume. The adaptation to the
measuring range should ensure that the analysed particles
are in the analytical range, i.e. smaller than the specified up-
per limit of the measuring range. If the anticipated particle
size distribution (PSD) expands over more than one measur-
ing range it is possible to add two or more measuring ranges
with the help of an optional available software module.

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Sample taking The conditioning of the sample volume requires representa-

tive sample-splitting to ensure reliable results. An repre-
sentative sampling is naturally the basis for the following
analysis. It should be performed with special care by taking
even sub-samples from distributed locations within the bulk
material to analyse.

Restrictions The particle size distribution (PSD) of non-spherical parti-

cles will be presented as the PSD of spherical particles with
the equivalent optical properties when exposed to a laser.
LD sensors require a low particle concentration to avoid
multiple diffraction. Dilution by a dispersing liquid must
not modify the PSD.

Start-up Please read chapter 3 carefully, before you start installation.

Application The operation is described in chapter 4 precisely.

We wish you every success with your application!

2.1 HELOS measuring range R1 … R8

There are up to eight different measuring ranges available within one instrument.
Five in the BR group (R1 - R5T), from 0.1 - 875µm and eight in the KR group
(R1 – R8T) 0.1 – 8,750µm. All systems may be equipped with an automatic chang-
ing of the measuring ranges if you use more than one. In his case, the number of
measuring ranges is limited to seven for the KR group.

The measuring range of the HELOS sensor can be adapted by a change in the
lens/objective set-up.

HELOS/BR: R1, R2, R3, R4T, R5T

HELOS/KR: R1, R2, R3, R4, R5, R6T, R7T, R8T

HELOS-VARIO/KR: R1, R2, R3, R4, R5, R6T, R7T, R8T

The exact details of the listed measuring ranges are given in the technical specifi-
cations at the end of these operating instructions with focal length, size-range and
range-code. The range of the lower particle size class differs from measuring range
to measuring range. The lower limit of this class acts as the boundary of an integral
(that is only particles above this particle size will be considered in the evaluation,
see also Table 1).

If the anticipated particle size distribution expands over more than one measuring
range it is possible to add two or more measuring ranges with the help of an optional
available software module.

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The exact limits of the measuring ranges can be found in the following table:

limits measuring ranges/µm

R1 R2 R3 R4(T) R5(T) R6T R7T R8T
f=20mm f=50mm f=100mm f=200mm f=500mm f=1000mm f=2000mm f=5000mm
lower () 0.10/0.18 - 0.25/0.45 - 0.5/0.9 - 0.5/1.8 - 0.5/4.5 - 0.5/9.0 - 0.5/18.0 - 0.5/45.0 -
upper 35.0µm 87.5µm 175µm 350µm 875µm 1750µm 3500µm 8750µm
(1) 0.10 0.25 0.5 0.5 0.5 0.5 0.5 0.5
2 0.18 0.45 0.9 1.8 4.5 9.0 18.0 45.0
3 0.22 0.55 1.1 2.2 5.5 11.0 22.0 55.0
4 0.26 0.65 1.3 2.6 6.5 13.0 26.0 65.0
5 0.30 0.75 1.5 3.0 7.5 15.0 30.0 75.0
6 0.36 0.90 1.8 3.6 9.0 18.0 36.0 90.0
7 0.44 1.10 2.2 4.4 11.0 22.0 44.0 110.0
8 0.52 1.30 2.6 5.2 13.0 26.0 52.0 130.0
9 0.62 1.55 3.1 6.2 15.5 31.0 62.0 155.0
10 0.74 1.85 3.7 7.4 18.5 37.0 74.0 185.0
11 0.86 2.15 4.3 8.6 21.5 43.0 86.0 215.0
12 1.00 2.50 5.0 10.0 25.0 50.0 100.0 250.0
13 1.20 3.00 6.0 12.0 30.0 60.0 120.0 300.0
14 1.50 3.75 7.5 15.0 37.5 75.0 150.0 375.0
15 1.80 4.50 9.0 18.0 45.0 90.0 180.0 450.0
16 2.10 5.25 10.5 21.0 52.5 105.0 210.0 525.0
17 2.50 6.25 12.5 25.0 62.5 125.0 250.0 625.0
18 3.00 7.50 15.0 30.0 75.0 150.0 300.0 750.0
19 3.60 9.00 18.0 36.0 90.0 180.0 360.0 900.0
20 4.20 10.50 21.0 42.0 105.0 210.0 420.0 1050.0
21 5.00 12.50 25.0 50.0 125.0 250.0 500.0 1250.0
22 6.00 15.00 30.0 60.0 150.0 300.0 600.0 1500.0
23 7.20 18.00 36.0 72.0 180.0 360.0 720.0 1800.0
24 8.68 21.50 43.0 86.0 215.0 430.0 860.0 2150.0
25 10.20 25.50 51.0 102.0 255.0 510.0 1020.0 2550.0
26 12.20 30.50 61.0 122.0 305.0 610.0 1220.0 3050.0
27 14.60 36.50 73.0 146.0 365.0 730.0 1460.0 3650.0
28 17.40 43.50 87.0 174.0 435.0 870.0 1740.0 4350.0
29 20.60 51.50 103.0 206.0 515.0 1030.0 2060.0 5150.0
30 24.60 61.50 123.0 246.0 615.0 1230.0 2460.0 6150.0
31 29.40 73.50 147.0 294.0 735.0 1470.0 2940.0 7350.0
32 35.00 87.50 175.0 350.0 875.0 1750.0 3500.0 8750.0

Table 1: Measuring ranges with limits

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Operating Instructions

3 Installation
3.1 Before Start-Up

CAUTION
Weight of the unit is more than 25 kg!
If this is not observed when transporting, there is a risk of injury to the
back, extremities or other body parts.
➢ Do not transport the unit on your own. Ask a second person for
assistance.

Please check the requirements and operating conditions before you start the instal-
lation. Only faultless components guarantee an uninterrupted operation.

Requirements
Environment The HELOS system should be installed in a dry location
and on a solid base.
Installation place Because of its weight, the HELOS sensor system is not
moved easily. Choose the location for the installation
carefully and reserve enough space for personnel com-
puter, dispersing unit and additional components.

Table 2: Requirements

Operating conditions
Phase-to-neutral voltage1: 90-250 VAC 50/60 Hz 300 Wmax
Voltage load power line: 16 Amax
Environmental temperature from 5 to 40°C
Environmental humidity Max. 80 %
(non-condensing)
IP marking IP20
(protected against foreign bodies > 12.5 mm)
Vibrations none
Draught none
Direct sunlight none

Table 3: Operating conditions

1 All systems of the HELOS/R series are equipped with a wide range power supply including a power factor correction
module (sinus shaped current consumption). The operation is possible at line voltages in the range of 90V to 250V
without any special input voltage selection.. Functions differing from sinus-shape, peaks and gaps are prohibited. The
operation of power controllers using thyristors close to the units must be avoided.

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3.2 Scope of Supply

The scope of supply of a HELOS laser diffraction spectrometer contains typically

the HELOS/R sensor unit itself, a personnel computer for operating the HELOS
sensor unit with pre-installed remote control software, a lens case with the measur-
ing ranges assigned to the instrument and some tools, manuals on CD and electric
connection cables like power cord and Ethernet cable.

3.3 Overview of Functional Parts

The figure below shows a HELOS/KR sensor as an example. Your HELOS sensor
can be a shorter version (BR) or a longer version (KR).

1
2 3

4 5
6

Figure 1
Front view of HELOS: 4 Key switch for power supply of
1 Measuring zone the HELOS sensor
2 Head side containing the optic box 5 X-95 profile for fixation of differ-
and power supply ent dispersing units
3 Detector side containing the detector 6 Key lock for detector housing
and the lenses

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Rear view of the HELOS head

side:

1 Laser shutter 1 2 3 4
2 External Trigger

3 AUX (2 digital outputs, 1 5 6

digital input)2

4 power supply for

dispersing units and RS
485 communication
Figure 2
5 power supply for addi-
tional components, e.g.
vacuum cleaner (90-250 V,
50-60 Hz, max. 1400 W)

6 power input for HELOS

unit (90-250 V, 50-60 Hz,
43 W idle)

More information about the technical data of the connectors are found in chapter 7
in the section “electrical connections”.

NOTICE
The sockets 1, 2 and 3 are covered to ensure safe transportation and to
protect the sensor against improper use.

2 Can be used for controlling of a central exhaust or an automatic cleaning function of a vacuum.

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2
3

4 5 6 7

8
9
10

Figure 3
Inside view of the HELOS detector side:
1 Cover lid 7 Pneumatic holder for cover lid
2 Copper grounding strip 8 X-95 profile for guidance of de-
3 Motor for lens disc rotation tector table
4 Lens magazine disc 9 Locking device for lens disc
5 Detector 10 Safety magnet for automatic laser
shutting
6 Reset knob for factory settings

CAUTION
Laser beam when housing is open!
Laser beam may be released and harm to the eyes of persons standing
near the instrument.
➢ Never bridge the safety lock for releasing the laser shutter.

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Accessories:

1 Power supply cable for

HELOS 1 2
2 Standard Ethernet cable

3 CD with documentations

4 Extension cord with multi 3 4

socket
(not within scope of delivery
in UK, US and JP)
Figure 4
Lens case with lens modules and
tools

Figure 5
Evaluation unit, usually:

1 TFT monitor
1
2 PC

3 Keyboard

4 Mouse 2
The scope of supply of 4
the evaluation unit differs
3
depending on your order.
Figure 6

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3.4 Execution of the Installation

3.4.1 Preparation of the Sensor

The multi range option of the HELOS/BR or HELOS/KR sensor offers the ad-
vantage that all installed measuring ranges are adjusted automatically. After the in-
stallation of a lens magazine disc any measuring range installed on the lens can be
selected via the remote control software.

Step 1:
Take the HELOS/R sensor out of
the delivery box and place it on a
solid surface, for example a labor-
atory table. Keep in mind to re-
serve enough space for the
personal computer and a dispers-
ing system.

Figure 7
Step2:
Take the key for the housing lock
at the right hand side of the
HELOS/R sensor out of the lens
case. Insert the key and turn it
clockwise. The locking cylinder
snaps out and unlocks the housing.

Figure 8

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Step 3:
a) For HELOS/R multi range:

Open the detector side of the hous-

ing. You may find a leaflet inside
which re-minds you to take out
and keep the transportation lock.
Remove the fixation screw of the
transportation lock and take it out
together with the leaflet.

Figure 9
Step 3:
b) For HELOS/R-OM:

Open the detector side of the hous-

ing. You may find a leaflet inside
which re-minds you to take out
and keep the transportation lock.
Remove the fixing screw of the de-
tector table and lift it as much as
necessary to take out the transpor-
tation lock.

Fix the detector table again after- 1. 2.

wards. Figure 10

Step 4:
Remove the two protection caps
covering the openings at both
sides of the measuring zone.

In some cases instead of the right

protection cap a sheet of paper or
a special protective sheet is used.

Figure 11

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Step 5:
Remove the foil cover from the de-
tector (the figure shows a detector
of HELOS/R multi range as an ex-
ample)

NOTICE
Do not touch the surface of the de-
tector! A sticker at the front edge
of the detector reminds you as well.

Figure 12
Step 6:
Close the housing again.

3.4.2 Installation and Connection of the Personal Computer

The HELOS/R sensor and all its extensions are controlled via the remote control
software installed on a personal computer. The communication between the com-
puter and HELOS/R is realised via a standard Ethernet connection. The figures be-
low show the set-up of the cable connection of both the computer and HELOS/R.
The scope of delivery may differ depending on your order. For detailed information
how to install the computer please read the relevant manuals.

Step 1:
Take the PC and the accessories
out of the shipping box. Arrange
the computer next to the HELOS/R
housing. Connect keyboard,
mouse and monitor to the plug-ins
at the rear of the computer. Read
the PC manual for further instruc-
tions.

There are three common scenarios for the set-up of the Ethernet connection:

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a) Direct connection of com-

puter and HELOS/R (peer-
to-peer):

A standard Ethernet cable is used

to establish this kind of connec-
tion. It is the common solution for
stand-alone systems without inte-
gration to the customer’s network.

Figure 13
b) Integration of both
HELOS/R and computer to
the customer’s network:

One or more computers are linked

to HELOS/R via an external
switch (HUB) and standard Ether-
net cables.

Figure 14
c) PC equipped with two Ether-
net interfaces for local net-
work to HELOS/R and
simultaneous integration to
the customer’s network:

The connection from the sensor to

the PC is realised via standard
Ethernet cable whilst the integra-
tion to the customer’s network is
realised via a second interface
Figure 15
card, standard Ethernet cables,
network switch (HUB) etc.

It depends on the network infrastructure at customer’s site which scenario is the

best solution. Please be aware to discuss this topic with your network administrator
in time.

Follow the next steps to establish your communication in accordance to set-up a).

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Step a2:

Take the Ethernet cable out of the

accessories box. Connect one plug
of the cable to the extra network
socket of the PC and...

Figure 16
Step a3:

... the other plug of the cable to

the network connector of the
HELOS/R sensor. It is located at
the detector side at the rear of the
housing.

Figure 17
Step a4:
Connect the power supply of the
PC and monitor according to the
relevant manuals.

Instead, you might like to follow the next steps to establish your communication in
accordance to set-up b). You need an external switch (HUB) and an additional
Ethernet cable for this kind of set-up. An example in shown in Figure 18.

Figure 18

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For integration of PC and HELOS/R sensor into your network on site

both shall be configured by your network administrator first.

Step b2:
Connect one Ethernet cable to the
network socket of the PC and to
the installed switch (HUB).

Take a second Ethernet cable and

connect it to the switch (HUB; no
figure) and...

Figure 19
Step b3:
... to the socket of the HELOS/R
sensor. It is located at the detector
side at the rear of the detector
housing.

Figure 20
Step b4:
Connect the power supply of the
PC and monitor according to the
desired manuals.

For the network scenario c) please follow the next steps to establish your commu-
nication. You might need an external switch (HUB) and an additional Ethernet ca-
ble for this kind of set-up. An example is shown in Figure 18.

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The Ethernet card to be used for the integration into your network on site
shall be configured by your network administrator first.

The standard configuration of the PC provided by Sympatec GmbH is as

follows:

• Additional network device (1) (192.168.1.2,

subnet 255.255.255.0)

• On-board network device (2) (DHCP, automatic)

Step c2:
Use the first Ethernet cable to
connect the PC to your network on 1
2
site or to a switch respectively.
The on-board socket of the PC (2)
is dedicated for this connection
and must be configured by your
network administrator. Use a sec-
ond Ethernet cable and connect
one plug of the cable to the net-
work socket of the extra Ethernet
card (1), and... Figure 21

Step c3:
... the other plug into the network
socket of the HELOS/R sensor. It
is located at the detector side at
the rear of the housing.

Figure 22
Step c4:
Connect the power supply of the
PC and monitor according to the
desired manuals.

The computer system and the physical connection between the computer and
HELOS/R are now ready for use.

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3.4.3 Installing a Lens Magazine Disc into HELOS/R Multi Range

There a two types of lens magazine discs available: one with holes for three lenses
out of the measuring ranges R1 – R7 and another with four holes for all lenses
except the R2 range. The lens magazine discs are preconfigured on delivery and
should be stored in the special lens case. The lens case offers the best protection for
the lenses and contains some maintenance tools and keys for the HELOS/R sensor
as well. The installation of lens magazine discs is simple and explained below:

Before you install a lens magazine disc into HELOS/R please initialise
the communication between sensor and PC first (compare chapter 3.4.2).
It is easier to install the disc with assistance by the remote control soft-
ware.

1 2
3
4 5 6

Figure 23
Look inside the lens case:
1 Service key for assembling and disas- 5 Allen keys for the transportation
sembling of the lens adapters or blind lock and SUCELL stirrers
plugs 6 Lens magazine disc with two
2 Service key for the counter rings of lenses and one blind plug (exam-
the objectives ple)
3 RODOS alignment tool (optional) 7 Service key for the dust protec-
4 Hard cover for the lens magazine disc tion window and keys for lens
protecting the lenses against dust and case and HELOS/R
scratches 8 Wrench for the transportation
lock of VIBRI

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NOTICE
The service keys are not needed for standard use of the HELOS/R sen-
sor. These are special tools used for upgrading the HELOS/R sensor
with additional lenses. Only a skilled or experienced technician is al-
lowed do the upgrade!

There are additional items in the case like cleaning gloves and cloths. Please refer
to chapter 5.2 for further information.

Step 1:
Start the personal computer and
the remote control software. Turn
on the HELOS/R sensor as de-
scribed in chapter 4.1. The soft-
ware will detect your HELOS/R
system automatically during the
initialisation. If not, please refer
to your software user manual to
find out how to redetect your sys-
tem.

For WINDOX users: For PAQXOS users:

Open the “Tools” menu at the menu bar In the “LIVE” window, select the button
and select “Move detector to safe posi- “Change the Measuring Range of the
tion”. Then, the detector automatically LD System” and there in the drop-down
moves to a safe position. “Moving Detector to Safe Position to
Change the Lens Revolver…”. Then, the
detector automatically moves to a safe
position.

Step 2:
After the detector has moved to its
safe position (no more noise can
be heard from the electric motor
drive) open the housing at the de-
tector side. You will notice that the
detector table has moved to the
right.

Opening the housing auto-

matically stops the move-
ment of the magazine
drive motor.
Figure 24

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Step 3:
Check if: 2
The fixing lever (1) at the bottom
of the left wall is opened.

The electric motor (2) of the mag-

azine drive at the top of the left
wall is not moving.
1
Take a lens magazine disc with the
desired measuring range out of its
lens case.
Figure 25
Step 4:
Insert the lens magazine disc care-
fully into the groove. Push the flat
surface slightly against the hous-
ing. Take care that the disc is par-
allel to the wall. Hold the lens
magazine disc and proceed with
step 5.

Figure 26
Step 5:
Fix the lens revolver by turning
the lever counter-clockwise from
the unlock position (1st) to the
locking position (2nd). It has to
lock easily but firmly.

1st 2nd
Figure 27

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Step 6:
Close the detector housing again.
You may now select one of the in-
stalled measuring ranges directly
via the respective drop-down-but-
tons of the remote control soft-
ware. Automatically the electric
motor turns the lens magazine disc
to its standard position, the se-
lected measuring range is set up
and the detector moves to the focal
point of the respective lens mod-
ule. At the end of this procedure,
the chosen measuring range is
coloured in the drop-down menu.

The sensor is now prepared for operation. However, the dispersing unit is still miss-
ing. Please refer to the operating instructions for your dispersing system to carry
out the installation.

In order to change the lens magazine disc for using other measuring ranges than the
installed one, carry out step 1 (detector movement to safe position) first and then
follow the procedure in reverse order.

3.4.4 Installing a Measuring Range into HELOS/R-OM

The measuring ranges (single lenses or lens modules) are delivered and should be
kept in a special lens case. The lens case offers the best protection for the lenses
and contains some maintenance tools and keys for the sensor.

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1 2 3 4

5 6
7a
8
7b 9

Figure 28
Look inside the lens case:
1 Allen keys for transportation lock and 6 Safety-coupling for RODOS, if
SUCELL stirrers RODOS is part of the delivery
2 Optional: RODOS adjusting tool, if a 7a Optional: spacer-bolt for profile
RODOS is part of the delivery adapter, if R4T is part of the de-
3 Wrench for transportation lock of livery
VIBRI 7b Profile adapter for measuring
4 Lens module (e.g. R5) , mounted at ranges R4T/R5T (HELOS/BR)
the bayonet and protected with plastic 8 Service key for dust protection
cap window
5 Keys for lens case and HELOS 9 Cleaning gloves and cloths

The additional parts in the case like cleaning gloves and cloths are re-
quired for maintenance. Please refer to chapter 5.2 for further infor-
mation.

The installation of the lenses is designed to be done with a bayonet fastening:

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Step 1:
Choose the desired lens and take it
out of the lens case. Remove its
protecting caps (black arrows).

The adjacent figure shows an R5

lens module with typical labels:

measuring range descriptor (R5),

focal length (f = 500 mm),

positioning arrow,
Figure 29
light barcode for auto-detection of
the lens by the remote control soft-
ware (only if more than one meas-
uring range is used).

There is a little groove

(white rectangle) above
the sticker. This groove
helps you to place the lens properly
into the fastening of HELOS.

Step 2:
Open the housing at the detector
side to get access to the detector.
Use the key to unlock the housing
if it is locked.

Loosen the fixing screw (1st) of the 2nd

detector table and push down the
position lever (2nd) at the right
side of the detector table. 1st

Figure 30

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Step 3:
Hold the lever and push the detec-
tor table to the right. The table is 2nd
now moveable over the stopping
point.

Be careful not to touch the detec-

tor! 1st

Figure 31
Do not touch the glass surface of the lens to avoid time-consuming clean-
ing procedures (see chapter 5.2)

Step 4:
If you look at the left wall of the
detector housing from the inside
you see: 1 2
1 Lock for correct lens posi-
tion
3
2 Barcode reader (installed
only if more than on range
is configured for the sys-
tem)
Figure 32
3 Positioning arrow

Step 5:
Insert the lens and assure that
both arrows are pointing to each
other. The lens shall be oriented
parallel to the wall.

Figure 33

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Step 6:
Turn the bayonet ring clockwise
while pressing it slightly against
the socket. After a quarter-turn the
ring slips a few mm into the
socket.

Figure 34
Step 7:
Continue to turn until the fixing
lever snaps into the groove.

Close the detector housing again.

Figure 35
The right beam diameter for the selected measuring range is automatically set up
via the remote control software by reading out the information from HELOS about
the installed measuring range. The next step before starting a measurement is to set
the detector up to the focal point.

3.4.5 Positioning of the Detector in HELOS/R-OM

Before you can carry out a measurement the detector has to be in the focus of the
lens. You will find a sticker marking the focal point for each lens on the X-95 pro-
file. The sticker is of the same design as the sticker on the lens.

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Step 1:
Unlock the housing at the detector
side if necessary and open it. Look
for the sticker marking the focal
point according to the selected
lens.

Figure 36
Step 2:
For the alignment of the detector
loosen the fixing screw (1st)and 2nd
push the detector to the focal point
of the installed lens (2nd).

You must hold the positioning

lever pushed down to move the ta-
ble across another focal point
stopper. Otherwise the table is
blocked during the movement.
1st

Figure 37
Step 3:
Push the detector from the left
against the stopper (1st) and 1st
tighten the fixing screw (2nd).

The end of the positioning lever

has to touch the headless screw
marking the focal point for the de-
tector (see small picture).

The detector is well-positioned if 2nd

the positioning lever is in tight
contact with the headless screw
after the fixation. Figure 38

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Operating Instructions

Never unscrew the headless screw marking the focal point! If this screw
is inaccurately adjusted the results of your measurements are biased. In
case that the screw has been loosened please contact your local Sympatec
distributor for support!

3.4.5.1 Special Installation of R4 and R5 into HELOS/BR-OM

The installation of the R4 and R5 lens modules differ from the description of chap-
ter 3.4.5.

An additional profile adapter is in

the scope of supply for the R4 and
R5 measuring range in combina-
tion with a HELOS/BR-OM sen-
sor.

For measuring range R5 the

adapter (1) is used alone. For use
with measuring range R4 a
spacer-bolt (2) has to be plugged 1
in. 2

Figure 39
Step 1:
Open the detector housing. Loosen
the fixing screw and move the de-
tector all the way to the right.

Insert the profile adapter to the in-

ner profile (1st).
1st
Move it to the left (2nd). The arrow
on the adapter has to align with
the arrow sticking to the wall of 2nd
the measuring zone.

Tighten the profile adapter with its

fixing screw (3rd).
3rd
Figure 40

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Step 2 (measuring range R4):

Move the detector from the right
to the left, until it touches the
screw marking.

Tighten the fixing screw of the de-

tector again.

Figure 41
Step 2 (measuring range R5):
Move the detector from the right
to the left, until it touches the
screw marking.

Tighten the fixing screw of the de-

tector again.

Figure 42
3.4.6 Connecting Mains Supply to HELOS/R

HELOS/R has to be connected to the mains supply. A power cable is delivered

together with the system. At one end, it has a country specific plug, at the other end
a special plug fitting into the power input socket at the rear of the HELOS/R head.

Rear view of HELOS/R head side:

Connect the appropriate plug of

the power cable to the socket at
the rear of the HELOS/R head.

Figure 43

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3.4.7 Connecting a Dispersing Unit to HELOS

A dispersing unit is connected to the sensor via one of the two 6-pin electric cables
delivered together with this sensor. The cable realises power supply as well as RS
485 communication between HELOS/R sensor and dispersing unit. It depends on
the socket size at the dispersing system which cable of both has to be used.

The network connection of HELOS/R is used for communication with the remote
control software.

NOTICE
Turn off the sensor before connecting a dispersing or dosing unit. If
this is not the case, the correct initialisation of the system may fail.
This will result to a malfunction of the system.

Rear view of HELOS/R head side:

After connecting HELOS/R to the

mains supply, install the black 6-
pin electric cable to connect the
HELOS/R sensor to the dispersing
unit.

Figure 44
The steps to follow are explained in the operating instructions of the dispersing unit.

3.4.8 Special Notes for the Installation in the United States

An additional plug is installed for the delivery of HELOS/R sensors to the United
States of America. This plug is an electric bridge and part of the laser safety equip-
ment. In some cases it might be necessary to interrupt the laser beam, e.g. if a person
enters the room. For this feature an additional electric switch has to be installed at
the doorway. It is intended to be linked to the same socket as the laser bridge, which
has to be replaced. For further information please contact your local Sympatec dis-
tributor.

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Rear view of HELOS/R head side:

The electric bridge is already in-

stalled and must not be removed
for normal operation!

Figure 45

For normal use of the HELOS system, the plug has to stay in place! If
your HELOS system is switched on and no laser light is detected (be-
cause the laser shutter does not release the laser beam) please check this
electric bridge!

3.5 Installation of HELOS-VARIO/KR

The HELOS-VARIO/KR sensor has a variable measuring zone allowing for meas-
urements of e.g. rather broad spray cones. The emitter (laser and beam expansion
system) and receiver (lens and detector) are arranged in separate housings for this
purpose. Both housing parts are installed on a supporting profile (X-95) as shown
in Figure 46 and hence can be moved easily.

CAUTION
Weight of the unit is more than 25 kg!
If this is not observed when transporting, there is a risk of injury to the
back, extremities or other body parts.
➢ Do not transport the unit on your own. Ask a second person for
assistance.
➢ Take very special attention to the place and stability during
HELOS-VARIO installation.

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Figure 46
3.5.1 Installation

Step 1:
Take the two profiles out of the
box and place them on a bench.
The profiles are marked at their
head sides with stickers “bottom”
and “top”. Arrange profiles in a
way that both show the stickers
“top” on top. Unscrew the four
marked Allen screws.

Figure 47

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Step 2:
Arrange the profiles parallel to
each other. The exact position is
defined by metal fitting spikes as
marked in the figure with the black
circle.

Figure 48
Step 3:
Insert the four Allen screws again
and tighten them very well. Pay
attention to the direction of the
screws.

Figure 49

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Step 4:
Take the stands delivered together
with the profile and mount them
one on each side about 20 cm
away from the edges. Tighten the
stands with the fixing screws very
well.

Figure 50
Step 5:
Take the HELOS/R detector side
of the housing (receiver) and optic
box side of the housing (emitter)
out of the packaging. Arrange
both housing in front of the pro-
file. Take care of the armoured
hose.

Place the HELOS/R receiver hous-

ing on the right part of the profile
and fix it with the two fixing
screws marked with the circles.
Figure 51
Place the HELOS/R emitter hous-
ing on the left part of the pro-file.
Fix it with the fixing screws.

The final set-up should look like in

Figure 46

The next steps are the same as described in the previous chapter for HELOS/R.
Please follow the descriptions of chapter 3.4.1 for preparation of the sensor, 3.4.2
for connection of the personal computer and 3.4.3 for installation of a lens magazine
disc.

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3.5.2 Adjusting the Width of the Measuring Zone

HELOS emitter housing and receiver housing are connected to the profile with two
fixing screws each. To move the emitter housing or receiver housing on the profile,
the fixing screws have to be loosened. As an example, this is described for the optic
box housing.

Loosen the fixing screws only as

far as you need to move the hous-
ing. Now, move the housing to the
left. Tighten the fixing screws
again.

CAUTION
Crushing hazard by fall-
ing objects when setting
the measurement zone
width!
If you loosen the fixing
screws of HELOS- Figure 52
VARIO too much, the
head part may fall forward
or backward or, addition-
ally, the detector side will
tilt to the side.
➢ Loosen the screws
only one turn be-
fore pushing.
➢ Don’t slide the
detector side over
the end of the 2nd
rack that an over-
weight arises.
1st
➢ Use a modified
measuring zone
Figure 53
(H4Z010 or
H4Z011), if the
adjustable dis-
tance appears to
be too low.

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If both HELOS-VARIO/KR hous-

ings are pushed together, the edge
of the measuring zone profile fits
perfectly into the groove at the
emitter housing.

Figure 54
As easy as the housings can be moved on the profile, as important is the position of
the dispersing unit and respectively the location where the sample is measured. The
geometry of laser beam, lens and focal distance (defining the maximum detection
angle) allows for a sufficient detection of the diffraction signals within a specified
range in front of the lens only. The following table lists the maximum distance be-
tween the lens at the detector side and the location where the sample is measured.
This distance is not the same for all lenses. Please check this specification carefully!

Measuring
R1 R2 R3 R4 R5 R6 R7
range

Distance 19  1 19  1  96  191  478  566  1132

[mm] 63  5

Table 4: Measuring ranges with limits

If your sample is not led through the laser beam within the respective
distance the system does not detect the entire diffraction information of
the sample. Then the measured particle size distribution will be severely
affected by lacking information (wrong result)!

The distance between the emitter housing and the measured sample has
not to be in a certain range.

3.5.3 Installation of the sealing air nozzles (optional, ex works only)

The HELOS-VARIO instrument can be equipped ex works with sealing air nozzles
in order to avoid contamination of the optics, especially in spray applications.
The option consists of two sealing air nozzles, hose lines, a pressure regulation
valve and the required mounting hardware.

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Step 1:
Screw the left sealing air nozzle to
the left housing wall with four cyl-
inder screws (M4x60).

The left housing can op-

tionally only be factory
fitted with M4 threaded
holes.

Figure 55
Step 2:
Fix the right sealing air nozzle
with the thumbscrew on the X-pro-
file.

Figure 56

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Step 3:
Connect the left and right sealing
air nozzles to the Y connector on
the pressure regulation valve us-
ing the two supplied PU hoses.

Connect the pressure regulation

valve to your pressure supply us-
ing the supplied coupling.

Figure 57
The pressure to be set on the pressure regulation valve must be individually adapted
to the respective application. Compare empirically different pressures and choose
the optimum pressure for your application. The influencing factors are for example
the sample material itself, the dispersion speed, the measurement setup and the suc-
tion power.

If the chosen pressure at the sealing air nozzles is set too high, it may
even worsen the contamination of the optics. If you having trouble find-
ing the optimal pressure for your application, please contact your local
Sympatec partner.

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3.6 Remote Control Software

The remote control software is pre-installed on the PC when the HELOS/R sensor
is shipped. If a repeated installation or an update of the software is necessary, please
refer to the software operating instructions. The remote control software starts only,
if a software protection key is present and installed.

The type of software protection

keys is usually a CRYPTOBOX®
USB-token. A serial number is
written on the software keys like
shown in the figure.

Figure 58

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Operating Instructions

4 Operation
4.1 Panel for Manual Operation

Ensure the preceding installation steps have been completed before starting the sys-
tem. See also chapter 3. The keys for the key switch are kept in the lens case of the
delivery.

Step 1:
If the power cable of HELOS/R
has been connected to the mains
supply, the sensor is in “stand-
by”-mode. It is indicated by the
red LED on the left.

The power consumption in stand-

by mode is about 0.1 W.

Figure 59
Step 2:
Turning the key switch of the sen-
sor to position “1” activates the
laser. This state is indicated by the
green left LED.

At this position no laser light is

emitted due to a special laser shut-
ter. Electronics and dispersing
system remain deactivated.

Figure 60

NOTICE
The laser system requires 30 minutes warm up time. Operation as well
as starting sequence have influence on the laser life time. We recom-
mend to switch the laser only once a day. Leave the laser switched on,
if you expect only shorter rest periods.
The power consumption is 20 W.

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Step 3:
Turning the key switch to position
“2” starts the HELOS/R electron-
ics. This state is indicated by the
red LED on the right.

Now the dispersing unit is sup-

plied with power. The external
power socket is activated by a
solid state relay.

After the successful initialisation 1st 2nd

of the internal electronics the right
LED changes to green. Figure 61

Now you may turn on the computer. We assume that you feel familiar with starting
a computer. Otherwise please read the shipped operating instructions of the PC.

After switching on all components the communication is set up between PC and

HELOS/R. The remote control software will recognize if the communication is suc-
cessfully established. If not, please check the installation again according to sec-
tion 3.4 or 3.5. It is impossible to operate the whole system or execute any
measurement without communication to the PC.

4.1.1 Error During Initialisation

If the HELOS/R sensor has not received a valid IP address during the initialisation
the right LED stays red and periodically double-flashes green. Please refer to chap-
ter 5.4 to overcome this situation.

4.2 Starting the Remote Control Software

The start of the remote control software and the tests of the communication are
described in detail in the software operating instructions.

4.3 Initial Operation

As the HELOS/R sensor is communicating via LAN with the remote control PC a
few settings have to be made before the first operation is possible. The simplest
setup is a direct connection between HELOS/R and the PC via a crossover connec-
tion. For this set-up a LAN cable or, depending on the type of used PC, a crossover
cable is needed. With this cable and the default factory settings of the sensor it is
always possible to establish a communication between remote control PC and sen-
sor. The sensor is set to the following default settings, shown in Table 5.

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Default
Logon admin

Passwort sympatec

IPv4 Adresse 192.168.1.1

Subnet Maske 255.255.255.0

Table 5: Measuring ranges with limits

If necessary, the sensor can be reset to these settings via a special button in the
housing as described in chapter 5.4.

If you intend to integrate your HELOS/R and the PC into your company network,
make sure to have the following information:

• Two IP addresses have to be reserved for HELOS/R and the PC, either au-
tomatically by a DHCP server in your network or manually by your network
administrator.

• The subnet mask of your network is either automatically communicated by

DHCP, or manually typed in. Please ask the network administrator.

• If DHCP is enabled, both, HELOS/R and the PC have to be given a name

that is unique in the network.

You can use the Web interface of HELOS/R to set these parameters for the sensor.
The network settings of the PC must match those of HELOS/R for this purpose. If
HELOS/R has been reset (e.g. via the reset button described in chapter 5.4), the PC
can communicate with HELOS/R via a direct cable by the following network set-
tings:

• fixed address, but different from HELOS/R, for example, 192.168.1.2.

• same subnet mask, 255.255.255.0.

Subsequently, please open your internet browser of the remote control PC and type
the URL http://192.168.1.1 (the default address listed above) to open the web page
of the HELOS/R sensor.

With the help of this web page you may set the instrument's name, IP Address (or
DHCP), subnet mask, and some more parameters which are described below.

Please be aware that changing the HELOS/R network settings might cut off the
communication between your PC and HELOS/R. This already happens at the mo-
ment when you click the “Submit” button on the Web page. You will not even get
a confirmation of success if, for example, the new parameters define a different

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subnet. The network parameters of the PC must then be changed accordingly to

resume the communication.

An alternative method of setting the network parameters is provided by

the remote control software and is described in the software operating
instructions. This method even works across subnet borders.

4.3.1 Access Control of the Connection

You may set a tick for activating a password preventing unauthorised access to your
HELOS/R. Then the login password of HELOS/R must be used for establishing a
connection between the HELOS/R sensor and the remote control soft-ware. If this
connection has been established once its parameters are kept even after a shutdown
of the remote control software.

4.3.2 Personal Area Network (PAN) as Option

An optional feature of the HELOS/R sensor is the control of a wireless personal

area network (PAN). The settings for the PAN ID or the control of the vacuum
extraction is done via the same web interface as described above. The default set-
ting for the vacuum extraction is “data cable”. The PAN ID of accessory delivered
by Sympatec GmbH is set in the factory and can be found on a sticker at the acces-
sory. All accessories belonging to one sensor have the same PAN ID. (They have
different addresses, though.) A PAN ID of “0000” disables the Personal Area Net-
work.

4.3.3 Date and Time Settings

The instrument has a built-in real-time clock which is set to UTC (Universal Coor-
dinated Time).

4.3.4 Password

The password can be individually set to prevent unauthorized access. In case it has
been lost, see chapter 5.4, how to reset to the factory settings.

4.4 Performing a Measurement

For a measurement the dispersing system has to be aligned correctly to the laser
beam. This alignment is described in the operating instructions of the dispersing
unit. How to take a measurement is also explained in this documentation and in the
operating instructions of the software, too.

The following Note applies if WINDOX 5 is used as the remote control

software:
Before measuring make sure you have chosen a correct trigger condition
by setting the radio button of the remote control software to “HELOS/R”.

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4.5 Changing the Measuring Range

NOTICE
Take special care while changing the measuring range. The sensitive
surfaces of the lenses must not be touched! Avoid finger prints!

NOTICE
The surface of the detector is unprotected and highly sensitive! The
HELOS/R detector housing shall only be opened for changing a lens or
lens magazine disc. Never try to clean or touch the surface of the detec-
tor! If the detector becomes dirty of whatever reason, please contact
your local Sympatec After-Sales-Service for further instructions.

The procedure how to exchange a lens in a HELOS/R-OM or lens magazine disc in

a HELOS/R-MAGIC is similar to the first installation. The only difference is that a
lens or lens magazine disc has to be taken out before the installation of a new one
can be carried out. After completing the change of the measuring range, the align-
ment of the detector table has to be done for HELOS/R-OM manually. In contrast
to the OM-Version HELOS/R-MAGIC sets the correct position of the detector table
automatically while changing to the lens. The software is reminding you to make a
new reference measurement after you have set up a new measuring range.

For changing a lens magazine disc at a HELOS/R-MAGIC please use the “Move
detector to safe position” function of the remote control software in order to drive
the detector to its safe position. Afterwards please follow the steps described in
chapter 3.4.3 in reverse order to take out the installed lens magazine disc. Follow
the steps in chapter 3.4.3 in correct order to install the disc with the chosen meas-
uring range. After the exchange a refocus of the detector will be done for the new
lens.

With the HELOS/R-MAGIC sensor you do not have to change the lens
magazine disc every time. If you want to change to another measuring
range, which is installed in the same disc, the disc will rotate and the
measuring range will be set-up automatically.

For changing a lens in the HELOS/R-OM system please follow the steps in chap-
ter 3.4.4 in reverse order to take out the installed lens. Install the new lens following
the steps in correct order and do not forget to set up the detector table at the accord-
ing position (chapter 3.4.5). After the exchange a refocus of the detector will be
done for the new lens.

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5 Maintenance and Care

All Instruments of Sympatec GmbH are designed to have minimum necessity of
maintenance. Nevertheless, a sensor has to be checked regularly in terms of the
quality of the signal with the help of the remote control software. Wear of sealing
and hoses is limited by the real operating conditions. It is important to check all
components in contact with fluids against leakage. This avoids failures of the in-
strument.

NOTICE
The painted surfaces of the equipment are not resistant to all kinds of
solvents. Please ask your local Sympatec partner regarding the suita-
bility of cleaning agents for the equipment.

5.1 Maintenance & Service Schedule

Regular maintenance and service of the HELOS system ensures its proper function.
The following service steps should be performed on a regular basis:

Component Maintenance interval …

daily monthly semi-yearly/yearly
signals of the height of the sig- - -
detector nals, comparison
with the initial sig-
nal

lenses cleanliness3 (see - -

also chapters 5.2
and 5.3)

housing cleanliness - -

qualification - comparison with certification of the

with reference specifications instrument by
material Sympatec service

Table 6: Maintenance interval

3 The application of dry dispersing systems may cause a need for more frequent control. Clean only if necessary.

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5.2 Cleaning the Lenses

Dismount the lens in the same way as for the change of the measuring range. This
is described in chapter 4.5.

The following two methods are recommended for cleaning:

• Cleaning with cleaning cloth

• Cleaning with lens cleaning tissue

5.2.1 Cleaning the Lenses with Cleaning Cloth

Cleaning cloths and gloves are supplied in the lens case. Use the gloves provided,
to avoid contamination of the cloth with grease from your fingers! Move the clean-
ing cloth over the surface in straight lines, not in circles! Put the cloth back into its
packaging after use. A cleaning cloth can be used for several cleaning cycles!

Blow bigger particles off the lens by using compressed air free of oil and water.

Figure 62
5.2.2 Cleaning the Lenses with Lens Cleaning Tissue

1. The lens should be cleaned with special lens cleaning tissue only. For this
purpose, the cleaning tissue has to be folded until it is about 4 cm2 in size.
The lens should be wiped dry gently.

NOTICE
The sides of the lens cleaning paper must not be used twice! Before
using the paper for a second time it has to be folded in such a way,
that a new area of the paper touches the lens. Any failure to adhere to
this procedure will definitely cause scratches and damages on the lens!

2. After that, one drop of acetone will be dripped on the paper on a side, which
has never been touched by your fingers. The lens must be wiped in one go
from the inside to the outside. Too much acetone solves the grease on your
fingers and leads to poor results!

3. If this procedure was not successful and the lens is still dusty or dirty, the
procedure has to be repeated. It has to be ensured, that a fresh part of the

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tissue faces the lens. This procedure must be repeated until an optimum re-
sult is obtained.

4. Reassemble the lens according to the procedure applied for changing the
lens magazine disc (see chapter 4.5).

5.3 Maintenance of the Dust Protection Window

5.3.1 Cleaning the Dust Protection Window

Cleaning of the dust protection window is possible with the window remaining built
in. Follow the same procedure as described for cleaning lenses (refer to chapter 5.2).

5.3.2 Exchanging the Dust Protection Window

The dust protection window has to be exchanged, when it is scratched. This can be
the case after improper cleaning.

Take care that no dirt or dust can enter the optic box, when the dust pro-
tection window is exchanged! Only special trained personnel is able to
execute cleaning of the inner optical components.

HELOS/R is delivered with a service key for changing the dust protection window:

Step 1:
Take the service key (3) for dust
protection window (2) out of the
lens case. The service key has two 1 2 3
pins, which are inserted into the
holes in the fastening ring (1) of
the dust protection window.

Figure 63

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Step 2:
Insert the service key in the holes
of the fastening ring.
1.
Loosen the ring by turning the ser- 2.
vice key counter clockwise.

Figure 64
Step 3:
Remove the fastening ring and
take out dust protection window. 2.

1.

Figure 65
For installation of the dust protection window perform the steps described above in
reverse order.

5.4 Factory Reset

In case that the communication between remote control PC and HELOS/R sensor
or the logon data for the instrument settings is lost, there is a reset button in every
instrument, by which the default values listed in chapter 4.3 can be restored. It is
not necessary to switch the instrument off and on for the purpose.

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Please press the button for more

than 5 seconds to reset the values.

Figure 66

If you still cannot connect to the instrument, make sure the PC is in the same sub-
net (IP address=192.168.1.x [x=2…254], subnet mask= 255.255.255.0) by check-
ing the properties of your PC network connection.

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6 Glossary
Laser Diffraction By this, the deflection (diffraction) of light waves
of a laser beam on a particle is understood.

Dispersion Distribution of a substance (dispersed phase) in in-

dividual particles or droplets in another substance
(dispersant). Both substances can be physically
separated from each other again.

Dispersing unit, (dry) A device for dispersing a solid in a gaseous dis-

persing medium, preferably in air.

Dispersing unit, (wet) A device to disperse solids or liquids into a dis-

persing medium. The formation medium is a liquid
for a wet measurements.

Dispersing liquid The liquid used to disperse and measure a solid.

Alternatively, the phase of the emulsion in pure
form, in which another liquid is to be dispersed.

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7 Technical Data
7.1 HELOS-OM

General Data HELOS/BR-OM HELOS/KR-OM HELOS-VARIO/KR-OM

System for particle-size analysis by means of laser diffraction

Up to five measuring ranges in the Up to eight measuring ranges in the Up to seven measuring ranges in the
range from R1 to R5T range from R1 to R8T range from R1 to R7T
Housing Head part Key-operated switch with stand-by position and bicolour LEDs
- Display of the status of sensor
- Display of the status of internal PC
Beam expansion unit (changeable beam diameter) with dust protection window
Connectors for mains input, switched mains output, dispersing unit, AUX (2 outputs, 1 input), external
trigger and external laser shutter. (optional)
Measuring zone Special mounting bench for adaption of the dispersing units with integrated grounding connection plate
fixed, 123 mm fixed, 123 mm variable, 123 – 1400 mm
Option: For devices with laser class 1, the laser is switched off if the disperser housing is opened
in the measuring zone
Detector part Lockable cover with security switch for laser shutter
Detector block with intelligent auto-focus drive for centring the detector
Socket for Ethernet cable
Identification: Type label, laser warning label, CE label, origin declaration label (Japan)

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General Data HELOS/BR-OM HELOS/KR-OM HELOS-VARIO/KR-OM

Optional: ZigBee compatible module for wireless communication
Beam generation HeNe laser light source with fibre optical cable and fixed beam expansion unit
Emitted light by HeNe laser:  = 632.8 nm, Pout <5 mW
Beam expansion4 Two steps Three steps Three steps
Beam diameter5 2.2 mm (R1, R2); 2.2 mm (R1, R2); 2.2 mm (R1, R2);
13 mm (R3, R4T, R5T) 13 mm (R3, R4, R5); 13 mm (R3, R4, R5);
26 mm (R6T, R7T); 26 mm (R6T, R7T)
35 mm (R6T, R7T, R8T)
Laser shutter6 Standard, with integrated security function
Laser class 1 (only in combination with spe- 1 (only in combination with spe- 3R
cially equipped dispersing cially equipped dispersing
units)7 units)7
3R (all other configurations) 3R (all other configurations)
Optics Bayonet fastening
Automatic detection of the measuring range during the initialisation phase
Option: barcode labelling for automatic detection if more than one measuring range is used

4 Automatic selection when changing the optical module of the measuring range.
5 The values denote the diameter of the circle on which the intensity is reduced to 1/e² with respect to the intensity of the centre of the beam.
6 The laser shutter interrupts the laser beam mechanically if the right housing lid or an optional external switch (door of the laboratory) is opened. Before operation the laser beam has to be released by the
sensor control software.
For exclusive use of a specially equipped disperser a shutdown occurs when opening a housing flap.
7 Only in combination with specially equipped dispersing units and because the user is not able to get his eye in contact with the laser beam neither directly nor by any optical instrument.

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General Data HELOS/BR-OM HELOS/KR-OM HELOS-VARIO/KR-OM

Possible measuring distances8 R1: 19 mm  1 mm 19 mm  1 mm
R1: R1: 19mm  1mm
R29: 19 mm  1 mm; 19 mm  1 mm;
R29: R29: 19mm  1mm;
63 mm  5 mm 63 mm  5 mm 63mm  5mm
R3:  96 mm R3:  96 mm R3:  96mm
R4T :  191 mm
10 R4 :  191 mm
10
R4:  191mm
R5T10:  164 mm R5 :  478 mm
10
R5:  478mm
R6T10:  566 mm R6T:  566mm
R7T10:  1132 mm R7T:  1132mm
special optics for R8T:
R6T10:  267 mm
R7T10:  535 mm
R8T10:  1337 mm
Data acquisition Manually moveable detector unit with mechanics for stoppers
Precision multi-element detector with 31 semi-circular detectors and 3 centre elements
Acquisition and transmission of 2000 particle size distributions per second
Each measurement is marked with a precise time stamp. Therefore, the detection time of the measure-
ments is independent of the type of PC
Digital trigger input for synchronisation of data acquisition with external events
Isolated RS485 interface for direct control of external dispersing and feeding units
Data processing Commercially available business-PC (state-of-the-art) with fast Ethernet LAN connection (100 MBit/s)

8 This is the maximum distance a particle may have with respect to the front of the lens/objective.
9 The SUBMICRON R2 module is optimised for two measuring positions. The correct position is identified depending on the dispersing system used.
10 Only of theoretical interest. The whole measuring zone is covered.

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General Data HELOS/BR-OM HELOS/KR-OM HELOS-VARIO/KR-OM

Dimensions L = 705 mm L = 1102 mm L = 2022 mm
B = 279 mm B = 279 mm B = 279 mm
H = 322 mm H = 322 mm H = 322 mm
Weight 29 kg 36 kg 70 kg
Power requirement11 Line in: 90 – 250 VAC | 50 – 60 Hz Standby: 0,1 W
Laser on: 31 W
Operation: 43 W w/o dispersing unit
Operation: 300 Wmax with dispersing unit
Electrical connections 12
Switchable power output (Line out) : 90 – 250 VAC | 50 – 60 Hz, 1400 Wmax
Disperser Connection 6-pin (Dosing Unit): only for connection of a Sympatec dispersing or dosing
unit
Additional socket 5-pin (AUX): 2 digital outputs: 24 VDC, 500 mA max.
1 digital input, galvanically isolated: (on: 22-24 VDC,
off: < 0,8 VDC, 5 mA)
For control of additional accessories, e.g. central exhaust
or a vacuum cleaner with automated cleaning
Only if a vacuum cleaner with automated cleaning is not
used, the second digital output is freely available
Auxiliary voltage: 24 VDC, <100 mA
Additional socket 4-pin (Trigger external): 1 digital input, galvanically isolated: (on: 22-24 VDC,
off: < 0,8 VDC, 5 mA)
For triggering the measurement by an external signal
Auxiliary voltage: 24 VDC, <100 mA

11 The system is powered by a wide range power supply. The current is specified without any connected dispersing unit or load at the switched mains output.
12 A switched mains connector at the rear is provided for the supply of vacuum cleaners or ultrasonic generators. It is switched either by software or external control input (e.g. used by dispersing units to switch
on the vacuum cleaner).

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General Data HELOS/BR-OM HELOS/KR-OM HELOS-VARIO/KR-OM

Additional socket 4-pin (Laser shutter): 1 digital input, galvanically isolated: (on: 22-24 VDC,
off: < 0,8 VDC, 5 mA)
For integration of an external signal or switch into the
laser safety chain.
Auxiliary voltage: 24 VDC, <100 mA
IP marking IP20
Accessories Software for sensor control
Operating instructions on CD
Case for optical modules with cleaning materials and special tools
Transportation locks13

13 Prior transporting the system the optical modules (magazine discs) have to be removed. The covers and safe-ty locks for dust protection window, optical modules, detector and detector unit have to be
installed.

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7.2 HELOS Multirange

General Data HELOS/BR multi range HELOS/KR multi range HELOS-VARIO/KR multi range

System for particle-size analysis by means of laser diffraction

Up to five measuring ranges in the Up to seven measuring ranges in the Up to seven measuring ranges in the
range from R1 to R5T range from R1 to R8T range from R1 to R7T
Housing Head part Key-operated switch with stand-by position and bicolour LEDs
- Display of the status of sensor
- Display of the status of internal PC
Beam expansion unit (changeable beam diameter) with dust protection window
Connectors for mains input, switched mains output, dispersing unit, AUX (2 outputs, 1 input), external
trigger and external laser shutter. (optional)
Measuring zone Special mounting bench for adaption of the dispersing units with integrated grounding connection plate
fixed, 123 mm fixed, 123 mm variable, 123 - 1400 mm
Option: For devices with laser class 1, the laser is switched off if the disperser housing is opened
in the measuring zone
Detector part Lockable cover with security switch for laser shutter
Drive unit for lens magazine discs with security function and position detection
Quick interlock for removal of the magazine disc
Detector block with intelligent auto-focus drive for centring the detector
Socket for Ethernet cable

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General Data HELOS/BR multi range HELOS/KR multi range HELOS-VARIO/KR multi range
Identification: Type label, laser warning label, CE label, origin declaration label (Japan)
Optional: ZigBee compatible module for wireless communication
Beam generation HeNe laser light source with fibre optical cable and fixed beam expansion unit
Emitted light by HeNe laser:  = 632.8 nm, Pout <5 mW
Beam expansion14 Two steps Three steps Three steps
Beam diameter15 2.2 mm (R1, R2); 2.2 mm (R1, R2); 2.2 mm (R1, R2);
13 mm (R3, R4T, R5T) 13 mm (R3, R4, R5); 13 mm (R3, R4, R5);
26 mm (R6T, R7T); 26 mm (R6T, R7T)
35 mm (R6T, R7T, R8T)
Laser shutter16 Standard, with integrated security function
Laser class 1 (only in combination with spe- 1 (only in combination with spe- 3R
cially equipped dispersing cially equipped dispersing
units) 17 units)17
3R (all other configurations) 3R (all other configurations)

14 Automatic selection when changing the optical module of the measuring range.
15 The values denote the diameter of the circle on which the intensity is reduced to 1/e² with respect to the intensity of the centre of the beam.
16 The laser shutter interrupts the laser beam mechanically if the right housing lid or an optional external switch (door of the laboratory) is opened. Before operation the laser beam has to be released by the
sensor control software.
For exclusive use of a specially equipped disperser a shutdown occurs when opening a housing flap.
17 Only in combination with specially equipped dispersing units and because the user is not able to get his eye in contact with the laser beam neither directly nor by any optical instrument.

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General Data HELOS/BR multi range HELOS/KR multi range HELOS-VARIO/KR multi range
Optics Triple magazine disc:

R1,R2,R3,R4T,R5T R1,R2,R3,R4,R5,R6T,R7T,R8T R1,R2,R3,R4,R5,R6T,R7T

Quad magazine disc:

R1,R3,R4T,R5T R1,R3,R4,R5,R6T,R7T,R8T R1,R3,R4,R5,R6T,R7T

Automatic detection of the measuring range during the initialisation phase
Automatic detection and management of two different magazine discs
Possible measuring distances 18 R1: 19 mm  1 mm R1: 19 mm  1 mm R1: 19 mm  1 mm
R219: 19 mm  1 mm; R219: 19 mm  1 mm; R219: 19 mm  1 mm;
63 mm  5 mm 63 mm  5 mm 63 mm  5 mm
R3:  96 mm R3:  96 mm R3:  96 mm
R4T20:  191 mm R420:  191 mm R4:  191 mm
R5T :  164 mm
20
R5 :  478 mm
20
R5:  478 mm

18 This is the maximum distance a particle may have with respect to the front of the lens/objective.
19 The SUBMICRON R2 module is optimised for two measuring positions.
20 Only of theoretical interest. The whole measuring zone is covered.

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General Data HELOS/BR multi range HELOS/KR multi range HELOS-VARIO/KR multi range
R6T20:  566 mm R6T:  566 mm
R7T :  1132 mm
20
R7T:  1132 mm
special optics for R8T:
R6T20:  267 mm
R7T20:  535 mm
R8T20:  1337 mm
Data acquisition Automatically moveable detector unit
Precision multi-element detector with 31 semi-circular detectors and 3 centre elements
Acquisition and transmission of 2000 particle size distributions per second
Each measurement is marked with a precise time stamp. Therefore, the detection time of the measure-
ments is independent of the type of PC
Digital trigger input for synchronisation of data acquisition with external events
Isolated RS485 interface for direct control of external dispersing and feeding units
Data processing Commercially available business-PC (state-of-the-art) with fast Ethernet LAN connection (100 MBit/s)
Dimensions L = 705 mm L = 1102 mm L = 2022 mm
B = 279 mm B = 279 mm B = 279 mm
H = 322 mm H = 322 mm H = 322 mm
Weight 30 kg 37 kg 70 kg
Power requirements21 Line in: 90 – 250 VAC | 50 – 60 Hz Standby: 0,1 W
Laser on: 31 W
Operation: 43 W w/o dispersing unit
Operation: 300 Wmax with dispersing unit

21 The system is powered by a wide range power supply. The current is specified without any connected dispersing unit or load at the switched mains output.

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General Data HELOS/BR multi range HELOS/KR multi range HELOS-VARIO/KR multi range
Electrical connections Switchable power output (Line out)22: 90 – 250 VAC | 50 – 60 Hz, 1400 Wmax
Disperser Connection 6-pin (Dosing Unit): only for connection of a Sympatec dispersing or dosing
unit
Additional socket 5-pin (AUX): 2 digital outputs: 24 VDC, 500 mA max.
1 digital input, galvanically isolated: (on: 22-24 VDC,
off: < 0,8 VDC, 5 mA)
For control of additional accessories, e.g. central exhaust
or a vacuum cleaner with automated cleaning
Only if a vacuum cleaner with automated cleaning is not
used, the second digital output is freely available
Auxiliary voltage: 24 VDC, <100 mA
Additional socket 4-pin (Trigger external): 1 digital input, galvanically isolated: (on: 22-24 VDC,
off: < 0,8 VDC, 5 mA)
For triggering the measurement by an external signal
Auxiliary voltage: 24 VDC, <100 mA
Additional socket 4-pin (Laser shutter): 1 digital input, galvanically isolated: (on: 22-24 VDC,
off: < 0,8 VDC, 5 mA)
For integration of an external signal or switch into the
laser safety chain.
Auxiliary voltage: 24 VDC, <100 mA
IP marking IP20

22 A switched mains connector at the rear is provided for the supply of vacuum cleaners or ultrasonic generators. It is switched either by software or external control input (e.g. used by dispersing units to switch
on the vacuum cleaner).

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General Data HELOS/BR multi range HELOS/KR multi range HELOS-VARIO/KR multi range
Accessories Software for sensor control
Operating instructions on CD
Case for optical modules with cleaning materials and special tools
Transportation lock23

23 Prior transporting the system the optical modules (magazine discs) have to be removed. The covers and safe-ty locks for dust protection window, optical modules, detector and detector unit have to be
installed.

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8 Appendix
8.1 Optional Accessories

Sympatec GmbH offers the following accessories to increase the performance of

the instrument.

Item Item Code and Description

BDOCCD00
Operating Instructions on CD

HELOS-OM
HMF01S
SUBMICRON lens system f=20mm for HELOS/F/R-series

HMF02S
SUBMICRON lens system f=50mm for HELOS/F/R-series

HMF030
Lens f=100mm for HELOS/F/R-series

HMF040
Lens f=200mm for HELOS/F/R-series

HMF04T
TOPMICRON lens system 350, f=200mm

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Item Item Code and Description
HMF050
Lens f=500mm for HELOS/F/R-series

HMF05T
TOPMICRON lens system 875, f=500mm (figure similar)

HMF06T
TOPMICRON lens system 1750, f=1000mm

HMR07T
TOPMICRON lens system 3500, f=2000mm (figure similar)

HMF08T
MEGAMICRON lens system 8500, f=5000mm (figure similar)

HELOS multi range

HMF11S
SUBMICRON lens system f=20mm for HELOS/F/R-series

HMF12S
SUBMICRON lens system f=50mm for HELOS/F/R-series

HMF130
Lens f=100mm for HELOS/F/R-series

HMF140
Lens f=200mm for HELOS/F/R-series

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Item Item Code and Description

HMF14T
TOPMICRON lens system 350, f=200mm

HMF150
Lens f=500mm for HELOS/F/R-series

HMF15T
TOPMICRON lens system 875, f=500mm

HMF16T
TOPMICRON lens system 1750, f=1000mm

HMR17T
TOPMICRON lens system 3500, f=2000mm (figure similar)

HMF18T
MEGAMICRON lens system 8500, f=5000mm (figure similar)

Table 7: Accessories

8.2 List of Spare Parts and Wearing Parts

All components of the instrument are manufactured of high-quality materials and

normally, spare parts are not required. In the rare event of a defect in the equipment,
spare parts may be ordered from the Sympatec After Sales Department. Keep your
project number (xxxx), located …, and the item code ready for your order.

Item Item code and Description

A520 660.1W
Dust protection window for HELOS optic box

A523 971.2W
Retaining ring for dust protection window HELOS/F/R-series

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Item Item code and Description
A520 293.0W
Retaining ring for R3 lens at small hole at HELOS/MAGIC lens wheel

A522 900.0W
HELOS/F/R-series key set

A500 650.0W
HELOS/F/R-power cable

K008RP03.0W
Patch-cable 3m for LAN-HELOS/R-connection

K008RC03.0W
Crossover-cable 3m for PC-HELOS/R-connection

A531607.1W
Gloves for cleaning with tissues, 5 packages

A523 971.2W
Cleaning tissues, 5 packages

A534178.1W
Lens cleaning tissue, carton with 25 wallets

w/o picture A534180.1W

5 compressed air-bottles 67 "PLUS" for cleaning of lenses and dust pro-
tection windows (differs by country)

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Item Item code and Description

A520 144.0W
Sealing rind, POM black and small, for HELOS/MAGIC lens disc,
d=50mm

A520 169.1W
Sealing ring, green and large, for HELOS/MAGIC lens disc, d=60 mm

A511 145.1W
Metal-rubber foot for HELOS/VARIO system

Table 8: Spare Parts

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