Megger KF-LAB Mk II User manual

Megger KF-LAB Mk II
Moisture Meter
User Guide
(v0816)

Megger KF-LAB Mk II
2

Megger KF-LAB Mk II
3
Contents
Chapter 1 Introduction------------------------------------------------------------------------5
1.1 Instrument Description-----------------------------------------------------5
1.2 Principle of Measurement-------------------------------------------------6
1.3 Instrument Connections--------------------------------------------------- 7
Chapter 2 Safety Information--------------------------------------------------------------- 8
2.1 General Safety Points------------------------------------------------------8
2.2 Electrical Safety------------------------------------------------------------- 8
2.3 Solvent and Chemical Safety-------------------------------------------- 8
2.4 Recycling and Disposal----------------------------------------------------8
Chapter 3 Instrument Setup-----------------------------------------------------------------9
3.1 Receiving a Megger KF-LAB---------------------------------------------9
3.1.1 Packaging---------------------------------------------------------9
3.1.2 Checks-------------------------------------------------------------9
3.1.3 Location----------------------------------------------------------- 9
3.2 Connecting the Power Supply------------------------------------------- 9
3.3 Setting Up the Glassware-------------------------------------------------10
3.3.1 Glassware Assembly-------------------------------------------10
3.3.2 Connecting to the Megger KF-LAB-------------------------10
3.3.3 Filling and Changing Reagents------------------------------11
3.4 Loading the Printer----------------------------------------------------------13
3.5 Connecting a USB Device------------------------------------------------ 14
Chapter 4 Basics of Operation-----------------------------------------------------------15
4.1 Switching ON and OFF---------------------------------------------------15
4.2 Setting the Date and Time-----------------------------------------------15
4.3 Preconditioning------------------------------------------------------------- 16
4.4 Program Functions---------------------------------------------------------17
4.5 Programming a Method---------------------------------------------------18
Chapter 5 Running a Test----------------------------------------------------------------- 24
5.1 Example Applications----------------------------------------------------- 24
5.2 Water Standard Test------------------------------------------------------ 26
5.3 How to Run a Test--------------------------------------------------------- 26
5.4 Drift Rate Compensation------------------------------------------------- 28
5.5 Overtitration------------------------------------------------------------------29
Chapter 6 Results---------------------------------------------------------------------------- 30
6.1 Printout Explanation------------------------------------------------------- 30
Chapter 7 Results Manager---------------------------------------------------------------32
7.1 Description--------------------------------------------------------------------32
7.2 Installation---------------------------------------------------------------------32
7.3 Running Results Manager------------------------------------------------ 33
7.4 Display Explanation---------------------------------------------------------34
7.5 Closing and Uninstalling---------------------------------------------------36

Megger KF-LAB Mk II
4
Chapter 8 Maintenance--------------------------------------------------------------------37
8.1 Reagent Life-----------------------------------------------------------------37
8.2 Cleaning the Glassware--------------------------------------------------37
Chapter 9 Technical Specifications--------------------------------------------------- 39
Chapter 10 Parts List-------------------------------------------------------------------------40
Chapter 11 Troubleshooting---------------------------------------------------------------41
Chapter 12 Conformity and Warranty-------------------------------------------------- 42
12.1 Declaration of Conformity--------------------------------------- 42
12.2 Quality Control----------------------------------------------------- 42
12.3 Customer Support and Service--------------------------------42
12.4 Warranty-------------------------------------------------------------43
12.5 Warranty Exemptions---------------------------------------------43

Megger KF-LAB Mk II
5
Ch pter 1 Introduction
1.1 Instrument Description
The KF-LAB model has a small footprint, is easy to use, and supplied complete with a
specifically designed low drift cell which is also suitable for outdoor use. The built-in
battery and optional carry case, provide the versatility required by the laboratory and also
the ease of use and portability required by the field engineer.
Aquamax KF reagents have been specially formulated for use with KF-LAB titrators.
Reagent A (anode) is suitable for most routine applications and is especially useful for
water content determination of oil samples, e.g. transformer oils, crude oils, etc. This
anode reagent is supplied in “single shot” bottles of 100ml – No measuring of volumes
required – No mixing of other solvents required. Reagent C (cathode) is supplied in
“single shot” 5ml vials.
The carry case provides the portability required by the field engineer. The KF-LAB can be
transported, complete with glassware assembled, ready for immediate use on arrival at
destination. Power cords, syringes, etc., can all be carried inside the carry case lid which
has a special compartment for this purpose.
To obtain the full benefits that this instrument can offer it is recommended that you read
this user manual before assembling the unit.
(All KF-LAB power supplies are double insulated units that do not need an earth (ground)
connection. These units are sealed and conform to CSA(LR84459), UL listings and CE
requirements. KF-LAB titrators only require a low voltage 15V input to the electronic /
control circuitry. The moulded plastc casing of the instrument also provides additional
insulation.)

Megger KF-LAB Mk II
6
1.2 Principle of Measurement
Karl Fischer titration is simply a means to measure water content of samples. Modern
instruments, such as the Megger KF-LAB, use the Coulometric principle, whereby the water
present in the sample is coulometrically titrated to a predefined end point at which there is a
minute excess of free iodine present. Stoichiometrically, 1 mole of water will react with 1
mole of iodine, so that 1 milligram of water is equivalent to 10·71 coulombs of electricity.
Combining the Coulometric technique with Karl Fischer titration, Megger KF Titrators
determine the water content of the sample by measuring the amount of electrolysis current
necessary to produce the required iodine. This is an absolute technique which does not
require calibration of the reagents.
SO
2
I
2
+SO
2
+3C
5
H
5
N+H
2
O → 2C
5
H
5
N.HI+C
5
H
5
N
O
SO
2
SO
4
CH
3
C
5
H
5
N +CH
3
OH → C
5
H
5
N
O H
2l ¯ - 2e →l
2
Using the latest pulse current technology and our patented “ACE” control system, (Patent
No.GB2370641), the Megger KF-LAB automatically selects the appropriate titration speed
dependent upon the amount of water present in the sample. The titration speed is reduced
as the end point is approached, and when the titration is completed the instrument prints out
and displays the results.

Megger KF-LAB Mk II
7
1.3 Instrument Connections
Various ports are located on the back plate of the instrument. Below is a list of ports that can
be found:
(1) Power Supply Port
The power supply port is for connecting to an 18V mains power supply, using the
supplied power adaptor.
(2) RS232 Port
For updating Titrator software, connecting to other equipment for remote controlling
(software specific protocols to be provided).
(3) USB/A Port
For exporting results data to a Removable Flash Drive (memory stick), when running
sample tests in the field or remote locations, and subsequent transfer to PC at a later
date for loading onto Results Manager files.
(4) USB/B Port
For connecting directly to PC to export data to Results Manager and enable results to be
saved on files for future reference. (See Results Manager User Manual section).

Megger KF-LAB Mk II
8
Ch pter 2 S fety Inform tion
2.1 General Safety Points
This product is in conformity with the EU Directives 2004/108/EC and
2006/95/EC. This is based upon the compliance of the products with the
harmonised standards: BS EN 61000-6-1:2007; BS EN 61010-2-030:2010;
and BS EN 61326-1:2013.
This product is manufactured in accordance to RoHS following the EU
Directive 2011/65/EU; it does not contain any of the restricted substances in
concentrations and applications banned by this directive.
2.2 Electrical Safety
The Megger KF-LAB Moisture Meter complies with the international
standard IEC 61010. Only operate this instrument within the mains
voltage supply that is specified on the back of the instrument, an
incorrect mains supply can damage the instrument. Never open the
housing of the instrument, only GR Scientific personnel who are trained
to service the instrument can open the housing. There is risk of
electrocution if live components are touched.
Always ensure the instrument is disconnected from the mains power supply when
connecting or disconnecting cables from the back of the instrument, as electrostatic
discharge can build up.
2.3 Solvent and Chemical Safety
When using flammable or irritant solvents and chemicals, follow suitable
safety measures to protect yourself and others around. Always use the
instrument in a well ventilated area, clean up spilled fluids immediately,
and keep flame sources away from the work area. Always follow the
safety instructions of the chemical manufacturer and apply the correct
countermeasures that are required.
2.4 Recycling and Disposal
This instrument is covered by the WEEE (Waste Electronic and Electrical
Equipment) Directive 2012/19/EU to prevent the negative and harmful
effects on the environment and public health. For more information on
how to dispose of the instrument safely, please contact your local
authority, your local waste disposal company or Megger directly.

Megger KF-LAB Mk II
9
Ch pter 3 Instrument Set Up
3.1 Receiving a Megger KF-LAB
3.1.1 Packaging
The Megger KF-LAB is packaged in suitable protective packaging to ensure that no damage
occurs during transit, only this packaging is suitable for the safe transportation during transit.
Please keep this packaging as transit of the instrument may need to occur in the future.
3.1.2 Checks
Once you have received the instrument, immediately check to make sure that there is no
damage and no parts are missing. A delivery note will be included within the package to use
to compare with the shipment.
Ensure that inside the shipment has a calibration certificate for the instrument, if not please
request this from the manufacturer.
3.1.3 Location
Locate the instrument within the work area where it is free from excessive:
−vibrations
−direct sunlight
−contamination from chemicals
−explosive environments
−corrosive atmospheres
−major temperature fluctuations
3.2 Connecting the Power Supply
The Megger KF-LAB is powered by an external mains source, with a power pack to ensure
this connection is the correct voltage of 18V DC for the instrument.
Damage may occur beyond repair and the user may be subjected to electric static shocks if
the incorrect power is supplied.
Note: Refer to Chapter 2 for more safety information.
To avoid risk of electrocution, make
sure the I/O switch is set to OFF
before connecting the power supply.

Megger KF-LAB Mk II
10
3.3 Setting Up the Glassware
3.3.1 Glassware Assembly
3.3.2 Connecting to the Megger-KF LAB Moisture Meter
(1) Position the titration vessel on the Titrator.
(2) Position the electrodes on the
titration vessel and tighten by
hand.
Note: The glass joints do not require PTFE
sleeves or grease. The special screw fittings
seal the vessel from the atmosphere and are
easily released, even after several weeks.

Megger KF-LAB Mk II
11
(3) Connect the generator and detector leads to the vessel
and then to the BNCs.
(4) Place the stirrer bar inside the titration vessel.
(5) Fit injection septas into the injection port caps and screw
tightly by hand onto the injection ports.
(6) Position the drying tube with desiccant and tighten by
hand.
The assembled titration cell is now ready to be charged with reagents prior to use. Please be
sure to assemble correctly every time the cell is cleaned or re-filled. It is recommended that
the Titrator is NOT switched on until after the titration vessel has been charged with
reagents. This will avoid damage being caused to the electrodes by the stirrer bar. Avoid
twisting the electrode leads otherwise they may become damaged.
3.3.3 Filling and Changing Reagents
Megger KF-LAB Titrators have been designed to operate with all major Coulometric Karl
Fischer reagents. For most routine applications generator electrodes with frit/diaphragm are
used in conjunction with 100ml of anode reagent and 5ml of cathode reagent. We strongly
recommend using Aquamax KF A and C Reagents as these have been specially formulated
for oil samples.
When analysing Transformer oils, Crude oils and other petroleum products, there are
specially formulated anode reagents which contain other solvents to improve sample
miscibility and solubility are recommended. There are also single Coulometric reagents
available for use with fritless generator electrodes. Although we do not recommend these for
oil sample analysis.
Note: When analysing samples of Ketones, amines or others which may interfere with the
reaction it is advisable to use specialised reagents which can be obtained from various
suppliers.

Megger KF-LAB Mk II
12
Although reagents can be poured into the titration vessel whilst it is located on the Titrator,
we recommend that the vessel, electrodes and electrode leads are removed from the
instrument whilst this procedure is performed to avoid reagent spillage onto the instrument
casing.
Note: Any spillage onto the instrument casing should be wiped off immediately to avoid
damage or staining.
Remove the drying tube and injection septa. Using the funnel
supplied, charge the titration vessel with 100ml anode reagent
(this is approximately to the bottom line on the vessel).
Also using the funnel, charge the inner chamber of the generator
electrode with 5ml of cathode reagent. (This is not required if
using fritless generator electrode).
Note: It is not necessary to clean the funnel between reagents.
Reconnect the drying tube and injection septa so that the titration vessel is sealed from
ingress of atmospheric moisture.
Locate the complete titration vessel onto the Titrator and connect
the electrode leads onto the appropriate sockets
There are some bi-products formed in the cathode chamber which
can react with the iodine in the anode chamber and this can cause
longer preconditioning times. It is advisable to have the cathode
reagent 2- 3mm lower than the anode reagent when first charging
the titration vessel to speed up preconditioning.
The Megger-LAB Titrator is now ready to be switched on.

Megger KF-LAB Mk II
13
3.4 Loading the Printer
To load the paper into the printer, first open the paper roll holder lid above the print head and
remove the old roll and rollers. Now fit rollers to new paper roll, load as shown and insert the
paper into the slot at the rear of the print head. As soon as the printer sees the paper it will
automatically load it. To avoid damage to the printer mechanism it is advisable to only use
the correct part number thermal paper rolls.
Cut the end of the paper roll at
a slight angle as shown. This
will make it easier to feed into
the printer
mechanism
.
The mechanism has optical
sensors which detect the
paper and will auto feed.
Schematic of paper feed.
Fit the paper bobbin onto both
sides of paper roll.
Locate paper roll into the
compartment.

Megger KF-LAB Mk II
14
3.5 Connecting a USB Device
To use the memory store, insert Flash Drive into USB port A, the Titrator will see it and a
symbol will appear on the display.
The symbol will appear blacked out while the drive is being written to and then clear when
idle.
The drive should only be removed when in the idle mode.
To read data saved on the drive insert it into a PC USB port. Start Results Manager, load
selected file and then save in the format you require. Refer to Chapter 7 Results Manager.

Megger KF-LAB Mk II
15
Megger KF-LAB
v2.6n Press START
Set Date/Time:
DD/MM/YYYY HH:MM:SS
Ch pter 4 B sics of Oper tion
4.1 Switching ON and OFF
The Megger KF-LAB Moisture Meter has one I/O switch and is powered by either a mains
power supply using an adaptor, or a built-in battery for power.
Note: Refer to Chapter 3.2 for power supply connections.
4.2 Setting the Date and Time
(1) Switch on the Megger KF-LAB and wait for it to display the following:
(2) Hold down the [START] key until the Megger KF-LAB displays:
(3) Use the [ . ] move the cursor across the screen.
(4) Use the numerical keys to set / alter the required number.
(5) When completed press the [ENTER] to save the changes and exit.
To avoid risk of electrocution,
make sure the I/O switch is set to
OFF before connecting the power
supply from a mains source.

Megger KF-LAB Mk II
16
Megger KF-LAB
v2.6n Press START
KF-LAB xxxx µg
||||||||| 4 Precondition
Dft xxxx µg
| Drift Test
Dft = 0 xxxx µg
| Ready
4.3 Preconditioning
(1) Assemble glassware (see Assembly Instructions)
(2) Charge vessel and generator electrode with reagents (see Filling & Changing
Reagents)
(3) Locate assembled titration vessel onto the Megger KF-LAB
(4) Connect the electrode leads
(5) Connect mains lead / power cord
(6) Switch ON (using switch on rear panel) and wait for display to show:
Note: If required adjust the stirrer speed using the arrow keys on the front of the instrument.
(1) Press [START] and allow the instrument to precondition (equilibrate).
At the end of the precondition period the display will show:
After the initial drift has been calculated, in micrograms of water per minute, the Megger KF-
LAB is ready for operation.
The background drift value will usually slowly decrease with time as the titration vessel
becomes drier and more stable. Although it is possible for the Titrator to be used at high drift
values, it is advisable to wait until the drift value is below 20 µg/minute, and stable, before
commencing, especially for low water content samples in the ppm ranges.
The lower and more stable the drift – the more accurate the result.
Detector Signal
Titration Speed
Microgram Count

Megger KF-LAB Mk II
17
4.4 Program Functions
When the Megger KF-LAB displays Ready you can enter titration parameters, recall or edit
existing methods, enter new method files, etc., by using [PROGRAM], [ENTER], [CLEAR],
and [.].
Menu List
Sample ID Number up to 8 digits
Recall Method method number 1 – 9
Result Format µg, ppm, mg/kg or % water
Calculation Mode V/SG, W/W, W/K or V/v
Sample Volume up to 100000000ml
Specific Gravity up to 100000000
Printer Mode off, every result or full report
Statistics Print up to 99 runs, will print min., max and mean.
Print Drift on or off
Start Delay Time up to 30 minutes
Min. Titration Time up to 30 minutes
End Sensitivity 0 – 9 seconds
Beep Mode off, key press, end titration or both
Language select language
Generator Electrode with frit, without frit
Save Method store up to 10 methods
Note: See Chapter 4.5 Programming A Method for an explanation of each Menu List
parameter.
KEY
FUNCTION
[PROGRAM]
Press [PROGRAM] to scroll through menus listed.
[ENTER]
Allows parameter values for the displayed menu to be entered
into memory.
[CLEAR]
1. If you have finished entering data, press [CLEAR] to return to
the Ready condition.
2. If you have started to enter an incorrect value, press [CLEAR]
to return to the previously stored value.
[ . ]
Scrolls through individual parameters in each menu. When the
required parameter is display, press [ENTER] to store it.

Megger KF-LAB Mk II
18
Dft = 0 xxxx µg
| Ready
Sample ID No. Sample ID No.:
12345678
Result Format
%
4.5 Programming a Method
After the initial drift has been calculated, in micrograms (µg) of water per minute, the Megger
KF-LAB is ready for operation. It is now possible to step through the PROGRAM parameters
and enter the required calculation data.
Press [PROGRAM] until the required option is displayed. Pressing [PROGRAM] will move
you on to the next prompt, pressing [CLEAR] will return to Ready condition. It is not
necessary to step through all of the programme functions for every method, for example, if
you only require to change the Beep Mode from Off to Both – simple press [PROGRAM] until
display shows Beep Mode, press the [.] until display shows “Both”, then press [ENTER] and
[CLEAR] to return to Ready.
Sample ID Number
Press [PROGRAM] Display will show: Key up to 8 numbers: Press [ENTER]
If you do not want to enter any further parameters simply press [CLEAR] to go back to the
Ready condition.
Press [PROGRAM] if you want to continue entering other parameters.
Result Format
Press [PROGRAM] Display will show:
Results can be selected in µg, ppm, mg/kg or % water.
If you want to select the format already stored in memory, and shown on the display, press
[PROGRAM] and the instrument will go to the next prompt. If you want to change format to
give results in ppm, mg/kg or % you can scroll through these options by pressing [.] until the
required format is displayed, and then press [ENTER] to store this in memory and
[PROGRAM] to move onto the next prompt. If you have selected a result format in ppm,
mg/kg or % the instrument will prompt you for the necessary calculation mode and data
values.

Megger KF-LAB Mk II
19
Result Format
%
Calculation Mode
V/SG
The display shows the calculated water content according to the programmed Result Format
and Calculation Mode program settings, i.e. whatever has been chosen to be shown/printed
at the end of the titration. The only exception to this is in the W/w mode when the Tare
Weight has not yet been entered. In this case the display will show the µg count. The
[PROGRAM] key can be used to enter the Tare Weight at any time during the titration; once
this has been done the display will start to show the calculated result in ppm, mg/kg or %
water.
Calculation Mode
Megger KF-LAB Titrators have four standard calculation modes in memory. Each of these
allow the instrument to divide the microgram count by the gram weight of sample introduced
so that the calculated result can be printed out in either ppm or percentage of water.
−Press [.] to scroll through the options that are available.
−Select the calculation mode required and press ENTER.
−The display will prompt you with the appropriate parameters.
−Enter the numerical value for each parameter and press ENTER.
The four standard calculations are:
1. Weight difference W/w
Note: This is the most accurate calculation and is suitable for almost all types of samples,
powders, liquids, gases, etc.
Result (ppm or %) = microgram count
W - w
Where: W = Total weight of sampler + sample (gm)
w = Tare weight of empty sampler (gm)
After entering the total weight (W) the instrument will return to the Ready condition. The Tare
weight (w) can be entered at any time during the titration by pressing [PROGRAM], or at the
end of titration. For ease of operation it is possible to enter the Total weight (W) as
0.0000gm, then place the full sampler on the balance and tare to zero.
Thereafter it is only necessary to enter the weight difference (tare weight, w) for each
titration. This procedure reduces potential data entry errors.

Megger KF-LAB Mk II
20
2. Weight/Dilution ratio W/K
Note: Use this method if you need to dissolve a sample in another solvent. Suitable for
samples which will not dissolve in the anode reagent or which might interfere with the KF
reaction).
Result (ppm or %) = microgram count - bl
W x K
Where: W = Weight of sample dissolved (gm)
K = Total volume of diluent + sample
Volume injected into Aquamax KF
bl = micrograms of water for same injected volume of diluent (µg)
e.g.
Accurately weigh approximately 2 gm of sample into a 20ml stoppered graduated flask.
Make up to the volume line with suitable solvent / diluent. Using appropriate syringe inject
100µl of diluted sample into the titration cell.
Calculation parameters for this example would be:
W = 2 gm
K = 20ml = 200
100µl
bl = microgram count of 100µl injected volume diluent
3. Volume / Specific Gravity V/SG
Note: The most widely used technique for liquid samples. However, care must be taken to
ensure removal of all air bubbles from the syringe.
Result (ppm or %) = microgram count
V x SG
Where: V = volume of sample (ml)
SG = specific gravity
4. Volume V/v
Result % volume = microgram count
V x 1·0
Where: V = volume of sample (ml)
This is essentially the same as V / SG mode, except that the sample SG is fixed at 1·0.