BANLAW FillSafe Zero 2 Operational manual

PRODUCT DATA SHEET
BFCV50NPTF
Banlaw FillSafe™
FillSafe Zero 2” NPT FxM Flow Control Valve
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Thankyou for purchasing this high quality Banlaw product. Please read through and understand
the information in this Product Data Sheet (PDS) BEFORE installation or operation to avoid
accidental personal injury or property damage.
Figure 1 - BFCV50NPTF Flow Control Valve
1PRODUCT DESCRIPTION
The range of patented and patents pending # Banlaw FillSafe™ Zero overfill protection (OFP) systems is
designed for the safe and reliable refuelling/refilling of diesel fuel tanks, commonly used in the mining, rail,
port, construction and other off-road industries. The system comprises two (2) major assemblies;
•Banlaw Flow Control Valve (e.g. BFCV50NPTF) –refer Figure 1.
•Banlaw Level Sensor (BVLS model);
oRefer applicable documentation (e.g. PSG, PDS) for information on the range of FillSafe Zero
Level Sensors.
# Patents and patents pending for various Banlaw FillSafe™Zero products include PCT/AU2017/051039, PCT/AU2015/050802 &
AU2018903182. Please see www.banlaw.com

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CAUTION
The content of this document is not meant to override or substitute any applicable
Statutory, Regulatory, Customer/Site, etc. Health Safety & Environment (HS&E)
requirements.
All works should only be performed by trained, qualified and competent personnel
who are aware of the hazards associated with the constituent components of this
installation in addition to the system as a whole. Failure to comply with these
practices may result in death, serious bodily injury, loss of equipment and
environmental damage.
A risk assessment (job hazard analysis - JHA) should be conducted PRIOR to the
start of any works or actions within this document. Whilst every effort has been
made to ensure the execution of this document represents no HS&E hazard of high
risk, Banlaw takes neither responsibility nor liability for the consequences and
damages that may occur in the execution of works within this document.
Persons conducting or otherwise involved with the execution of the works within
this document and project have an obligation to ensure that all HS&E requirements
are known and understood, and subsequently followed at all times.
The important features of the BFCV50NPTF Flow Control Valve are illustrated in Figure 2 (Piston shown in
closed/forward position).
Figure 2 –Key Features of the BFCV50NPTF Flow Control Valve
PILOT LINE
CONNECTION
PISTON
2” NPT (M)
FRONT
WITHIN TANK
2” NPT (F)

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Figure 3 - Key Dimensions of the BFCV50NPTF Valve
The part number and (unique) serial number for the Valve is marked on each Assembly - Figure 4.
Figure 4 - Example of Serial Code
2KEY FEATURES AND BASIC OPERATION
The BFCV50NPTF Valve incorporates one independent means of diesel flow control;
•Flow Control Valve Piston (rear of Valve assembly);
oOpen and closed status actuated by fuel flow (pressure).
oPiston forced into the closed position upon actuation of the Level Sensor used in conjunction
with the Valve assembly (specifically closure of the fuel trickle flow from the Valve to the
Level Sensor via the Pilot Line).
oThe Flow Control Valve is not designed nor intended to act as a non-return (check) valve to
prevent the discharge of fuel from the tank via the Receiver.
Key Advantages of the Banlaw FillSafe Flow Control Valves;
•The internal flow path through the Flow Control Valve assembly has been optimised to provide lower
resistance to fuel flow, increased flow efficiency, and reduced incidence of premature shut-off of a
pressure sensitive (auto shut-off) dry-break diesel refuelling nozzle.
•Achieves a higher (diesel) flowrate capability with lower resistance to fuel flow (pressure drop) when
compared with some competitor OFP valves.

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•Only a single fuel pilot (signal) line is required to connect the FillSafe Zero Flow Control Valve and
Level Sensor assemblies.
•The 2” NPT-F inlet suits either;
oA Banlaw 23 series 2” NPT (M) Receiver, or equivalent industry standard Receiver;
▪Banlaw “standard” (Non-FuelTrack) Receivers e.g. BRM23K series.
▪Banlaw FuelTrack™(auto ID) Receivers, e.g. BFT23KS series.
oA 2” NPT (M) threaded fitting connecting the Valve inlet to a remotely mounted Receiver or
other diesel tank refuelling/refilling fluid coupler.
oA Banlaw proprietary 43 series 2” NPT (M) Receiver, provided the maximum flowrate
capability of the Valve is not exceeded –refer section 0.
Figure 5 illustrates an example of a FillSafe Zero system incorporating a BFCV50NPTF Flow Control Valve in
conjunction with a Banlaw BVLS model Level Sensor. The tank is being refilled in this illustration;
•Level Sensor; Pilot Line passage open, and BVLS venting air from the tank to atmosphere.
•Flow Control Valve; open, allowing fuel to enter the tank.
•Dry-break Diesel Refuelling Nozzle; securely connected and in the ON (open) position.
Figure 5 - Example of FillSafe Zero Install - Tank Filling
The Banlaw BVLS series “venting” Level Sensors incorporate features not illustrated nor
covered within this document. For detailed information on the BVLS series - and other
Banlaw products –please refer to Banlaw product specific literature, e.g. BVLS series
Product Specification Guides (PSG’s) and Product Data Sheets (PDS’s).

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Figure 6 now illustrates this same system once the tank has been filled to the nominated capacity;
•Level Sensor; Pilot Line passage closed.
•Flow Control Valve; closed, prohibiting fuel entering the tank.
•Dry-break Diesel Refuelling Nozzle; in the OFF (closed) position, awaiting disconnection.
Figure 6 - Example of FillSafe Zero Install - Tank Full
Figure 7 shows an alternate means the Valve may be installed on a diesel tank. This specific arrangement
may also help to address the risks of excessive diesel foaming and fuel spray out of the Valve affecting
the function of the Level Sensor –these issues are discussed in section 5.1.1.
Figure 7 - Example of BFCV50NPTF Installed on Drop Pipe Within a Tank

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Figure 8 illustrates an example of a FillSafe Zero Level Sensor –BVLS80 –compatible with a BFCV50NPTF Flow
Control Valve. The Flow Control Valve is connected to a Level Sensor via the Pilot Line routed internally
(within) the tank. The BFCV50NPTF Valve does not incorporate a means for an external Pilot Line, and as such
are not compatible with the Banlaw non-venting Level Sensors, i.e. the BLS series (e.g. BLS100B, etc.).
Figure 8 - Example of a Level Sensor (BVLS80 shown laying on side)
Figure 9 illustrates an example of a genuine Banlaw FillSafe Zero (Internal) Pilot Line. This specification of the
Pilot Line has been selected and tested by Banlaw for routing within a diesel fuel tank. The use of a non-
genuine Pilot Line is not condoned by Banlaw, and may cause cause improper operation and inferior safety
and reliability of a FillSafe Zero system –refer also section 8.
Figure 9 –Banlaw FillSafe Zero Internal Pilot Line
3IMPORTANT RESTRICTIONS ON THE USE OF THIS PRODUCT
1. The safe installation and subsequent operation of a Banlaw product relies on the
completion of all necessary “due diligences” for the assessment of the Banlaw
product(s) being suitable for the intended application(s). Such an assessment is best
achieved through the mutual cooperation of the supplier/OEM (Banlaw) and the
customer or end-user. Once such an assessment deems the Banlaw product(s) to be
suitable, the customer or end-user shall ensure effective “change management”
applies should any prominent or influential aspect of the application (upon which the
initial assessment was based) be subject to change and may affect the ongoing
suitability (i.e. safety and proper function) of the Banlaw product.
2. The Banlaw FillSafe Zero BFCV50NPTF Flow Control Valve incorporates internal
components manufactured from aluminium. Products containing external (exposed)
aluminium are typically unsuitable for use within an underground coal mine, or
otherwise within an area where the use of external aluminium components (or other

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materials within the product) are prohibited for use in such areas in accordance with
applicable governances.
1. Unless noted otherwise by Banlaw, the Banlaw FillSafe Zero tank overfill protection
(OFP) system has not been assessed under any Regulatory or Industry Standard, Code,
Directive, Guideline or other governance which may apply to the use of this product in
applications where a governance applies. Please consult Banlaw prior to installation if
in doubt.
2. The Banlaw FillSafe Zero system is designed for use only with clean (i.e. filtered)
automotive grade diesel fuels, including commercial bio-diesel blends. This Banlaw
product is not recommended for use with waste diesel fuel, or with diesel fuel
containing contamination levels beyond those stipulated by governances and
guidelines such as the current Worldwide Fuel Charter (WWFC) and fuel quality
requirements of modern diesel engine manufacturers. The use of this product with fuel
of higher contamination levels may cause the improper operation (failure) of the
product and other detrimental effects. Banlaw recommends adequate fuel
contamination controls (e.g. filtration) for all fuels passing through the Banlaw FillSafe
Zero system.
4PRODUCT SPECIFICATIONS
BANLAW BFCV50NPTF FLOW CONTROL VALVE
Max. Diesel Flow Rate LPM (GPM)
800LPM (211GPM)
Min. Flow Rate LPM (GPM)
100LPM (53GPM)
Operating Temp. Range °C (°F)
-51°C (-60 °F) to 55°C (131°F)
Max. Internal SWP kPa (psi)
2,500kPa (363psi)
Compatible Fluid Types
Clean Diesel Fuels, including Bio-Diesel Blends
Principal Material Composition
Zinc Plated Steel, Aluminium, Fluorosilicone (Seals)
Process Connections
2” NPT (F) Inlet and 2” NPT (M) Outlet
Pilot Line Port Connection
9/16” JIC (M) - Swivel
Nominal Mass of Flow Control Valve
1.77kg (3.9lb)
Legend: “SWP”; Maximum recommended Safe Working Pressure
“LPM”; Litres per minute (volumetric flowrate)
“GPM”; US Gallons per minute (volumetric flowrate)
“Max.”; Maximum (upper limit)
“Min.”; Minimum (lower limit)
Notes: 1. All pressure data refers to the internal fluid pressure, where each product is in “as new” condition.
4.1 FillSafe Zero Pilot Lines
The Banlaw Vented Level Sensor (BVLS model) may be connected to the Banlaw Flow Control Valve 2” (e.g.
BFCV50NPTF, etc.) via an internal Pilot Line (i.e. routed within the tank), or to an array of alternate Flow
Control Valves (e.g. BFCV23, BFCV43, etc.) via an external Pilot Line (i.e. routed external to the tank).
This product is unsuitable for use with AdBlue (DEF) or with an alternative fluid (or
substance) whose properties may affect the safety, function or reliability of the product.
Please consult with Banlaw to confirm fluid compatibility if in doubt.

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•Specifications (including limits/thresholds) apply to all FillSafe Zero Pilot Lines, so
please contact Banlaw at time of order to ensure correct Pilot Line selection.
•Please refer to the applicable Banlaw FillSafe Zero System Installation Procedure
for details on the proper installation & commissioning of internal and external Pilot
Lines.
•The use of a non-genuine Banlaw Pilot Line, or otherwise, the use of a Pilot Line
which does not conform with Banlaw specifications may cause the improper,
unsafe and unreliable operation of the FillSafe Zero system.
Figure 9 illustrates some of the key specifications of an internal Pilot Line, namely the means of mechanical
protection to help avoid excessive wear & tear, rupture, and other damage to the hose assembly. Internal
Pilot Lines are especially susceptible to damage (and subsequent failure) sustained within diesel fuel tanks
due to contact with such structures as internal baffles, and also fatigue due to “flexing” of the line in
response to the movement (i.e. turbulence and sloshing) of the fuel. Reference to the Banlaw FillSafe Zero
System Installation Procedure must be made prior to any attempt to install an internal Pilot Line assembly
to best avoid such failure modes. The Installation Procedure also includes hints on the most appropriate
methods, tools & accessories to use.
Unless otherwise noted by Banlaw, some of the key internal Pilot Line specifications and requirements
include:
1. Supplied by Banlaw, or otherwise manufactured strictly in accordance with Banlaw specifications.
2. Minimum ID (bore); 8mm (5/16”).
3. Maximum recommended overall length; 3.5m (11.5’). Contact Banlaw for applications requiring an
extended length.
4. Maximum recommended vertical head; 2.5m (8.2’) between Flow Control Valve location (lower)
and Level Sensor location (top). Contact Banlaw for applications requiring an extended head height.
5. Minimum (internal) safe working pressure (SWP); 2,500kPa (25 bar, 363psi).
6. Installed within a diesel tank;
a. To achieve the minimum possible Pilot Line length. Excess Pilot Line length should be
avoided.
b. Via a routing (pathway) which minimises the probability for contact between the Pilot Line
and structures within the tank, e.g. baffle plates, structural members, drop pipes, etc.
c. If passing through a baffle plate port (or similar opening), every effort is made to ensure
the Pilot Line is not held against the edge of such ports.
d. Any twisting or sharp (small) radius bends of the Pilot Line must be avoided. The swivel
action of the Pilot Line connections at the base of a BVLS model Level Sensor and at the
rear of a 2” BFCV50 model Flow Control Valve are to be tested (verified) prior to connecting
the Pilot Line –refer relevant PDS’s.
e. Other than the weight of the Pilot Line itself, no additional mass or tension (stretch) shall
be added to the hose assembly.
5INSTALLATION & COMMISSIONING GUIDELINES
This Installation & Commissioning Guide is general, and is not meant to replace or override installation
guidelines that arise out of a due diligence assessment of a Banlaw product for a specific (intended)
application.

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The scope of this section applies to the Banlaw BFCV50NPTF Flow Control Valve assembly. Whilst other
FillSafe Zero products are mentioned –e.g. Level Sensors and Pilot Lines –end-users must refer to separate
Banlaw documentation covering each product prior to their installation.
5.1 Pre-Installation Guidelines
•The BFCV50NPTF Flow Control Valve may be installed in any angular position, i.e. ± 90° from the
horizontal.
•The outlet (i.e. back end) portion of the Flow Control Valve cannot be installed within a Pipe or some
other “extended” socket or extension (>70mm, 2.7”) which may impede the flow of diesel fuel from
the array of circumferential ports on the forward (upstream) side of the Piston. It is recommended
the Valve be installed within a 2” NPT half socket (half coupling) –refer Figure 10.
Figure 10 - Do NOT Install Valve Back End within Pipe or Extended Socket
5.1.1 Fuel Discharge from Valve and Diesel Foaming
Figure 11 provides a basic illustration of the fuel discharge array from the Valve. This “spray-pattern”
discharge requires consideration of 2 important issues which may affect the function and reliability of the
FillSafe Zero OFP system;
General Installation Notes;
1. Conduct a Job Hazard Analysis (JHA) prior to install to mitigate health,
environmental and equipment hazards.
2. Do NOT install any parts that are damaged or are otherwise faulty.
3. Do NOT install parts which are not compatible with mating parts or parts
which do not satisfy the specifications of the FillSafe Zero system.
4. Conduct all necessary measures to prevent the ingress of contamination
into the Banlaw Flow Control Valve and other parts.
5. Only engage threads of the same thread type. Ensure all threaded
connections are clean and in good condition. Avoid over-tightening.
6. An appropriate thread sealant is recommended on the 2” NPT (M) process
connection. Use sparingly and avoid excess use of Loctite and similar
products –residual thread sealants etc. may cause contamination and
malfunction of the FillSafe Zero system. No thread sealant is required on the
JIC Pilot Line connection.
7. Use only proper handtools for the installation of all components –e.g. 3”
(75mm) deep socket. Avoid the use of power or impact tools, and adjustable
wrenches (e.g. stilsons).
8. Use consumables (e.g. Loctite products) strictly in accordance with the OEM
Safety Data Sheet (SDS) and operating guidelines. Do not use consumables
beyond their expiry date.

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1. Diesel foaming;
a. The spray-like discharge of diesel fuel will increase the aeration (foaming) of the fuel and
may also increase the generation of static electricity (charge) within the fuel tank. It is
therefore important every available effort is made to install the Valve as close to the base of
the tank as possible. This way, the fuel discharge will be below the surface of the liquid diesel
for a longer period during refuelling of the tank minimising foaming and static charge. In
smaller tanks or where the Valve position cannot be moved lower, the foaming may delay
the actuation of the Level Sensor, cause some spillage of fuel from the Level Sensor or Tank
Vent(s) until such time as liquid fuel actuates the Sensor, allowing the Valve to close.
Figure 11 - Fuel Discharge Array from Valve
2. Location of Valve relative to Level Sensor and Tank Vent(s);
a. Figure 12 illustrates the Valve discharge impacting the Level Sensor or Tank Vent(s). This
situation should be avoided as it may cause;
i. Discharge of liquid fuel from the venting passage(s) to atmosphere during tank
refuelling.
ii. Malfunction of the Level Sensor and/or Tank Vent(s).

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Figure 12 - Fuel Discharge Impacting Level Sensor
5.2 Installation Procedure
In preparation for the installation of this new FillSafe Zero Valve, the fuel level within the
tank must be below the tank fill point. This will prevent the discharge (spillage) of fuel from
the tank once the existing BFCV50NPTF, Receiver or other tank refuelling coupler is
removed. If necessary, drain fuel fromthe tank into a clean reservoir for reuse, or otherwise
dispose of in a responsible manner. The flow control valve (piston) within the BFCV50NPTF
is not designed nor intended to act as a non-return (check) valve.
1. Complete all necessary hazard mitigation, monitoring and control actions as per the JHA.
2. Once the tank is ready to accept the new BFCV50NPTF Flow Control Valve, remove the Valve from
its packaging (leave within packaging until just prior to install). Remove any dust caps, plugs etc. from
ports.
3. Invert Valve a number of times to confirm the Valve piston is freely sliding within the Valve body.
4. Inspect the Pilot Line and Pilot Line connection for visual damage or defects. If condition is
unsatisfactory, do NOT attempt to repair a damaged Pilot Line –instead replace with a new Pilot Line
assembly constructed in accordance with Banlaw specifications.
5. Verify 9/16” JIC (M) pilot line connection at rear of Valve “swivels” (rotates) when moderate torque
is applied by hand. If jammed or excessive torque is required, do NOT install this Valve but instead
replace the Valve assembly and return the faulty Valve assembly to Banlaw for warranty assessment.

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6. Using suitable hand tools –i.e. 19mm and 10mm spanners –secure the Pilot Line to the Valve –refer
Figure 13. Tighten securely but do not overtighten. Typical recommended tightening procedure
(torque) for a 9/16” JIC connection is; hand tighten firmly (up to wrench resistance), then tighten
using hand tools by an additional 1.5 hex flats (i.e. 90°).
Figure 13 - Tightening of JIC Pilot Line Connection
7. Apply thread sealant –e.g. Loctite 567 –sparingly to the central area of the 2” NPT (M) thread of the
Valve. Ensure the mating 2” NPT (F) port on the tank inlet is in good condition, clean, dry and free
from any debris and contamination. Align the Valve concentrically with the port and carefully install
the Valve and attached Pilot Line into the tank port. Using a 3” (75mm) AF hex long socket, place the
socket fully onto the Valve and tighten into the port as per;
a. Hand tighten firmly.
b. Tighten by no more than an additional 6.5mm (1/4”) thread length.
8. Ensure the (unused) external Pilot Line port on the BVLS series Level Sensor is plugged (sealed).
•Avoid overtightening.
•Do NOT use power tools, i.e. impact wrenches etc.

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Figure 14 - BVLS Series Level Sensor External Pilot Line Port (sealed)
Figure 15 - Valve Installed within Tank Inlet
9. Install the Receiver or refuelling point line into the 2” NPT (F) threaded inlet of the Valve. Avoid the
use of excess thread sealant, as residual sealant may enter the Valve and Banlaw FillSafe OFP system
and cause system malfunction. Do NOT over-tighten threaded connection.
•For Banlaw FuelTrack™ “auto ID” Receivers, the unique ID “tag” (code) must be
entered into the FuelTrack database and assigned to the asset (plant equipment)
onto which it is installed prior to commissioning of the system. With the security
feature of the FuelTrack system enabled, no fuel dispensing will be authorised until
the Receiver tag is correctly registered.
•A “Light” spring setting Receiver is recommended –e.g. Banlaw BRM23KL –when
used with a FillSafe Zero OFP system. The use of a Receiver with a higher (“heavier”)
spring setting will increase the probability of premature nozzle shut-off.
BFCV50NPTF
FRONT OF
PISTON
2” NPT-F
INLET

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5.3 Commissioning
1. Pre-commissioning checks for a dry-break diesel refuelling system comprising FillSafe Zero OFP;
a. Ensure all dry-break nozzles to be used with the installed system are compatible with the
Banlaw Receiver fitted to the FillSafe Zero Flow Control Valve –refer section 1.
b. Ensure the process conditions will be maintained within the FillSafe Zero BFCV50NPTF
Specifications –refer section 0.
c. Inspect the tank vent breather for excessive contamination ingress, which may restrict the
free flow of exhaust air duting tank refuelling. If a breather hose is installed, inspect the hose
outlet for contamination build-up and the hose of damage, kinking and distortion which
could also affect airflow. If a filtered breather system is used, inspect the serviceable filter
element for condition and replace if necessary. Ensure the exhaust breather outlet is routed
towards the ground and away from potential ignition sources (e.g. hot surfaces).
Inspect the fuel tank(s) for signs of visible damage, distortion and fuel leakage which may
indicate the past over-pressurisation of the tank(s) due to a failure with the overfill
protection (OFP) system previously used. If the root cause of such failure has not been
identified and will not be mitigated by the installation of this new BFCV50NPTF Valve,
commissioning of the new Valve shall not commence until all such failures are identified,
mitigated, controlled and/or managed.
2. When the FillSafe Zero BFCV50NPTF Valve assembly is completely installed, and all other refuelling
“system” components are all properly installed and awaiting commissioning, the initial (maiden) tank
refuelling event shall serve as the means of commissioning the FillSafe Zero system.
3. Prior to any attempt to refuel the tank, ensure the fuel level is below the SFL and subsequently, the
OFP system will permit fuel to enter the tank for a period of no less than approx. 30secs (i.e. adequate
time for system commissioning).
4. Remove the Receiver Dust Cap from the Fuel Receiver and securely connect a Banlaw (or other
compatible) dry-break refuelling Nozzle to the Receiver. Now disconnect and reconnect the nozzle
to confirm ease of engagement with the receiver. In the event of a problem connecting or
disconnecting the nozzle, please refer to section 8. Prepare to refuel the tankas per normal refuelling
procedure.
5. Any air entrainedwithin the FillSafe Zero system will need to be bled from the system until the system
is fully operable. This is best achieved by throttling (reducing) the maximum achievable refuelling
flowrate to approx. 50% and steadily oscillating the flowrate between zero and 50% - this can be
readily achieved by manually cycling the operating (open/closed) handle of the refuelling nozzle, or
similar means. Continue this for approx. 10-15sec.
6. Once the system is completely bled, the nozzle can be fully opened. If the nozzle automatically closes
prior to the tank reaching capacity and the FillSafe Zero system closing, refer to section 8. Do NOT
manually or otherwise forcibly maintain the nozzle operating handle in the ON (open) position.
Automatic shut-off of a Banlaw nozzle prior to the FillSafe Zero system closing is an issue known as
premature nozzle shut-off, and should be addressed/corrected in accordance with Banlaw guidelines
–contact Banlaw for further information.
7. Whilst the tank is being refilled, carefully check the FillSafe Zero system for any signs of fuel leakage.
Mark/record any sources of leakage for prompt corrective action after the tank is refilled. If the
degree of leakage is unacceptable, manually close the refuelling nozzle, disconnect it from the

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receiver and rectify the leak. If the fuel leakage occurs from between the nozzle and receiver, please
refer to section 8.
8. As the tank level approaches the nominated capacity (or SFL), remain next to the refuelling nozzle.
Closely monitor the fuel level to ascertain whether the FillSafe Zero OFP system automatically
terminates the inflow of fuel into the tank at the required level. In the event of a failure, promptly
close the refuelling nozzle or otherwise stop the fuel supply before the tank(s) is overfilled –refer
section section 8. Only for this commissioning procedure, manually reopen the Banlaw nozzle and
hold it fully open for approx. 5sec. Confirm negligible (no greater than approx. 10LPM/4GPM) fuel
can enter the tank by observing the flow meter measuring fuel dispensed via the nozzle. If additional
fuel enters the tank, please refer to section 8.
9. At the completion of refuelling, remove the Nozzle from the Receiver and return the Nozzle to its
nominated holster or storage location. Replace the Receiver Dust Cap onto the Receiver.
10. After the above commissioning procedure has been successfully completed, the FillSafe Zero system
may be placed into service. A system that does not perform correctly should not be placed into
service, but instead quarantined until the problem is identified and rectified.
In the event the root cause(s) of the OFP system failure cannot be identified and rectified
prior to the next refuelling event, alternate means shall remain in place to prevent
overfilling of the tank until such root cause(s) are identified, mitigated, controlled and/or
managed.
6PRINCIPLES OF OPERATION
The FillSafe Zero system itself is fully “automated” and requires no manual operation or manipulation.
Whether using a Banlaw FuelTrack system, a “standard” Banlaw dry-break system, or an alternative dry-break
system, the installation of the FillSafe Zero system onto a tank requires no change to the normal operating
procedure of the dry-break refuelling system (i.e. the procedure by which a tank is normally refuelled).
It is the typically a legal responsibility of the person(s) who has identified the potential
hazard to isolate the part of the system whose continued may result in an unacceptable
risk to health, safety and environment. Complete the applicable procedure for the proper
and positive isolation of the system and inform worksite management immediately.
Refuelling couplings, e.g. nozzle and receiver, that are contaminated with dust and other buildup must be
cleaned prior to use. This will help prevent;
•Contamination entering the FillSafe Zero system, subsequently increasing the probability of system
failure.
•Contamination from entering the fuel stream, increasing the probability of engine fuel system
problems.
•Accelerated wear & tear of mating parts.
•Damage to fluid seals, creating fuel leakage.
•Difficulty in properly engaging/connecting the nozzle and receiver.
The following process flow diagram illustrates a typical operating sequence for a dry-break refuelling system
incorporating a Banlaw (or similar) refuelling nozzle refilling a tank fitted with FillSafe Zero (OFP system). This
sequence is a guideline and is not meant to replace an existing safe refuelling procedure for a specific

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application. Equipment that is damaged, leaking or otherwise unfit for operation must not be used, but must
instead be replaced or repaired prior to use of a diesel refuelling system.
REMOVE RECEIVER DUST CAP. REMOVE NOZZLE FROM ANCHOR OR HOLSTER
RETRACT NOZZLE ACTUATOR AND PUSH ONTO RECEIVER. RELEASE ACTUATOR AND ALLOW IT
TO RETURN FORWARD. PULL BACK SLIGHTLY ON NOZZLE TO CONFIRM SECURE CONNECTION
WITH RECEIVER
START FUEL DISPENSING PUMP
MANUALLY OPEN REFUELLING NOZZLE. IF NOZZLE IMMEDIATELY SHUTS OFF, MANUALLY
CYCLE NOZZLE BETWEEN OPEN AND CLOSED FOR APPROX. 2-3SECS. IF NOZZLE WILL STILL NOT
REMAIN OPEN, CONFIRM TANK IS NOT ALREADY FILLED TO CAPACITY. IF NOT, REFER SECTION
8
ALLOW TANK TO REFILL. IF REQUIRED BY SITE REFUELLING PROCEDURE, WITNESS ENTIRE
REFUELLING EVENT WHILST VISUALLY MONITORING RISING FUEL LEVEL
ONCE TANK REACHES CAPACITY, THE FILLSAFE ZERO LEVEL SENSOR WILL “CLOSE”, PROMPTING
THE FLOW CONTROL VALVE TO CLOSE. THE BANLAW NOZZLE WILL THEN PROMPTLY CLOSE.
ENSURE NOZZLE OPERATING T-HANDLE IS LATCHED IN “OFF” (CLOSED) POSITION PRIOR TO
DISCONNECTION
STOP FUEL DISPENSING PUMP. RETRACT NOZZLE ACTUATOR AND DISCONNECT FROM
RECEIVER. REPLACE RECEIVER DUST CAP AND RETURN NOZZLE TO STORAGE HOLSTER/ANCHOR
7MAINTENANCE & SPARE PARTS
The BFCV50NPTF Flow Control Valve is a non-serviceable Banlaw product. Banlaw warranty is void in the
event an attempt is made to repair, modify or otherwise tamper with the Valve assembly. Further, tampering
with the Valve may increase the risk of hazards jeopardising the operation of the Valve and OFP system, and
subsequent safety of the refuelling system.
7.1 Preventative Maintenance
The integrity (sound working condition) of refuelling couplings and tank overfill protection systems is
critical to ensure all equipment can be operated in a safe and proper manner.
The working life of refuelling equipment depends on many factors, including the environment in which it
operates, and the care by which such equipment is used and maintained. Dusty and dirty environments more
prone to contamination buildup in equipment such as refuelling couplings cause accelerated wear & tear, as
does excessive contamination within the fuel stream. Due to the many varied operating environments in
which Banlaw equipment is used, any preventative maintenance information provided within this document
shall be used a guide –unless noted otherwise.
The BFCV50NPTF Valve contains relative moving parts which will wear after a period of use. Such wear will
be accelerated by contamination within refuelling couplings and within the fuel stream itself. Excessive
contamination within the fuel stream may even cause malfunction of the dry-break refuelling equipment and
FillSafe Zero (OFP) system.
The following preventative maintenance guidelines apply to the BFCV50NPTF Flow Control Valve;

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1. Ensure adequate controls and condition monitoring are in place to ensure the contamination levels
(and other specifications) of your fuel supply are maintained –PREVENT poor quality fuel entering
your sites fuel infrastructure and plant equipment.
2. Install inline (bulk) filtration on all diesel dispensing lines –contact Banlaw for advice.
3. Maintain the use of the Receiver Dust Cap and Nozzle Anchors, Holsters, or Dust Caps.
4. Remove any contamination from the dry-break Receiver (front end) prior to connecting a Nozzle.
5. Visually inspect the Receiver for excessive wear & tear or damage prior to connecting a Nozzle.
6. Replace the BFCV50NPTF Valve assembly no later than every 8 years.
7. Replace the Internal Pilot Line no later than every 2 years.
7.2 Banlaw Site Service and Preventative Maintenance
Clients can benefit from a Banlaw Service Level Agreement (SLA) to assist in the preventative and corrective
maintenance of a FillSafe Zero system onsite, in addition to other diesel, fuels, oils and coolant infrastructure.
Clients with an SLA can focus on their core business activities and allow experienced Banlaw technicians and
engineers to help keep such infrastructure operating at optimum safety, performance and reliability.
8TROUBLESHOOTING
This section provides troubleshooting recommendations for the BFCV50NPTF Valve and FillSafe Zero system
when installed, operated and maintained in accordance with Banlaw guidelines.
PROBLEM
PROBABLE CAUSE AND SOLUTION
Premature nozzle
shut-off at the start
of or during the
refuelling.
•Zero system requires bleeding (to remove air). With the supply pump
running, cycle nozzle T-handle between ON and OFF several times to
resolve this issue (also refer section 5.3).
•Residual pressure in Pilot line. Cycle nozzle T-handle between ON and OFF
several times to resolve this issue.
•Pilot line blocked/obstructed, kinked or undersized. Check Pilot line size
and connections for blockages or obstructions. Avoid the use of restricted
bore style fittings, sharp elbows etc. within the Pilot Line routing between
the Flow Control Valve and Level Sensor.
•Level Sensor installed too high (over 4m (13’)) above the Flow Control
Valve).
•The BVLS model “venting” Level Sensor is not installed correctly onto the
tank, e.g. installed within an “extended” socket or riser pipe etc. Refer to
BVLS requirements (i.e. PDS document) and rectify.
•Float Valve at base of Level Sensor is “stuck” in the closed (up) position.
Remove Level Sensor, investigate, identify root cause and rectify.
•Faulty Level Sensor. Replace Level Sensor.
•Fuel flow out of the Flow Control Valve outlet ports is “choked” – i.e. the
Valve is installed within a pipe, extended socket, etc. or installed too close
to the side of the tank or internal tank baffle (plate). Refer section 5.1.
•Piston mechanism within Flow Control Valve is “stuck” in the closed
(forward) or otherwise restricted in its “free” reciprocating action.
Remove Valve, investigate, identify root cause and rectify.
•Faulty Flow Control Valve. Replace Flow Control Valve.
•Flow rate below recommended minimum. Increase delivery flow rate.
•Flow rate above recommended maximum. Reduce delivery flow rate.

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•The shut-off setting of the nozzle & receiver combination is too “low” (i.e.
too light) for this application. Contact Banlaw or your nearest Banlaw
agent for advice.
oUnless instructed otherwise, Banlaw recommends a fuel Receiver
with a “Light” spring setting when used with a FillSafe Zero system.
•Faulty nozzle. Replace nozzle.
•Excessive restriction to the “free” discharge of air from the tank’s venting
(breather). Check vent(s), vent exhaust, breather hose, and filtered
breather system (if fitted) for the source of the restriction. Also confirm
the venting system is rated for the tank refuelling flowrate.
•Excessive restriction in the refuelling line connecting the Receiver to the
Flow Control Valve. Upsize line size (bore) and remove short radius bends
and unnecessary chokes to fuel flow.
•Accidental/premature activation (closure) of the Level Sensor by fuel
movement (sloshing) in the tank. Pause for 1 min and restart refuelling.
Nozzle shut-off
and/or Flow
Control Valve
closure as tank
approaches SFL
(capacity).
•Accidental (premature) trigger of the Level Sensor by fuel movement in
the tank. Pause for 1 min (60 seconds) to allow fuel to settle and try again.
•Incorrect Level Sensor for the required ullage. Contact Banlaw or your
nearest Banlaw agent for advice.
Fuel discharged
from vent outlet
during refuelling
•Fuel discharge from Flow Control Valve is impacting the tank venting
passage –refer section 5.1.1 for guidance.
•Pilot Line fuel flow discharged from Level Sensor into tank is impacting the
tank venting passage. Refer to the Level Sensor PDS for guidance.
Tank overfilling
•Incorrect Level Sensor (length) for the required ullage. Refer Level Sensor
PDS or contact Banlaw or your nearest Banlaw agent for advice.
•Leakage from Pilot Line and/or connections. Check Pilot line and
connections.
•Float Valve within Level Sensor has failed to close. Remove Level Sensor,
investigate, identify root cause and rectify.
•Faulty Level Sensor. Replace Level Sensor.
•Piston mechanism within Flow Control Valve is “stuck” in the open
(rearward) or otherwise restricted in its “free” reciprocating action.
Remove Valve, investigate, identify root cause and rectify.
•Faulty Flow Control Valve. Replace Flow Control Valve.
•Flow rate below the recommended minimum. Maintain flowrate within
the recommended minimum and maximum range.
•Excessive foaming of the diesel fuel during refuelling –refer section 5.1.1
for guidance.

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Fluid Leakage
between Nozzle
and Receiver during
Refuelling
•Worn Receiver and/or Nozzle preventing effective locking of Nozzle to
Receiver. Install new Receiver Kit or replace and/or Nozzle.
•Dirt and debris interfering with locking action and/or fluid seals. Clean
both Nozzle and Receiver and ensure that the Receiver Dust Cap and
Nozzle Plug are always used.
•Front face of Receiver is damaged. Install new Receiver.
•Seals worn out on Nozzle. Replace Nozzle and return to an authorised
Banlaw nozzle repair agent for servicing.
Fluid Leakage from
front of Receiver
•Worn Poppet Seal in Receiver or debris on Seal. Remove Receiver sub-
assembly and inspect seal. If damaged, install new Receiver Kit.
Nozzle accidently
uncouples from
Receiver during
refuelling
•Incorrect combination of Nozzle and Receiver. Confirm compatibility. Only
use the correct combination of Nozzle and Receiver.
•Worn ball lock mechanism on Nozzle and/or Receiver. Inspect both
equipment and replace if necessary.
•Contamination within ball lock groove on receiver body. Clean thoroughly
and reconnect nozzle.
•Nozzle improperly coupled to Receiver. Try again.
Fuel drains from
Tank via the Flow
Control Valve
•The Piston within the Flow Control Valve is not designed nor intended to
act as a normally closed check (one way) valve. Fuel must be drained within
the tank to a level below the Valve prior to installing or removing the Valve.
No fuel issued via
Nozzle
•Supply (source) tank is empty, or valve on fuel dispensing line closed.
•Banlaw FuelTrack receiver ID tag (code) has not been entered into the
onsite FMS database and/or properly configured within the database.
•Banlaw FMS is installed at fuel dispensing location, but a non-Banlaw
“Auto ID” Receiver is installed on the tank refuelling point. Contact Site
Management.
•FuelTrack receiver ID tag has not been received by local FMS depot;
a. Existing fault with auto ID dry-break system –investigate and
rectify.
b. Faulty auto ID chip in receiver –install new Banlaw receiver kit.
c. Turn nozzle on (open) and verify code is read.
d. Contact your onsite FMS “champion” or Banlaw Helpdesk.

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9PRODUCT RECYCLING & DISPOSAL
Banlaw values and supports the sustainable use of resources, and the safe, responsible and proper disposal
or recycling of all materials within its products. For a description of the principal materials within the Banlaw
FillSafe Zero system, please refer to section 4.
10 PRODUCT WARRANTY
Banlaw is committed to providing quality products and services. To provide further assurance, our products
and services are backed by generous warranties.
For the BFCV50NPTF Valve Assembly, the current Banlaw warranty term is ninety (90) days from the date of
product delivery or first install, whichever expires first.
A copy of the Banlaw product warranty terms and conditions is available from Banlaw, the Banlaw website,
or your nearest authorised Banlaw agent.
END OF DOCUMENT
BANLAW –UNIFIED FUEL MANAGEMENT
Website –www.banlaw.com