BANLAW 800 Series Operational manual

PRODUCT DATA SHEET
Dry-Break Diesel Refuelling Nozzles
Banlaw ReFuelling™
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Thank you for purchasing this high quality Banlaw product. Please read through and
understand the information in this Product Data Sheet (PDS) BEFORE installation or operation
of the product to avoid accidental personal injury or property damage.
1PRODUCT DESCRIPTION
Banlaw Dry-Break Diesel Refuelling Nozzles are fluid (e.g. diesel fuel) dispensing couplings which
incorporate both calibrated (automatic) pressure shut-off, and “dry break”functions.
Banlaw introduced their first dry-break diesel refuelling nozzles into the market in the 1980’s in
response to a requirement for a more ergonomic and robust “industry standard” nozzle rated for higher
diesel flowrates.
800 Series
1000 Series
Figure 1 - Examples of Banlaw Nozzles
Figure 1 shows examples of current Banlaw 800 and 1000 series Nozzles. The “800” refers to the
maximum rated diesel flowrate of 800LPM (211GPM) of the 800 series, and likewise the “1000” refers
to the maximum rated diesel flowrate of 1000LPM (264GPM) of the 1000 series.
Banlaw Nozzles are available in a variety of models (variants) within each series, including the Banlaw
FuelTrack™Nozzles incorporating the Banlaw proprietary automatic (vehicle) identification –i.e. “auto
ID” – feature. Banlaw Nozzles also incorporate other features including the patented#means of
adjusting the automatic shut-off setting (#US 6,622,760).
The 800 series “Mining” Nozzles are compatible with the industry standard refuelling “receivers”,
commonly used as the means of refuelling plant equipment and smaller bulk diesel storage tanks in the
mining and construction industries. Other 800 series models –e.g. “Rail” – and Banlaw 1000 series
Nozzles are only compatible with the matching Banlaw receiver.
This document specifically covers the principal specifications, installation, commissioning, operation,
maintenance and servicing requirements and guidelines of Banlaw 2” (DN50) Diesel Refuelling and Fluid
Transfer Nozzles. End-users requiring additional information should refer to the Banlaw website,
contact Banlaw or your nearest authorised Banlaw distributor. Similarly, persons wanting information
other Banlaw refuelling products and Nozzle accessories should also refer to the website or same
contacts.

BANLAW PRODUCT DATA SHEET DRY-BREAK DIESEL REFUELLING NOZZLES
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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,
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.
Contents
1PRODUCT DESCRIPTION..............................................................................................................................................................................1
1.1 Glossary of Terms ....................................................................................................................................................................................3
1.2 System Overview .....................................................................................................................................................................................4
1.3 Key Features.............................................................................................................................................................................................5
1.4 Part Numbering........................................................................................................................................................................................ 6
1.5 Available Nozzle Models.......................................................................................................................................................................... 7
1.6 Nozzle Spring Settings.............................................................................................................................................................................. 8
1.7 FuelTrack Nozzle Variants...................................................................................................................................................................... 10
1.8 Nozzle and Receiver Compatibility ........................................................................................................................................................ 11
2IMPORTANT RESTRICTIONS ON THE USE OF THIS PRODUCT...................................................................................................................12
3PRODUCT SPECIFICATIONS .......................................................................................................................................................................13
3.1 Nozzle Flow Performance...................................................................................................................................................................... 14
4INSTALLATION & COMMISSIONING GUIDELINES .....................................................................................................................................15
4.1 Pre-Installation Guidelines..................................................................................................................................................................... 15
4.1.1 Nozzle –Ergonomics....................................................................................................................................................................16
4.1.2 Nozzle –Storage..........................................................................................................................................................................18
4.2 Installation Guidelines ........................................................................................................................................................................... 19
4.2.1 Banlaw FuelTrack Nozzles ...........................................................................................................................................................20
4.3 Commissioning Guidelines..................................................................................................................................................................... 21
5PRINCIPLES OF OPERATION ......................................................................................................................................................................21
6MAINTENANCE & SPARE PARTS................................................................................................................................................................26
6.1 Preventative Maintenance .................................................................................................................................................................... 26
6.2 Banlaw Onsite Maintenance..................................................................................................................................................................28
7TROUBLESHOOTING..................................................................................................................................................................................29
8PRODUCT RECYCLING & DISPOSAL...........................................................................................................................................................31
9PRODUCT WARRANTY...............................................................................................................................................................................31

BANLAW PRODUCT DATA SHEET DRY-BREAK DIESEL REFUELLING NOZZLES
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1.1 Glossary of Terms
The following glossary defines key terms used within this document.
Dry-Break
An industry term used to describe a fluid coupling which is of the “normally closed”
or liquid tight state whilst ever this coupling remains disconnected from its mating
coupling. Fluid (fuel) pressure may exist within the coupling, although no fluid
discharge may occur whilst the coupling remains in the normally closed (dry-break)
state.
Nozzle
A female refuelling coupling (coupler) –sometimes referred to as a “fuel gun” -
normally attached to the end of the dispensing (supply) line (e.g. dispensing hose).
A Nozzle engages with a Receiver to form a sealed (liquid-tight) connection for the
pressurised transfer of a liquid (e.g. diesel).
Receiver
A male refuelling coupling (coupler), normally attached to the inlet of the vessel to
be filled via the Nozzle.
Tank Vent
For the purposes (scope) of this document, a Tank Vent (or Vent) shall refer to a
Banlaw Vent (or Vent of same kind) specifically designed to be compatible with the
Banlaw quick-fill refuelling system.
Quick-Fill
An industry term used to describe a complete dry-break diesel refuelling system,
consisting of a Nozzle, Receiver and Tank Vent(s). This system is the same kind as
the Banlaw refuelling system, specifically a system which relies on the closure of
the Tank Vent(s) once the Tank(s) is refilled, the short-term pressurisation of the
Tank(s), and the automatic shut-off (i.e. closure) of the Nozzle.
Overfill
Protection
(OFP)
Refers to a system designed to supplement (complement) a Quick-Fill System, but
where the OFP system acts as the primary (first) means of terminating the inflow
of liquid into the tank without the need for pressurisation of the tank(s).
Flash Point (FP)
“The lowest temperature, corrected to a barometric pressure of 101.3kPa(a) (i.e.
1 atm), at which application of a test flame causes the vapour of the test portion
to ignite under the specified conditions of the test.” [AS1940-2004].
Combustible
Substance
(Liquid)
“Any liquid, other than a Flammable Liquid, that has a Flash Point, and has a Fire
Point that is less than its Boiling Point.” [AS1940-2004]. Other definitions denote a
combustible liquid as having a Flash Point of >60.5°C (>140.9°F). In addition;
“Combustible liquids that are stored, handled or processed at a temperature T ≥
(FP−6°C) should be considered as flammable liquids. Zonal (hazardous area)
distances for such liquids should be determined accordingly in accordance with
this Standard unless a detailed classification indicates otherwise.” [AS/NZS
60079.10.1-2009 ZA.5].
Flammable
Substance
(Liquid)
“Liquids, or mixtures of liquids, or liquids containing solids in solution or
suspension which give off a flammable vapour at temperatures of not more than
60.5°C (140.9°F), closed cup test, or not more than 65.6°C (150.1°F), open cup test,
normally referred to as the Flash Point.” [AS1940-2004]. In addition; “Combustible
liquids that are stored, handled or processed at a temperature T ≥ (FP−6°C)
should be considered as flammable liquids.
Diesel Fuel
Clean (filtered) automotive grade diesel fuels, including summer and winter
blends. Excludes heavy distillates, e.g. bunker oils, heavy fuel oils (HFO), etc.
Explosive
Atmosphere
“Mixture with air, under atmospheric conditions, of flammable substances in the
form of gas, vapour, dust, fibres, or flyings which, after ignition, permits self-
sustaining flame propagation.” [AS/NZS 60079.10.1-2009].

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Hazardous Zone
“An area in which an Explosive Atmosphere is or may expected to be present, in
quantities such as to require special precautions for the construction, installation
and use of equipment.” [AS/NZS 60079.10.1-2009]. The classification of a
Hazardous Zone is conducted in accordance with the governing Standards –
typically specific to regions/countries, in the absence of universal (harmonised)
Standards.
Spring Setting
Within this document “spring setting” applies to the setting of the automatic shut-
off (closure) feature of a Nozzle. This feature is responsive to liquid (i.e. diesel)
pressure within the Nozzle and can be adjusted by changing the specification of
the Piston Spring within the Nozzle and/or the specification of the Poppet Spring
within the Receiver. In simple terms, increasing the spring setting will increase the
liquid pressure at which the Nozzle will automatically shut-off, and decreasing the
spring setting will decrease the pressure required for shut-off.
1.2 System Overview
Banlaw Dry-Break Diesel Refuelling Nozzles are a key component used in “quick-fill” refuelling systems.
Banlaw Nozzles provide a means of fuel shut-off and are often used in systems incorporating storage
tank Overfill Protection (e.g. Banlaw FillSafe™Zero, FillSafe Power) and fluid asset management systems
(i.e. Banlaw FuelTrack™ Banlaw ResTrack™).
Figure 2 –Example of a “Pressurised Tank”Refuelling System
The example shown in Figure 2 is a basic “quick-fill” tank refuelling system incorporating Banlaw Nozzle,
Receiver, and Tank Vent. The means of fuel flow shut-off in such systems is by closure of the Vent,
(internal) pressurisation of the tank, and automatic shut-off (closure) of the Nozzle. Incorporating a
Banlaw FuelTrack Receiver provides a means of identifying the unique asset “tag” (code) of the tank
within the FuelTrack or ResTrack system.
The example shown in Figure 3 is a refuelling system using a separate means of tank OFP –specifically
a Banlaw FillSafe™Zero system. In this example, the Banlaw “pressurised tank” system acts as a backup
in the unlikely event the primary OFP fails.

BANLAW PRODUCT DATA SHEET DRY-BREAK DIESEL REFUELLING NOZZLES
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Figure 3 –Example of a “Pressurised Tank” Refuelling System with Separate OFP
1.3 Key Features
Since their inception, Banlaw refuelling nozzles have evolved as a key part of Banlaw’s commitment to
innovation and continuous improvement. Considered a market leader, Banlaw nozzles provide industry-
leading standards of safety, reliability, durability and serviceability. Designed to provide an extended
service life, some of the earliest generation of Banlaw nozzles are still being serviced and returned into
operation!
Key advantages of Banlaw nozzles include;
•Patented means of adjusting the automatic shut-off (closure) setting, accommodating a wider
variety of refuelling applications.
•Banlaw 800 model “Mining” series Nozzles (e.g. BNM800M) suit all industry standard Receivers,
e.g. Wiggins ZN2 & JNX series, Caterpillar, FloMAX FR series, etc.
•Industry-proven ball lock latching mechanism, providing superior safety and durability.
•Wearing and structural parts manufactured from metals, not plastic.
•Parts manufactured from stainless steel for superior durability.
•Serviceable by accredited (trained) Nozzle Repair Agents in most regions and countries.
•“Arctic” (cold temperature) models available for safe and reliable operation in extreme cold
climates.
•High quality OEM fluid seals used in all dynamic sealing applications, not inexpensive O’Rings.
•Manufactured, assembled and factory tested in accordance with Banlaw’s ISO9001 certification.
Every nozzle is traceable by its serial code.
•Banlaw FuelTrack™ models available to support the automatic identification (auto ID)
functionality of a Banlaw FuelTrack or ResTrack system –arguably the most secure fuels and
resource management system of its kind available in the market.

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Figure 4 illustrates the overall dimensions (millimetres, mm) of a Banlaw refuelling nozzle;
Conversion; 1mm ≈ 0.039”, i.e. 25.4mm = 1”.
Figure 4 - Overall Dimensions of an 800 Series Banlaw Refuelling Nozzle
Figure 5 illustrates the key external features of a Banlaw refuelling nozzle.
Figure 5 - Key External Features of Banlaw Nozzle
1.4 Part Numbering
Figure 6 and Figure 7 denotes the part numbering system used for Banlaw nozzles currently available.
Earlier (superseded) Banlaw nozzles were assigned a different part number –if required, please contact
Banlaw for details. Refer to section 1.6 for important information on Nozzle Spring Settings.
OPERATING “T”
HANDLE
CARRY “D”
HANDLE
ACTUATOR
DUST
PLUG
HANDLE
CATCH
NOZZLE INLET
2” NPT (F)
NOZZLE
OUTLET
FRONT
REAR
BUMPER
BALL
LOCKS

BANLAW PRODUCT DATA SHEET DRY-BREAK DIESEL REFUELLING NOZZLES
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Figure 6 - 800 Series Nozzle Part Numbering
Figure 7 - 1000 Series Nozzle Part Numbering
1.5 Available Nozzle Models
The 800 Nozzle series currently consists of 12 different models, whilst the 1000 Nozzle series consists
of 4 models –as per Table 1. Please refer to Banlaw Sales & Marketing material for further details.
800 Series
1000 Series
Standard
FuelTrack
Standard
FuelTrack
BNM800
BNMF800
BN1000
BNF1000
BNM800-CT
BNMF800-CT
BN1000-CT
BNF1000-CT
BNR800
BNRF800
BNR800-CT
BNRF800-CT
BNH800
BNHF800
BNH800-CT
BNHF800-CT
Table 1 - Nozzle Models

BANLAW PRODUCT DATA SHEET DRY-BREAK DIESEL REFUELLING NOZZLES
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NOTES: 1. Not all Models are available ex-stock and are made to order.
2. Each Model is available with select spring (i.e. shut-off pressure) settings. Not every spring
setting is available in each Model.
3. Nozzle availability is subject to change –please refer to the Banlaw website or contact Banlaw
or your nearest authorised Banlaw distributor for the most up to date details.
Figure 8 illustrates the location on a Nozzle where the model and unique serial code details are marked.
Figure 8 –Example of Model and Serial Details on Right Side of Nozzle
1.6 Nozzle Spring Settings
Each Nozzle is available with a pre-set spring setting, specifically the setting (specification) of the piston
spring. Banlaw document EBL-33 provides further important information on spring settings.
Selection of the required Spring Setting should be performed prior to purchase of a
Nozzle. Any adjustment of the Spring Setting within a Nozzle must only be
conducted by Banlaw or a Banlaw authorised Nozzle Repair Agent. The use of a
Nozzle with an inappropriate Spring Setting is potentially unsafe, and likely to
increase the risk level of hazards such as:
•Overfilling of the tank(s).
•Internal over-pressurisation of the tank(s).
•Fuel spillage.
•Personal injury, fire, or explosion.
Please conduct Banlaw for information on Nozzle Spring Settings.
“IF IN DOUBT, ASK!”
Available spring settings are detailed within Table 2.
Shut-Off (Spring) Setting
Nozzle Series
Setting
Code/Marking
800 Series
1000 Series
Light
L
Medium-Light
ML
Medium
M
Medium-Heavy
MH
Heavy
H
Extra-Heavy
XH
Table 2 - Available Nozzle Shut-Off (Spring) Settings
Table 2 Legend: Yes (available) No (unavailable)

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Figure 9 is a simplified diagram illustrating the interface between the nozzle and receiver during
refuelling and the forces involved in opening or closing the nozzle.
Figure 9 - Simplified General Arrangement of Nozzle and Receiver Interface
Figure 10 provides a basic illustration of the relationship between Nozzle and Receiver spring settings.
Figure 10 - Relationship Between Nozzle and Receiver Spring Settings
Figure 11 illustrates the location on a Nozzle where the Spring Setting is marked.
Figure 11 - Example of Spring Setting Marking on Top of Nozzle
For a given Nozzle spring setting, the effective (actual) liquid pressure at which the automatic shut-off
mechanism of a Nozzle is activated is dependent on several factors, including;
•Spring setting of the Receiver onto which the Nozzle is connected.
•Make (OEM) of Receiver.
•Liquid flowrate.
•The working condition of the Nozzle, i.e. whether the Nozzle is operating within the applicable
specifications for an “as new” (i.e. compliant) Nozzle.
“M”
(MEDIUM)

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Table 3 details the relationship between the various Nozzle settings, specifically with respect to the
“Medium” (M) setting. I.e. the “offset” refers to the change in nozzle shut-off pressure from a Medium
setting. This data only applies when the Banlaw Nozzle is used with a Banlaw Receiver and the Receiver
spring setting remains unchanged. The data may be subject to change when a nozzle is used with a non-
Banlaw (third party) receiver.
Nozzle Spring Setting
Code/Marking
Nozzle Shut-Off Pressure Offset (± 5 kPa)
Light
L
-40 kPa (5.8psi)
Medium-Light
ML
-20kPa (2.9psi)
Medium (Standard)
M
0 kPa
Medium-Heavy
MH
+10 kPa (1.5psi)
Heavy
H
+25 kPa (3.6psi)
Table 3 - Nozzle (Piston Spring) Shut-Off Settings
Examples;
•Adjusting the Nozzle spring setting from a Medium (M) to a Light (L) setting will decrease the
shut-off pressure by 40 ± 5 kPa.
•Adjusting the Nozzle spring setting from a Medium (M) to a Heavy (H) setting will increase the
shut-off pressure by 25 ± 5 kPa.
Please refer to the Product Data Sheet (PRH-REF-72) for information on Receiver spring settings.
1.7 FuelTrack Nozzle Variants
Figure 12 illustrates the basic architecture of the Banlaw FuelTrack dry-break auto ID system, specifically
the Nozzle and Receiver in the 2 operating states;
•Nozzle disconnected from Receiver;
o4.6 to 5Vdc at the centre contact of the Nozzle.
oReceiver is passive.
oNo auto ID circuit.
•Nozzle connected to Receiver;
oAuto ID circuit energised between Nozzle and Receiver.
oCircuit “reads” unique ID tag (code) of Receiver. The Signal from the auto ID circuit is
transmitted through the active data cable and is Received and processed by the Local
Controller (i.e. “Depot”).
Most refuelling applications utilising a Banlaw or similar Nozzle are accommodated
using a “Medium” (M) spring setting, however growing use of larger plant equipment
and higher refuelling flowrates is creating a requirement for heavier (higher) Nozzle
spring settings. In addition, the use of non-metal (i.e. plastic, resin) fuel tanks are often
best refilled using a lighter Nozzle spring setting. Please refer document EBL-33.
To provide the highest practicable level of protection, Banlaw recommends a suitable
zero pressure overfill protection (OFP) system –e.g. Banlaw FillSafe™ is considered
for all tanks.