EasyFuel+ Passive Tag Installation Procedure

The Passive Tags are used to communicate with the pump RF Nozzle. These Passive Tags arealways mounted and secured around the uppermost portion of a vehicle’s fuel inlet in respect oflong neck commercial vehicles, and around the fuel inlet in respect of light motor vehicles.

Note

1. Proximity to metallic surfaces influences antenna’s range. Vehicle Fuel Antenna’sinternal diameter should therefore be at least 10mm greater than the externaldiameter of the refueling inlet.

2. Once Passive Tag antennas have been installed, they must be tuned tooptimize the reading range. Please refer to section 1.8.

1 Passive Tags – Flexible

Passive Tags are available in diameters of 60, 70, 80, 90, 100, 115, 120, 130, 140 and 150mm forlong neck tanks and light motor vehicles.

FIGURE 1: Passive Tag Flexible Antenna

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2 Passive Tags – Rigid

Rigid Tags are available in diameters of 60, 90, 110 and 130mm for long neck tanks and lightmotor vehicles.

FIGURE 2: Passive Tag – Rigid

3 Flexible and Rigid Passive Tag Installation

Where screws are provided in the fuel inlet cavity to secure the fuel inlet pipe to the body panel,these screws are to be used in conjunction with plastic P-Clips to secure the Passive Tag to thevehicle body around the fuel inlet. A minimum of 3 P-Clips are to be used.

If it is found that after mounting the antenna, the antenna is too recessed, affix a length of cableto the underside of the antenna loop with cable ties and then remount using the P-clips on thecable. This will have the effect of lifting the antenna and minimizing the distance between theinlet antenna and dispensing nozzle antenna..

FIGURE 3: Passive Tag – Rigid with Tail

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Where no screws are utilized in the fuel cavity to support the fuel inlet pipe, a minimum of 3 x 2mholes to be drilled into fuel inlet cavity to facilitate installation using plastic P-Clips.

FIGURE 4: Passive Tag – Mounting Method – no pre-existing screws

If there is a rubber boot around the fuel inlet, and this rubber boot may be easily removed, thenthe Passive Tag may be mounted behind this rubber boot and affixed to the fuel inlet by way ofcable ties.

If it is not possible to remove this rubber boot, then the Passive Tag may be affixed to the rubberboot utilizing cable ties threaded through 2 slits made using a screwdriver of blade. A minimumof 3 cable ties to be used.

Installing a Passive Antenna on a Rubber Boot

1) Remove the rubber boot and make two small incisions close to each other in theboot.

2) Thread a cable tie through the incision from the rear of rubber boot, pass aroundthe antenna and then tread cable tie through second incision to the back ofrubber boot and fasten the cable tie.

3) This process must be repeated until the antenna has been secured with aminimum of 3 cable ties.

4) After cable ties have been fastened, snip off the excess lengths of the cable ties.

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FIGURE 5: Passive Tag – Mounting Method – rubber boot

To prevent unauthorized removal, this antenna type may be supplied with a 25cm tail that housesthe microprocessor and tuning cavity, where this must be affixed to a motor body panel by usinga one-way or keyed 3mm self-tapping screw. Forced removal of this component will result incatastrophic damage to this component rendering the Passive Tag useless.

FIGURE 6: Antenna Tail

Where the fuel cap fits flush with a vehicle, the only way to fit a Passive Tag Antenna is toutilize a smaller fuel cap, where with the Passive Tag being secured around the fuel inlet byway of Plastic P-Clips. The customer will have to procure this component beforecommencement of the installation.

VW Golf’ s and VW Chico’s

The VW Golfs and VW Chico vehicles are examples where the fuel cap fitsflush with the vehicle. The VW Chico (< year 2000) will require a PJ1337 fuelcap, with later models using the PJ1418/22 cap.

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Fix to vehicle

body screw

Float capacitor

3.1 Truck Installations

Choose appropriate Passive Tag Antenna (Plastic or Flexible) for the vehicle’s refueling inlet.This antenna to be installed as close as possible to the top of the refueling inlet and as far aspossible from fuel tank’s body.

The antenna is to be secured around a CB-7 / T-120R polypropylene composition cable tieand prevented from removal by use of at least 4 x CB-3 / T - 50R polypropylene cable ties.

FIGURE 7: Flexible / Rigid Antenna affixing method

FIGURE 8: Mounted Flexible Antenna

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The antenna mounting process is described below:

After removal of the fuel cap, the area on the fuel inlet from the inlet lip to where theantenna’s CB7 (or T120R) cable tie is to be fitted must be wiped with cleaning benzene. Aclean material swab saturated with this benzene to be used.

After evaporation of the benzene, lightly sand the area on the fuel inlet where the antenna isto be fitted with a fine emery cloth (P120 grit) to expose the bare metal. After sanding, wipethis area once more with a clean portion of the material swab saturated with benzene toremove any metal filings, paint and dirt.

Mix Pratley Steel Adhesive (product code 87005) in a ratio 1:1 on a clean surface, void of anyoil products.

Apply the Pratley Steel adhesive in a uniform and liberal manner to the cleaned area of thefuel inlet, and secure the CB7 cable tie with four vertically positioned CB3 or T50R cable tieson the applied adhesive. Allow the head of the cable ties (CB3) to protrude about 2cm pastthe top of the thick cable tie so that when it is fastened around the antenna, the buckle of thecable tie will not interfere with the closing of the fuel cap.

Make sure that the large cable tie (CB7 / T120R) is positioned at the highest possible pointon the fuel neck. If the neck is tapered, then the underside of the cable tie must be bufferedwith rubber tubing to prevent the cable tie from slipping down when tightening. The CB7cable tie is to be tightened using long nose pliers until there is no further allowance on theCB7 cable tie ratchets. The excessive adhesive is to be wiped with a clean cloth, free of anysolvents or cleaning agents.

Note

It is expected that when the CB7 cable tie is tightened, the adhesive willsqueeze out forming a wall on each side of the cable tie. This adhesive wallshould be retained for added cable tie support; however, it is the non-uniformexcess adhesive that should be removed.

If the tank has breather holes, ensure these are not restricted by the cable tie orantenna.

The fuel inlet antenna is to be mounted around the CB7 cable tie, and secured in place withthe CB3 (or T50R) cable ties. All cable tie loose ends to be trimmed off using a side cutter.

The antenna should fit snugly and not tightly around the thick cable tie and fuel neck. If thisoccurs, choose the next size antenna (10mm larger in diameter).

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If the fuel inlet has a lip overhang, then the installed antenna used must clear this overhangafter fitment. The use of an oversized antenna may be required.

If an antenna is used that is larger than the fuel inlet, ensure that the loop that results aftertightening the 4 x T50R cable ties is not more than 15mm in diameter.

4 Passive Collar Tag Installation

Collar Tags are used where no physical attachment method (such as P-Clips, Cable Ties withadhesive etc) may be used to secure antenna to fuel inlet. These Collar antennas are availablehaving rubber diaphragms of 50 -90mm, 50 – 120mm and 70 – 150mm that may be trimmed tothe outer diameter of the fuel inlet.

FIGURE 9: Passive Tag – Collar with Tail

Prior to mounting, measure the outer diameter of the fuel inlet and cut the rubber diaphragm tothe same diameter using a blade. Slide the Collar antenna over the fuel inlet.

FIGURE 10: Passive Tag – Collar with Tail mounted on a Truck

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If permitted, the tail may be glued to the tank using a fuel-resistant epoxy (Pratley Steel – ProductCode 87005) and a flexible silicone-like compound (e.g. Sikaflex 295) may be used at theunderside of the collar antenna to affix this to the tank.

Should a removable plate be available in the fuel inlet cavity, this may be removed with the CollarPassive Tag mounted directly on the tank. Remounting this metal plate prevents removal of thisantenna, as shown below.

FIGURE 11: Passive Tag – Collar Passive Tag mounted on Bus

5 Passive Antenna Holder Installation

Antenna Holder Tags are used for short neck fuel inlets with affixing method being 10mmstainless steel Band-It strapping with associated buckles.

FIGURE 12: Passive Tag – Antenna Holder

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A strapping tool is required for the fitting of the Antenna Holder Passive Tag around the fueltank.

FIGURE 13: Passive Tag – Antenna Holder mounted on a short neck tank

6 Passive Truck Tag Installation

Truck Tag Passive Tags are suited to short neck installations where the fuel inlet is too close tothe side of the tank to permit an Antenna Holder Passive Tag to be fitted. This antenna may alsobe fitted to long-neck vehicles.

The Truck Tag Passive Antenna has been specially designed for installation on fuel tank inlets ofboth light and heavy-duty trucks. A specially designed slot for the insertion of a metal bandenables the unit to be installed on lets of various diameters. Very compact and packaged in amoulded plastic body, it provides flexibility during installation.

This antenna is secured at the uppermost portion of the fuel inlet using a stainless steel clamp.

FIGURE 14: Truck Tag Passive Antenna

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7 Button Passive Tag Installation

The 40mm Button Passive Tag is used on motor-cycles as the affixing method of this antennautilizes industrial grade double-sided tape or Pratley Steel Epoxy adhesive instead of cable ties orscrews. Permission to be obtained to utilize the epoxy-mounting option as this may result inresidue / paint removal on the tank after removal of this antenna type.

The Button Passive Tag is mounted at the front of tank adjacent to the fuel inlet.

FIGURE 15: Mounted Button Passive Tag

8 Passive Tag Tuning

The RF Nozzle Test Unit is required to configure the optimum reading range distancebetween the RFN and the Passive Tag. The unit is activated for 1-minute test cycles. A LEDindicator will blink to inform the technician when the RFN detects a Passive Tag in itsreading range.

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FIGURE 16: RFN Test Unit

Operation as follows:

Press button on RFN Test Unit and present to Passive Tag Inlet Antenna. When the front ofRFN Test Unit is at a distance of approximately 5cm from inlet antenna, turn the adjustmentscrew of the Passive Antenna using a ceramic screwdriver until the red LED on the RFNTest Unit starts to flash.

After programming the Passive Tag (required if Passive Tag Serial Number-only not used as acriteria to refuel), a refueling transaction using the RFN is to be effected to verify efficacy oftuning range adjustment.

Note: Until such time as the antenna tuning cavity is sealed, the reading range may beadjusted.

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After completion of a successful refuel where no stop-start refueling noted, seal the tuningcavity with the plastic button supplied and apply a small amount of epoxy adhesive to preventthe button insert from being dislodged as shown below.

FIGURE 17: Sealed Antenna Tuning Cavity

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