PRM ISI02

Rev.06
Meta® LNG1
Engineering
INSTALLATION AND SERVICE dpt.
INSTRUCTIONS 1

METATRON SRL

INSTALLATION & SERVICE

INSTRUCTIONS
META LNG1 Model
CHECK: AUTHOR: APPROVAL:
L.Notaro S.Luppi;N.Vittoso;F.Del Monte F.Michelini
(Quality Assurance) (Tech. Dpt) (Tech Dir)

Revision Date Description

00 2012, Feb. 14 First edition
01 2013, Aug. 01 CNG inlet and outlet connection § changed.
02 2013, Nov. 18 Added note about Map connection
03 2016, Jun. 29 Added SOV valve, screen filter, dampers
04 2017, Jun. 13 General update, Outlet overpressure warning
05 2018, Oct. 03 Inlet and outlet fitting replacement added
Installation and fixing guidelines § revised and title
changed
Fuel system service procedure revised.
Notices revised.
06 2021, Mar. 03 Installation and fixing guidelines § revised
Venting valve image updated
Troubleshooting list revised.

Installation guidelines and recommendations concerning pressure regulator METATRON META LNG1
model.
 PRM ISI02
Rev.06
Meta® LNG1
Engineering
INSTALLATION AND SERVICE dpt.
INSTRUCTIONS 2

Summary
Scope .................................................................................................................................................... 3
Safety warning for operators ................................................................................................................ 3
Disclaimer ............................................................................................................................................ 3
Keys ..................................................................................................................................................... 3
Main terms and definitions .................................................................................................................. 4
PR schematics ...................................................................................................................................... 5
PR base configuration “B” ............................................................................................................... 5
PR with valve and inlet particle screen configuration “BV” ........................................................... 6
PR with dampers .............................................................................................................................. 6
Notices ................................................................................................................................................. 7
Installation and fixing guidelines ......................................................................................................... 9
Fuel system service procedure ........................................................................................................... 11
NG inlet and outlet fitting .................................................................................................................. 12
Assembly of the O-ring on the seal seat in the inlet fitting............................................................ 12
Inlet and outlet fittings replacement – B version ........................................................................... 15
Inlet and particulate screen replacement - BV version .................................................................. 18
SOV coil replacement ........................................................................................................................ 22
Manifold Air Pressure (MAP) connection ......................................................................................... 25
Fitting replacement ........................................................................................................................ 27
Venting membrane (valve)................................................................................................................. 28
Encapsulated venting membrane replacement ............................................................................... 28
Dampers installation .......................................................................................................................... 29
Troubleshooting list ........................................................................................................................... 31
Contact ............................................................................................................................................... 32
 PRM ISI02
Rev.06
Meta® LNG1
Engineering
INSTALLATION AND SERVICE dpt.
INSTRUCTIONS 3

Scope
To provide assembly and service instructions to correctly handle pressure regulator (PR) META®
LNG1.
This document targets engineers from the Technical Department aware of the Natural Gas (NG)
engine metering system and normal maintenance operations on vehicles.
Safety warning for operators
Always take out rings, watches, loose hanging jewelry. Do not wear loose clothing such as ties. Avoid
contact with hot metal parts.
Instructions listed here are relevant to flammable and high pressure gas.
In case of PR operation with NG:
• it is strictly forbidden to operate near burning flames and embers;
• do not vent NG in a closed building or area;
• operate engine only in a well-ventilated area;
• keep solvents away from ignition sources;
• it is necessary to operate with protective gloves and mask suitable for low temperatures too.
Disclaimer
Metatron is not liable for:
• technical regulations, government directives or laws in force in the region of operation of
vehicle concerning assembly and service of pressure regulator;
• any quality issue if the regulator was tampered or disassembled by the customer or any other
party before analysis by Metatron entitled engineers;
• any damage due to the wrong handling at customs or customer warehouse;
• any issues concerning vehicle wiring harness connectors;
• all other cases specified in the product technical specification.

Keys

Tool list Attention! Information

 PRM ISI02
Rev.06
Meta® LNG1
Engineering
INSTALLATION AND SERVICE dpt.
INSTRUCTIONS 4

Main terms and definitions

• LNG: Liquefied Natural Gas
• NG: Natural Gas
• PR: Pressure Regulator
• MAP: Manifold Air Pressure
• SOV: Shut Off Valve
 PRM ISI02
Rev.06
Meta® LNG1
Engineering
INSTALLATION AND SERVICE dpt.
INSTRUCTIONS 5

PR schematics
PR base configuration “B”

OUTLET

INLET FLOW DIRECTION

FIXING HOLES AND SLOTS

MAP REFERENCE FTTING

(IN PLACE OF VENTING VALVE)

INLET / OUTLET
CUSTOMIZED FITTING

VENTING VALVE
 PRM ISI02
Rev.06
Meta® LNG1
Engineering
INSTALLATION AND SERVICE dpt.
INSTRUCTIONS 6

PR with valve and inlet particle screen configuration “BV”

Configuration differs for additional shut-off valve at inlet.

SOV
Shut Off Valve INLET FITTING WITH SCREEN

ENCAPSULATED
VENTING VALVE

PR with dampers
Configuration differs for additional dampers, supplied NOT assembled.

DAMPERS
 PRM ISI02
Rev.06
Meta® LNG1
Engineering
INSTALLATION AND SERVICE dpt.
INSTRUCTIONS 7

Notices

The PR comes provided with a warranty card and usually also with the EOL test report

Metatron is not liable for any issue concerning vehicle wiring harness connectors.

Scrap parts fallen down on handling or service, i.e. if the PR falls down it must be replaced.
Metatron cannot assess the damage entity.

Do not use hydrocarbons or any solvents to clean the PR and its internal components on
service.
 PRM ISI02
Rev.06
Meta® LNG1
Engineering
INSTALLATION AND SERVICE dpt.
INSTRUCTIONS 8

Inlet and outlet connection on PR are the same; please check the flow direction indicated by
the arrow on the PR body in order to distinguish inlet and outlet.

Do not remove the encapsulated venting valve from PR! Components inside could be
subjected to rust or corrosion.

Encapsulated
venting valve AIR AIR

WATER

ENCAPSULATED VENTING VALVE

Do not paint over the encapsulated venting valve at any time! Atmospheric reference
pressure must be ensured.

Keep other parts off the venting valve!

Do not pressurize through the outlet!

 PRM ISI02
Rev.06
Meta® LNG1
Engineering
INSTALLATION AND SERVICE dpt.
INSTRUCTIONS 9

Installation and fixing guidelines

Refer to PR specification (SPC) and customer drawing for:
• installation specifications;
• maximum allowed tightening torques;
• hydraulic interfaces and material;
• wiring harness connector.

DO not operate the PR with NG in liquid phase; PR must be installed downstream an heat
exchanger.

PR is ECE R110 engine compartment class.

The PR can be installed

• on the vehicle body with the brackets provided
• on the vehicle body with the brackets made by the Customer
• on the engine (engine block side preferred) using proper brackets and damping elements,
refer to relevant drawing for exact installation.

If the regulator is provided without bracket it must be installed by minimum 2 holes M4 for
each side.

Dampers are not suitable for any engine applications; contact Metatron technical
department to assess feasibility and layout of the engine mounting.
PR should be
• preferably installed in horizontal position with the SOV in vertical position and the coil on
the top (see SPC for reference);
• not painted;
• not subjected to continuous presence of dust and mud;
• not subjected to gravel bombardment;

PR must be positioned
• in a ventilated area, under atmospheric pressure
• in a safe area in case of vehicle collision.

PR must NOT be subjected to

• gravel bombardment in case it features the SOV;
• high temperature heat sources, such as exhaust gas treatment systems;
• the wind chill, especially in cold climates application;
• water jets or water drops regularly.

Do not obstruct or paint over the venting valve.

 PRM ISI02
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Meta® LNG1
Engineering
INSTALLATION AND SERVICE dpt.
INSTRUCTIONS 10

PR must not be supported by inlet and outlet NG pipes: it must be fixed to the vehicle body by
means of properly designed brackets.

It is highly recommended the bracket hole nearest to the SOV is used to fix the PR.

PR must be connected to the fuel rail through a flexible pipe in order it is not subjected to
engine vibrations.

In order to minimize pressure drops, it’s strongly recommended that

• both high and low pressure lines have at least 10 mm inside diameter (ID Ø ≥ 10 mm) pipe;
• bendings of outlet fuel hose are minimized as much as possible;
• the position is as much as possible close to the fuel metering.

Refer to the requirements of the vehicle mission in order to correctly design features of
components facing the PR, i.e.:
• surface treatments of screws and pins;
• bracket resistance;
• connectors
• etc.

In case of need of further information contact Metatron.

 PRM ISI02
Rev.06
Meta® LNG1
Engineering
INSTALLATION AND SERVICE dpt.
INSTRUCTIONS 11

Fuel system service procedure

Following procedure concerns the right way to service the PR and also the fuel system parts.
Ensure by the operators strictly abide by.

Always empty the capacity downstream the PR before emptying the capacity upstream the
PR.

Avoid to empty the high pressure line by fast decompression (see SPC).
Example of correct procedures:
1. On vehicle stopped and engine off, close the manual shut-off valve
• of the LNG tank
• or the buffer tank
• or heat exchanger,
i.e. NO FLOW between LNG tank and SOV.
2. On vehicle stopped, let the engine consume the remaining NG with the PR SOV on till it
stops.
3. Proceed to service.

SOV opens if the high pressure line upstream the PR is empty and low pressure line is under
pressure.

The regulator must never be filled up through the outlet.

Always check the leakage before operating the fuel system.

 PRM ISI02
Rev.06
Meta® LNG1
Engineering
INSTALLATION AND SERVICE dpt.
INSTRUCTIONS 12

NG inlet and outlet fitting

Assembly of the O-ring on the seal seat in the inlet fitting

Do not install the fittings after that the regulator has been installed on the engine/vehicle; the
bracket could be bended by the tightening torque.

Do not spread any kind of material inside PR.

1. Clean the fitting in the seat of the O-ring with compressed air.
Metatron recommends to lubricate the seat in the fitting with PTFE-based grease.
2. Put the O-ring into the sealing seat of the fitting

Do not scratch the O-ring against the thread of the fitting.

INLET PIPE SIDE

SEALING SEAT

PR SIDE
 PRM ISI02
Rev.06
Meta® LNG1
Engineering
INSTALLATION AND SERVICE dpt.
INSTRUCTIONS 13

3. Firmly hold the pressure regulator by the dedicated surfaces in the body;

Be careful to NOT damage and NOT bend the MAP connection:

DEDICATED SURFACES

MAP CONNECTION

4. Screw the fitting manually until it reaches the pressure regulator flange

Be careful to NOT scratch nor hit the sealing surface on the PR (flange).

5. Tighten the fitting using a proper dynamometric wrench.

Metatron recommends 45 ± 1 Nm tightening torque

Tightening torque must not exceed 50 Nm.

Visually check the O-ring is in place correctly.

NOT OK!! OK

6. Install the regulator into the vehicle.

 PRM ISI02
Rev.06
Meta® LNG1
Engineering
INSTALLATION AND SERVICE dpt.
INSTRUCTIONS 14

7. Apply tightening torque to the nut using a proper wrench.

Balance torque applied to nut using another wrench to support inlet fitting of the
PR.

8. Check leakage before operating the fuel system.

9. Open manual shut-off valve of NG tank.

10. Check leakage before operating NG metering system

Before cranking engine be sure the capacity downstream the PR is properly

pressurized. Metatron recommends to power the SOV on for 15 s before cranking the
engine. If the system is not properly pressurized the SOV cannot get fully open, leading to
lack of power.
 PRM ISI02
Rev.06
Meta® LNG1
Engineering
INSTALLATION AND SERVICE dpt.
INSTRUCTIONS 15

Inlet and outlet fittings replacement – B version

1. Manual shut-off valve of NG tank must be in closed position (NO FLOW) and the
engine off

2. Disconnect pipes according to relevant interface standard, using the wrench to

balance the untightening torque.
3. Remove the PR from the vehicle

4. Clean PR inlet or outlet area with compressed air before taking out the fittings

5. Unlock inlet fitting with a proper wrench

6. Unscrew it gently, in order to let the NG still present to flow out and to avoid
damaging the O-ring gasket

7. Visually check the O-ring gasket has no cuts or particles on the surface.

Use new fitting group in case of any damage to the O-ring.

 PRM ISI02
Rev.06
Meta® LNG1
Engineering
INSTALLATION AND SERVICE dpt.
INSTRUCTIONS 16

8. Manually screw the fitting in PR till O-ring comes in contact with its seat.
See picture below

9. Visually check the O-ring is in place correctly.

NOT OK!! OK

10. Tighten fitting with proper wrench at 45 ± 1 Nm

Tightening torque must not exceed 50 Nm.

11. Install the PR into the vehicle and connect the pipes.
12. Open manual shut-off valve of the NG tank.

13. Check leakage before operating NG metering system

 PRM ISI02
Rev.06
Meta® LNG1
Engineering
INSTALLATION AND SERVICE dpt.
INSTRUCTIONS 17

Before cranking engine be sure the capacity downstream the PR is properly

pressurized. Metatron recommends to power the SOV on for 15 s before cranking the
engine. If the system is not properly pressurized the SOV cannot get fully open, leading to
lack of power.
 PRM ISI02
Rev.06
Meta® LNG1
Engineering
INSTALLATION AND SERVICE dpt.
INSTRUCTIONS 18

Inlet and particulate screen replacement - BV version

14. Manual shut-off valve of NG tank must be in closed position (NO FLOW) and the
engine off
Take out SOV connector from PR.

15. Disconnect pipes and remove the PR from the vehicle

16. Install PR in vertical position, as shown in the picture below

17. Clean PR inlet fitting area with compressed air

18. Unlock inlet fitting with a proper wrench

 PRM ISI02
Rev.06
Meta® LNG1
Engineering
INSTALLATION AND SERVICE dpt.
INSTRUCTIONS 19

19. Unscrew it gently, in order to let the NG still present to flow out and to avoid
damaging of O-ring

20. Take out the current screen with pliers

 PRM ISI02
Rev.06
Meta® LNG1
Engineering
INSTALLATION AND SERVICE dpt.
INSTRUCTIONS 20

22. Clean the internal side of inlet fitting only with pressurized air
Avoid to damage the O-ring and to contaminate it with solid particles.

23. Insert the new screen in the seat of the fitting.

With plier or by hand, carefully put the component in the correct position, see picture
below. Once inserted in the seat, push the screen with one finger until it doesn’t slide.
Take care to not damage the new screen with pliers.

24. Visually check the O-ring gasket has no cuts or particles on the surface.

Use new fitting group in case of any damage to the O-ring gasket.
 PRM ISI02
Rev.06
Meta® LNG1
Engineering
INSTALLATION AND SERVICE dpt.
INSTRUCTIONS 21

25. Manually screw the fitting in PR till O-ring comes in contact with its seat.
See picture below

26. Tighten fitting with proper wrench at 45 ± 1 Nm

27. Connect shut-off valve connector to PR.

28. Open manual shut-off valve of NG tank.

29. Check leakage before operating NG metering system

Before cranking engine be sure the capacity downstream the PR is properly

pressurized. Metatron recommends to power the SOV on for 15 s before cranking the
engine. If the system is not properly pressurized the SOV cannot get fully open, leading to
lack of power.
 PRM ISI02
Rev.06
Meta® LNG1
Engineering
INSTALLATION AND SERVICE dpt.
INSTRUCTIONS 22

SOV coil replacement

Assembly instructions to correctly replace the coil of SOV assembly of pressure regulator installed
on vehicle.

Exploded view (spare parts)

Assembled coil

SPARE PARTS LIST:

1) Nut
2) O-ring
3) Coil
4) Protection gasket
 PRM ISI02
Rev.06
Meta® LNG1
Engineering
INSTALLATION AND SERVICE dpt.
INSTRUCTIONS 23

1. Manual shut-off valve of NG tank must be in closed position (NO FLOW), engine
off.
2. Disconnect vehicle wiring harness from SOV connector of PR.

3. Unscrew the nut on top of the coil using proper wrench.

4. Remove the coil, taking care of not losing/damaging the sealing O-ring, as showed in picture
below.

5. Insert the O-ring on the new coil and keep it in position.

6. Insert the new coil on valve tube.
7. Put the nut on the coil and screw it manually at least 1 complete turn.
 PRM ISI02
Rev.06
Meta® LNG1
Engineering
INSTALLATION AND SERVICE dpt.
INSTRUCTIONS 24

8. Tighten the nut with proper wrench (19 mm) at 10 ± 1 Nm.

Before cranking engine let at least 15 s since PRM SOV coil supply to fill in with
CNG all metering system downstream PRM.
 PRM ISI02
Rev.06
Meta® LNG1
Engineering
INSTALLATION AND SERVICE dpt.
INSTRUCTIONS 25

Manifold Air Pressure (MAP) connection

FUEL INJECTORS
RAIL

INLET PIPE SIDE

MAP
CONNECTION

INTAKE
MANIFOLD

Manifold Air Pressure connection

➢ improves transient performance of PR with turbocharged engines (because of direct
feedback);
➢ decreases maximum rail pressure at low flow rates (low engine load) with normally aspirated
engines;
➢ with PR must be made with a hose of suitable rubber reinforced with a layer of proper material
to avoid it swells up without increasing pressure.

In case of PR with barbed fitting for MAP connection configuration, hose must be blocked
onto fitting through a proper clamp.

Check protection plug is off before operating PR, in case MAP connection fitting is not used.
Internal components can be subjected to rust, because internal parts must be protected by venting
filter (see Notices).

Check water or dirt cannot enter into PR through MAP connection.

It’s strongly recommended that the MAP fitting is oriented downward

 PRM ISI02
Rev.06
Meta® LNG1
Engineering
INSTALLATION AND SERVICE dpt.
INSTRUCTIONS 26

BARBED END FITTING

 PRM ISI02
Rev.06
Meta® LNG1
Engineering
INSTALLATION AND SERVICE dpt.
INSTRUCTIONS 27

Fitting replacement

1. Clean PR MAP fitting area with compressed air.

2. Remove MAP fitting with a proper wrench (wr 13 mm).

3. Clean the seat in the liner with compressed air.

4. Screw in the new MAP fitting manually at least 1 complete turn.

5. Tighten the MAP fitting with a proper wrench (wr 13 mm) at 3 ± 0.2 Nm.
 PRM ISI02
Rev.06
Meta® LNG1
Engineering
INSTALLATION AND SERVICE dpt.
INSTRUCTIONS 28

Venting membrane (valve)

Encapsulated venting membrane replacement

1. Clean the PR encapsulated venting valve area with compressed air.

2. Remove the encapsulated venting valve with a proper wrench (wr 13 mm).

6. Clean the seat in the liner with compressed air.

7. Screw in the new MAP fitting manually at least 1 complete turn.

3. Tighten the encapsulated valve with a proper wrench (wr 13 mm) at 3 ± 0.2 Nm.
 PRM ISI02
Rev.06
Meta® LNG1
Engineering
INSTALLATION AND SERVICE dpt.
INSTRUCTIONS 29

Dampers installation
Refer to drawing.
1. Install the damper in the bracket.
2. Put the washer on the damper
3. Insert the screw inside the damper and the washer

Washer and screw must be installed in the direction showed in the picture (and relevant
drawing)
 PRM ISI02
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Meta® LNG1
Engineering
INSTALLATION AND SERVICE dpt.
INSTRUCTIONS 30

4. Position the PR with dampers and screw into the fixing block

5. Tighten each screw with a proper wrench at 22 ± 1 Nm.

 PRM ISI02
Rev.06
Meta® LNG1
Engineering
INSTALLATION AND SERVICE dpt.
INSTRUCTIONS 31

Troubleshooting list
Check PR has not been tampered or damaged.

Issue Check:
No flow 1. Shut Off Valve installed before PR is properly
connected, voltage supply is correct and wiring
harness is not damaged.
2. Check the direction of the arrow on the PR
indicating flow direction.
3. Tank valves are open.
4. No obstructions hinder NG flow, both upstream
and downstream PR.
Abnormal outlet pressure 1. p\n is the right one (correct setup pressure).
2. MAP connection is done according to drawing.
3. No obstructions hinder NG flow, both upstream
and downstream PR.
4. Pipes internal diameter is correct, according to
drawing (> 10 mm).
5. Inlet pressure is in the right range.
6. Inlet and outlet fittings are properly connected.
NG Inlet\Outlet leaks 1. O-rings have been installed on the fittings.
2. Tightening torque is correct.
3. Interface parts are not damaged.
4. Inlet\Outlet pipes are properly fixed after service
operation.
PR frozen 1. Heater installed before PR is working properly.
 PRM ISI02
Rev.06
Meta® LNG1
Engineering
INSTALLATION AND SERVICE dpt.
INSTRUCTIONS 32

Contact
Metatron Engineering dpt or entitled local representative.