Bergstrom NITE Phoenix Installation Manual
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Bergstrom NITE Phoenix Installation Manual

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Installation Manual

Classic Sleeper including
T600, T660, T800 and W900
2390 Blackhawk Road ● P.O. Box 6007 ● Rockford, IL 61125 ●
● 1-866-204-8570
www.nitesystem.com

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  • Page 1: Installation Manual

    Installation Manual Classic Sleeper including T600, T660, T800 and W900 2390 Blackhawk Road ● P.O. Box 6007 ● Rockford, IL 61125 ● ● 1-866-204-8570 www.nitesystem.com...
  • Page 2 Table of Contents Installation Procedures Introduction Before You Start Parts List Tools Required Installation Procedures Electrical Installation Espar Heater Install Webasto Heater Install Wiring Diagrams Operating Instructions Battery Management Kenworth T600-T660-T800-W900 rev 10/7/13...
  • Page 3 The NITE Phoenix A/C unit will not pull down a hot sleeper that has been sitting in the starting batteries. sun without the factory A/C running. To...
  • Page 4 ● Electrical installation ● Heater installation (optional) There is also a section on how to check your NITE Phoenix to make sure the installation was successful, and a section on how to operate your NITE Phoenix. If relocation or reinstallation of any pre-installed...
  • Page 5 1000007552 NITE WARRANTY POLICY Bergstrom Bergstrom 585414 1000251583 OPERATION CARD 585511 NITE WARRANTY CARD/SURVEY Bergstrom Bergstrom Bergstrom 1000230787 NITE PHOENIX AC/HEAT - ESPAR Bergstrom Bergstrom Bergstrom 1000386342 NITE UNIT 1000038693 ESPAR HEATER KIT** Bergstrom Bergstrom Bergstrom 1000342516 PHOENIX POWER KIT*...
  • Page 6 Installation Procedures Parts List 1000230794 KIT, NITE PHOENIX STD HARDWARE (cont) 600159 SCREW, NO 12-16 X 1 INCH HI-LO Bergstrom Bergstrom Bergstrom 600187 PLASTITE NO8-16 C.75 IN TORX Part # 600282 BOLTCARRIAGE .25-20 X 3 IN 585414 Bergstrom Bergstrom 600283...
  • Page 7 Installation Procedures Parts Breakdown Bergstrom Bergstrom Bergstrom Part # 585414 Bergstrom Bergstrom Bergstrom Bergstrom Bergstrom Bergstrom Bergstrom Bergstrom Bergstrom Bergstrom Bergstrom Bergstrom Bergstrom Bergstrom Bergstrom Bergstrom Bergstrom Bergstrom Bergstrom Bergstrom Cardboard Template Layout Parts List Kenworth T600-T660-T800-W900 rev 10/7/13...
  • Page 8 Tools Required Installation Procedures 1) Drill Bit Set 2) Hole saws (1″, 1-5/8″, 2″, 2-1/2″, 4-1/2″ and 4-3/4″ ) 3) Electric/Air Drill 4) Screwdrivers/Assorted Bits (Flat Head & Phillips Head) 5) Impact Gun 6) Air saw/Jigsaw (Cutting Sheet metal) 7) Torx Head (T20-T25) Bit Set 8) Metric Wrenches 9) SAE Wrenches 10) 1/4″, 3/8″...
  • Page 9 Installation Procedures Attention: evaporator blower Phoenix will rotate. This unit will always be side discharge! Prepare the Work Area. Start by disconnecting the ground wire from the starting batteries. Set up your work light, clear the sleeper compartment of loose items, and remove the divider curtain if there is one.
  • Page 10 1-10 Installation Procedures Installation Procedures Cut Driver’s Side Support Wall to Allow Clearance for the NITE Phoenix Unit. Mark area as shown to allow proper clearance around unit for the Phoenix to protrude inside the driver’s side storage box. Use an air saw to cut opening. When necessary cut bottom, front and rear edges flush.
  • Page 11 Note location of cross members prior to drilling holes. Use air saw/jigsaw to cut through truck floor. Position the NITE Phoenix mounting template, as shown, with the condenser openings over the holes cut in the truck floor. Mark and drill pilot holes for 4 mounting feet.
  • Page 12 (see photo showing outline for cutout marked on center support wall)The opening should be positioned in front of where the NITE Phoenix unit will be positioned. The size should be 11-1/2″ x 4-5/8″. Use provided template for marking.
  • Page 13 If the sleeper has a window, continue with step 12. If the sleeper does not have a window, proceed to step 24. Determine Location for the NITE Phoenix Duct Next to Window. Set duct on top of decking on the driver’s side of the sleepers back wall.
  • Page 14 Secure wiring in channel with tape. The duct is now ready to be attached. Attach stealth to the NITE Phoenix Duct. After the controls are installed slide NITE Phoenix duct and wiring down through the slot in the decking enough to fasten the elbow to the duct using two 1″...
  • Page 15 1-15 Installation Procedures Installation Procedures Attach seal strip to duct bracket and elbow. Prepare to Install Unit Install the duct elbow mounting bracket to the Phoenix unit using #10 X 1/2″ T20 elbow bracket screws. Now install one half of the elbow support ring using elbow flange screws #8 X 3/4″...
  • Page 16 Attach Flexible Duct to Transition Duct. Run flexible duct through support wall to the NITE Phoenix duct location. Attach the flexible duct to the transition duct. Tighten hose clamp to secure flex duct to transition duct.
  • Page 17 A clearance cut needs to be made in the aluminum flange on the back wall. This will allow clearance for the NITE Phoenix duct to be mounted flush on the back wall. Remove the driver side seat belt (A) and relocate and reattach it.
  • Page 18 Installation Procedures Preassemble Elbow (see page 1-15) Install mounting feet. See page 1-16 step 20. Test Fit the NITE Phoenix Unit, Elbow Duct and Flange. Set the NITE Phoenix unit in place as shown. Install unit. Now secure the unit using eight 1″...
  • Page 19 Attach Stealth to the NITE Duct. After the controls are installed and the stealth is cut and rotated 90° fasten the stealth to the NITE Phoenix duct using four 1″ X 5/16 self-tapping screws. Apply silicone sealant around seam. Duct shown has been cut and rotated 90 degrees.
  • Page 20 Removing this flare will allow the 90 degree elbow to slide inside the stealth providing 360 degrees of rotation. Secure with self-drilling screws. Install the NITE Phoenix Unit Power Harness Grommet. Chose a good location for the flanged grommet provided. Drill a 2″ hole and install provided grommet in the floor.

  • Page 21: Electrical Installation

    Section 2 Electrical Installation Rev 9/25/2013...
  • Page 22 Electrical Installation NOTE: Bergstrom does not condone putting batteries under the sleeper bunk. The floor is not designed to carry that amount of weight and even deep cycle AGM batteries can emit gas under certain circumstances. Bergstrom can only support batteries being placed in battery boxes or tool boxes designed to support the weight of the batteries outside the cab of the truck.
  • Page 23 Electrical Installation Attaching Hold-down Brackets Set two batteries side-by-side in the battery box and place a hold-down bracket on top, with the u-channel facing up. Take two 5/16″ bolts, place a 5/16″ flat washer on each, and then put the bolts through the outer holes. Tighten each bolt securely from under- neath using the supplied nuts and washers.
  • Page 24 Electrical Installation Directions for Wiring A 6-Volt Series/Parallel, 4 Battery NITE Phoenix Step 1: Make and install the two short terminal and heat. Then loom it. Use battery cables. These cables connect this cable to connect the positive (+) of...
  • Page 25 Electrical Installation Directions for Wiring A 12-Volt Parallel, 4 Battery NITE Phoenix Parallel is all positives connected together and all negatives connected together. Step 1: For the positive (+) to positive (+) parallel connections measure and cut pieces of red cable to length. Attach a ring terminal to each end using a professional grade crimper.
  • Page 26 Harness. Take the power harness and place the protective split plastic loom around each cable. Route the cables from the NITE Phoenix unit, down through the floor grommet and along the frame rails to the NITE Batteries. Secure harness at the unit to prevent...
  • Page 27 5/16 lugs Connect Power Cables from Phoenix Unit to the NITE Batteries. Connect positive cable from the NITE Phoenix unit to the 100 amp mega fuse in the fuse holder. Kit contains 2 lugs with 5/16 diameter holes. Make a short (jumper)
  • Page 28 Electrical Installation STOP! FOLLOW STEPS 10-19 FOR KISSLING SEPARATOR PROCEED TO PAGE 2-10, STEPS 20-41 FOR THE TERRA POWER SEPARATOR KISSLING TERRA POWER...
  • Page 29 Electrical Installation Disregard the enclosure Mounting the Separator Enclosure instructions if you mount the The battery separator can be located in a separator inside the battery box. battery box or in the supplied protected enclosure. Mark and drill two ¼″ holes through the back of the plastic box and the support it will be mounted to.
  • Page 30 Electrical Installation Battery Management System Wiring Harness. 8 pin connector plugs into the BMS. Auxiliary battery power wire with fuse connects to battery pos on the aux. batteries. This harness splits three ways: Red/black goes to truck starting batteries, orange/tan/white go to separator, green/yellow go to can bus on Phoenix unit inside the truck.
  • Page 31 2-10 Electrical Installation Connect Battery Management System to Start Batteries. 2 wire harness from 8 pin connector. This harness routes from the BMS in the Aux battery box to the truck starting battery box. This harness must be loomed. The red connects through the supplied, field installed, 5 amp mini fuse and holder (A) to any 12 volt POS post in the truck starting battery...
  • Page 32 2-11 Electrical Installation Connect Battery Management System to Battery Separator Solenoid This 3 wire harness from the 8 pin connector routes to the battery separator solenoid. Orange Cut wires to length, crimp snap fork White terminals on each wire and connect to designated terminals.
  • Page 33 2-12 Electrical Installation WIRING THE TERRA POWER SEPARATOR Disregard the enclosure instructions if you mount the separator inside the battery box. Install Separator Enclosure Remove the enclosure cover, Place the separator mounting bracket, centered on the inside of the cover. Mark and drill 4 holes to secure the bracket to the cover.
  • Page 34 2-13 Electrical Installation Install the assembly to the cover using 4 10 x 32 x ¾″ screws, lock and flat washers provided. Next, drill a 2″ hole in the center of the bottom of the box as shown. Trim the hole on each side as shown, creating a 2″...
  • Page 35 2-14 Electrical Installation Run Cables from Truck Batteries Loom 2 full length battery cables, 1 red and 1 black. The red (pos) cable will connect the truck starting batteries positive post to the (start) post (A) of the battery separator. You must use the provided 90 degree battery terminal end at the Terra Power separator rotated to the center of the switch.
  • Page 36 2-15 Electrical Installation Battery Management System Wiring Harness. 8 pin connector plugs into the BMS. Auxiliary battery power wire with fuse connects to battery pos on the aux. batteries. This harness splits three ways: Red/black goes to truck starting batteries, orange/white go to separator, green/yellow go to can bus on Phoenix unit inside the truck.
  • Page 37 2-16 Electrical Installation Attach Can Bus Cable to Unit. Connect can bus harness, coming from the BMS, into connector at the NITE Phoenix unit – it only fits one way. Also connect the digital controller harness installed in an earlier step.
  • Page 38 2-17 Electrical Installation Connect Battery Management System to Start Batteries. 2 wire harness from 8 Black pin connector. This harness routes from the BMS in the Aux battery box to the truck starting battery box. This harness must be loomed. The red connects through the supplied, field installed, 5 amp mini fuse and holder (A) to any 12 volt POS post in the truck starting battery...
  • Page 39 2-18 Electrical Installation...
  • Page 40 2-19 Electrical Installation Cut wires to length, strip insulation as instructed in the Deutsch tool section. Crimp terminals on each wire. Install 4 sealing plugs into the unused terminal locations 3 through 6. Install separator control wires into Deutsch connector Terminals are marked as: 1–...
  • Page 41 2-20 Electrical Installation Connect the assembled connector to the existing connector on the Terra Power switch Complete Electrical Wiring Recheck and tighten all battery and separator connections. Zip tie cables where necessary. Your wiring should look like the diagram on page 5-1. This completes the electrical section of the installation.
  • Page 42 Section 3 ESPAR Fuel Operated Heater Installation...
  • Page 43 Heater Installation The heater instructions in this manual are generic. For the latest install information please refer to the Espar D2 heater install manual WARNING: If you have an Espar fuel operated heater that was installed at the factory or prior to the Phoenix install, you can continue to operate the heater with the existing controller.
  • Page 44 Heater Installation Drill Outlet Hole for Heat Unit. Mark the floor of the truck using the 5 small holes of the mounting plate. Remove mounting plate, place a 4 ¼″ hole saw over the middle of the floor marks, and drill the outlet hole for the heater, intake, exhaust and pickup tube.
  • Page 45 Heater Installation Heater Unit Assembly –Attach Mounting Plate. Snap end cap on heater unit (A). Place mounting plate over heater unit (B). Attach with flat lock washers and 10mm lock nuts— tighten down securely. Heater Unit Assembly – Attach Gasket and Fuel Line Connection Peel off backing from gasket and place gasket over mounting plate edges, sticky-side down.
  • Page 46 Heater Installation Heater Unit Assembly – Identify Intake and Exhaust Ports. Look closely at the two small metal tubes. One has an arrow pointing out away from the unit—this is the exhaust. One has an arrow pointing in towards the unit—this is the intake.
  • Page 47 Heater Installation PREPARE TO MOUNT UNIT Check to make sure truck batteries are still disconnected. Carry unit into truck. It will be mounted over the 4 ¾″ hole that was drilled earlier. Make sure hoses and tubes don’t get tangled or caught on anything. Run Lines Through Cab Floor Feed exhaust hose, intake hose, and fuel line through the 4 ¾″...
  • Page 48 Heater Installation Attach Heat Line to Sleeper Vent. Take the black metallic flex tube, measure and cut length to run from heater unit to louver/vent opening (A). Place two clamps over ends of tube, and clamp tube to heating unit and louver. Tighten clamps securely but do not over tighten.
  • Page 49 Heater Installation Optional Heater controlled by the Phoenix controller. WARNING: If you have an Espar fuel operated heater that was installed at the factory or prior to the Phoenix install, you can continue to operate the heater with the existing controller. IF you choose to wire the existing factory installed heater to the Phoenix controller, YOU WILL VOID THE FACTORY WARRANTY OF...
  • Page 50 Heater Installation Finish Intake and Exhaust Hose Installation. First, attach intake air tube to truck structure with zip ties. Put cap on bottom of intake tube. Next, run exhaust hose to the back of cab, attach with clamps to the structure of the truck.
  • Page 51 Heater Installation Drill Hole in Fuel Tank, Insert Pickup Tube and Mount Fuel Assembly. Use a 1″ hole saw to scribe initial location for two outer holes. Drill the two outer 1/4″ holes centered on scribe. Then complete drilling the 1″ hole.
  • Page 52 3-10 Heater Installation Run Heater Unit Power Cable to NITE Batteries. Take the heater unit power cable, run it under the truck (attach with zip ties where necessary) over to the NITE Batteries. Strip back outer cover to expose two inner wires. Attach Connectors.
  • Page 53 Section 4 WEBASTO Fuel Operated Heater Installation...
  • Page 54 Heater Installation Optional Webasto Heater controlled by the Phoenix controller. WARNING: If you have a Webasto fuel operated heater that was installed at the factory or prior to the Phoenix install, you can continue to operate the heater with the existing controller. IF you choose to wire the existing factory installed Webasto heater to the Phoenix controller, YOU COULD VOID THE...

  • Page 55: Wiring Diagrams

    Section 5 Wiring Diagrams NOTE: Pages 5-1 and 5-2 are for unit manufactured after 2/8/2012 Pages 5-3 and 5-4 are for units manufactured prior to 2/8/2012 Rev 7/10/14...
  • Page 56 External Wiring Diagram...
  • Page 57 Internal Wiring Diagram...
  • Page 58 External Wiring Diagram...
  • Page 59 Internal Wiring Diagram...
  • Page 60 Section 6 Operating Instructions...
  • Page 61 Operating Instructions To start the system push ON/OFF button. Display will show current mode/ temperature setting / battery level. Initial default setting is blower speed 1/ AUTO- MODE /60 °F ON/OFF Changing MODE – press ENTER, while mode is flashing use up or down arrows to select AUTO / COOL / HEAT.
  • Page 62 Operating Instructions Changing TEMPERATURE set point. Anytime the temperature set point is displayed on the screen, push the up or down arrows to change. Temperature range is from 60 °F (coolest) to 85 °F (warmest). NOTE: Control will always default to the last setting when the unit is turned on.
  • Page 63 Operating Instructions To enter SERVICE MODE: Push both the ON/OFF and ENTER button simultaneously at any time. Display will show service indicator and a code #1 to #3. Use up and down arrows to scroll through the Fault Codes. 1) Evap sensor open or shorted high 2) Evap sensor shorted low 3) High pressure switch open or shorted high ON/OFF...
  • Page 64 Section 7 Battery Management System (BMS) Installation...
  • Page 65 Battery Management Bergstrom NITE System BMS 100 Installation...
  • Page 66 Battery Management...
  • Page 67 Battery Management...

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