Bergstrom NITE Phoenix Installation Manual
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Bergstrom NITE Phoenix Installation Manual

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Installation Manual
ANTHEM
The information contained herein is proprietary to Bergstrom Inc and/or its subsidiaries shall
not be reproduced, copied, or disclosed in whole or in part, or used for manufacture or any
other purpose, without prior written permission of Bergstrom Inc. The only controlled version
is that viewed electronically on the designated Bergstrom intranet site.
2390 Blackhawk Road ● Rockford, IL 61109 ●
● 1-866-204-8570
www.nitesystem.com
1

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  • Page 1 Installation Manual ANTHEM The information contained herein is proprietary to Bergstrom Inc and/or its subsidiaries shall not be reproduced, copied, or disclosed in whole or in part, or used for manufacture or any other purpose, without prior written permission of Bergstrom Inc. The only controlled version is that viewed electronically on the designated Bergstrom intranet site.

  • Page 2: Table Of Contents

    Table of Contents Introduction Before You Start / EPA Unit Exploded View Warranty / Website Tools Required 1-10 Installation Procedures Electrical Installation Espar Heater Install Refrigerant Charging Wiring Diagrams Operating Instructions Battery Management...

  • Page 3: Introduction

    ® NITE Phoenix from Bergstrom. NOTE: The NITE Phoenix A/C system is The NITE Phoenix is a powerful 12V designed to maintain a comfortable rechargeable DC system that keeps temperature inside the sleeper sleeper compartments cool in hot without running the engine.

  • Page 4: Before You Start / Epa

    If you are missing any parts, please call 1-866-204-8570. 2. To prevent damage to compressor, keep the NITE Phoenix unit in an upright position at all times. If unit is tipped, place back in upright position for a minimum of 6 hours prior to running.
  • Page 5 Under certain Health, Safety, and Environmental Policy circumstances, failure to comply with these Under any condition Bergstrom Inc. is committed to protecting instructions can cause severe or life-threatening the health and safety of all working individuals at or visiting our impairment.
  • Page 6 Before You Start / EPA Precautions for working with HFC134a (R134a) Refrigerant and Polyvinyl Ether (PVE) Refrigerant Oil WARNING  Note Do not breath A/C refrigerant, oil vapor, or mist. Exposure may cause irritation to the The air conditioning system is designed only for eyes, nose, and throat.
  • Page 7 Before You Start / EPA Important Safety Notices  When handling corrosion inhibitors and lubricating oils avoid exposure to eyes and repeated contact WARNING to skin for they may contain alkali. In case of Ill-advised practices, negligence, and/or contact, immediately wash skin with soap and ignoring warning signs may cause death, water.
  • Page 8 Before You Start / EPA                      ...

  • Page 9: Unit Exploded View

    Unit Exploded View Cardboard Template Layout...

  • Page 10: Warranty / Website

    Warranty / Website WARRANTY TO REGISTER YOUR NEW SYSTEM OR FILE A WARRANTY CLAIM FOLLOW LINK LISTED BELOW. https://warranty.bergstrominc.com For technical manuals or service parts go to https://us.bergstrominc.com/eproduct-systems/ Email us at parts@bergstrominc.com Or call the - NITE LINE 1-866-204-8570...

  • Page 11: Tools Required

    Tools Required 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 12: Installation Procedures

    1-10 Installation Procedures 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 open or remove the divider curtain if there is one. Choose Location Photo shows approximate location of Phoenix unit.
  • Page 13 1-11 Installation Procedures Check underneath truck before cutting or drilling. Cross members and wire harness should not be cut. Install Condenser Air Deflector Assemble sections (A) and (B) and install in the condenser openings. Fasten with (2) 1″ screw with 5/16 head self-drilling. Modification of this assembly may be required if cross members do not allow proper air flow.
  • Page 14 1-12 Installation Procedures Reposition 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. The unit has 8 possible locations but you will only use 4. Use equal spacing to provide adequate stability of the Phoenix unit.
  • Page 15 1-13 Installation Procedures Prepare to Install Unit Install the duct elbow mounting bracket to the Phoenix unit using #10 x 1/2″ T20 elbow bracket screws. Install One Half of the Elbow Support Ring Using elbow flange screws #8 x 3/4″ T20. Do not completely tighten screws at this time.
  • Page 16 1-14 Installation Procedures Test Fit the NITE Phoenix Unit, Elbow Duct and Flange Set the NITE Phoenix unit in place as shown. Test fit the flange and elbow for clearance. Rotate the elbow towards the passenger side. Secure the Unit Using eight 1″...
  • Page 17 1-15 Installation Procedures Ducts are held in place by push clips. Reuse these to reinstall OE ducts. Turn OE Duct Upside Down Cut out the section of OE duct. The flanged adapter will point down. Fasten with 1″ x 5/16 self-drilling screws. Seal any Voids with Silicone Sealant NOTE: Silicone sealant is not included in kit.
  • Page 18 1-16 Installation Procedures Relocate OE Air Sensor Remove sensor from OE duct by removing one screw and retaining clip. It will be relocated into the unit just below the ducting. Drill One Hole Approximately 7/8” in OE Unit Below the Blower Outlet, as shown Slide the retaining clip into position in the 7/8 hole and mark the location for the mounting screw.
  • Page 19 (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 20 1-18 Installation Procedures Install Trim Lock Around the Opening Cut in Step # 8 Models having a speaker in the front support wall will need an opening in the left support wall and the front wall. Opening in left support wall Models With Speaker Install recirculation grill in front support wall.
  • Page 21 1-19 Installation Procedures Remove OE Bunk Control Center Disconnect all OE wires and cables form the control panel and remove. Photo shows approx. location of control. Place Template Over Area to be Cut for Phoenix Controller Mark and remove. Attach Control Panel to the Sleeper Carefully depress the lock and remove the controller cover.

  • Page 22: Electrical Installation

    Section 2 Electrical Installation...
  • Page 23 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 24 Locate the battery box on the frame as close as possible to the sleeper NITE Phoenix unit. When positioning the box, always keep the top of the box as close to the top of the frame rail as possible –...
  • Page 25 Electrical Installation Electrical Installation Preparing Cables The batteries are wired series/parallel for 6 volt or parallel only for 12 volt. See diagrams on pages 2-4 and 2-5 Make and Install All Cables Described in steps 5a or 5b depending on which batteries are being used.
  • Page 26 Electrical Installation Electrical Installation Directions for Wiring a 6-Volt Series/Parallel, 4 Battery NITE Phoenix Step 1: Make and install the two short battery cables. These cables connect the positive (+) of one battery to the negative (-) of the other to create a set or bank.
  • Page 27 Electrical Installation Electrical Installation Directions for Wiring a 12-Volt Parallel, 4 Battery NITE Phoenix Parallel - 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.
  • Page 28 Electrical Installation Electrical Installation Install the NITE Phoenix Power 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.
  • Page 29 NITE Batteries. Trim end of lug if necessary to prevent damage to fuse. Connect the negative cable from the NITE Phoenix unit to the negative threaded stud (C) on the BMS. DO NOT CONNECT POSITIVE TRUCK BATTERY CABLE YET.
  • Page 30 Electrical Installation Electrical Installation STOP! FOR KISSLING SEPARATOR FOLLOW STEPS 9-18 FOR THE TERRA POWER/ LITTLE FUSE SEPARATOR PROCEED TO PAGE 2-13, STEPS 19-39 KISSLING TERRA POWER/ LITTLE FUSE...
  • Page 31 Electrical Installation Electrical Installation Electrical Installation Mounting the Separator Enclosure Disregard the enclosure The battery separator can be located in a instructions if you mount the battery box or in the supplied protected separator inside the battery enclosure. Mark and drill two ¼″ holes box.
  • Page 32 2-10 Electrical Installation Electrical Installation Battery Management System Wiring Harness 8 pin connector plugs into the BMS. Auxiliary battery power wire with fuse connects to battery positive on the auxiliary batteries. This harness splits three ways: Red/black goes to truck starting batteries; orange/tan/white go to separator;...
  • Page 33 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...
  • Page 34 2-12 Electrical Installation Electrical Installation Electrical Installation Connect Battery Management System to Battery Separator Solenoid This 3 wire harness from the 8 pin Orange connector routes to the battery separator White solenoid. Cut wires to length, crimp snap fork terminals on each wire and connect to designated terminals.
  • Page 35 2-13 Electrical Installation WIRING THE TERRA POWER/LITTLE FUSE 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 36 2-14 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 37 2-15 Electrical Installation Run Cables from Truck Batteries Loom 2 full length battery cables, 1 red and 1 black. The red (positive) 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 38 Phoenix unit. 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 39 2-17 Electrical Installation Connect Battery Management System to Black Start Batteries 2 wire harness from 8 pin connector. This harness routes from the BMS in the auxiliary 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 (G) to any 12 volt POSITIVE post in the truck starting battery box.
  • Page 40 2-18 Electrical Installation...
  • Page 41 2-19 Electrical Installation 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 42 2-20 Electrical Installation Electrical Installation Connect the assembled connector to the existing connector on the Terra Power switch. Optional Phoenix System Lockout Beginning 6/26/2017 Connecting the 12 volts to terminal 2 on the 4 pin connector will disable the Phoenix system.
  • Page 43 2-21 Electrical Installation This completes the electrical section of the installation. If you are installing the ESPAR heater proceed to section 3. If you are not installing an aftermarket heater, your installation is complete and you may reconnect the truck batteries. WARNING: If you have a fuel operated heater that was installed at the factory or prior to the SSI install, you can continue to operate the heater with the existing controller.
  • Page 44 Section 3 ESPAR Fuel Operated Heater Installation...
  • Page 45 Espar Heater Install 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 SSI install, you can continue to operate the heater with the existing controller.
  • Page 46 Espar Heater Install 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 47 Espar Heater Install 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-...
  • Page 48 Espar Heater Install 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 49 Espar Heater Install 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 50 Espar Heater Install 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 51 Espar Heater Install WARNING: If you have an Espar fuel operated heater that was installed at the factory or prior to the SSI install, you can continue to operate the heater with the existing controller. IF you choose to wire the existing factory installed heater to the SSI controller, YOU WILL VOID THE FACTORY WARRANTY OF THE HEATER! Optional Heater Controlled by the SSI Controller...
  • Page 52 Espar Heater Install 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 53 Espar Heater Install 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. See diagram A. Option: When possible drill holes in the fuel sender block off plate.
  • Page 54 3-10 Espar Heater Install Option 1: Heater Power from Phoenix Unit Notice: Beginning 6/26/2017 the Phoenix unit harness changed. Phoenix unit now contains an additional fuse and connector for powering an aftermarket heater. Your Phoenix kit includes a mating electrical connector for connecting the heater battery power.

  • Page 55: Espar Heater Install

    3-11 Espar Heater Install Option 2: Heater Power from Auxiliary Batteries not Phoenix Unit 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.

  • Page 56: Wiring Diagrams

    Section 4 Wiring Diagrams NOTE: Pages 4-1 and 4-2 are for unit manufactured after 6/26/2017 Pages 4-3 and 4-4 are for unit manufactured 2/8/2012 to 6/26/2017 Pages 4-5 and 4-6 are for units manufactured prior to 2/8/2012...
  • Page 57 Wiring Diagrams New Phoenix wiring for units built from 6/26/2017 to current...
  • Page 58 Wiring Diagrams New Phoenix wiring for units built from 6/26/2017 to current...
  • Page 59 Wiring Diagrams Use for units manufactured from 2/08/2012 to 6/26/2017...
  • Page 60 Wiring Diagrams Use for units manufactured from 2/08/2012 to 6/26/2017...
  • Page 61 Wiring Diagrams Use for units manufactured prior to 2/08/2012...
  • Page 62 Wiring Diagrams Use for units manufactured prior to 2/08/2012...

  • Page 63: Operating Instructions

    Section 5 Operating Instructions...
  • Page 64 Operating Instructions OPERATING INSTRUCTIONS FOR CONTROLLER To start the system push ON/OFF button, Display will show current mode/ temperature setting / battery level. First time system is powered on - Initial default setting is Blower Speed 1 / AUTO- MODE / Temp 72 °F Battery charge level indicator shows 4 bars for fully charged and 1 bar equals low batteries.
  • Page 65 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 retain the last Mode and Blower settings but the Temperature will always default back to 72 °F degrees on restarts.
  • Page 66 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 00 unless a fault has occurred. If there is an active fault the display will show it as 01, 02, etc. Use up and down arrows to scroll through the Fault Codes.

  • Page 67: Battery Management

    Section 6 Battery Management System (BMS) Installation...
  • Page 68 Battery Management Bergstrom NITE System BMS 100 Installation...
  • Page 69 Battery Management...
  • Page 70 Battery Management...

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