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Bergstrom eCoolPark 1.0 12V Installation Manual

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Installation Manual
eCoolPark 1.0 12V – Ford Explorer
Developed by: Bergstrom Inc.
Updated 2/28/2023
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 ● P.O. Box 6007 ● Rockford, IL 61125 ●
● 1-866-204-8570
www.nitesystem.com

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Summary of Contents for Bergstrom eCoolPark 1.0 12V

  • Page 1 Developed by: Bergstrom Inc. Updated 2/28/2023 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……………………………………...……………………0-3 Before You Start……………………………………….……………..0-5 Parts List…………………………………………………………..….0-9 Tools List……………………………………………………………0-12 Installation Procedures………………………………………………..1-1 Overview………………………………………………………...1-2 Disconnect Power Source and Reclaim OEM Refrigerant..…….1-3 Prepare and Loose Fit eCoolPark Unit..………………………...1-4 Run Hoses (loose)……...………………………………………..1-5 Identify OEM Refrigerant Tubing/Hoses and Install T Fittings...1-6 Fitting Assembly………………………………………………...1-7 Connect to Hoses………………………………...…………….1-10 Secure Hoses and Connect to Unit….…………………………1-12 Leak Check and Charge System……………………………….1-14...

  • Page 3: Introduction

    Congratulations! You have chosen the premier no-idle climate control system on the market today – the eCoolPark 1.0 from Bergstrom Inc. The eCoolPark 1.0 is a powerful 12 VDC system that keeps the cab compartment cool in hot weather without having to idle the vehicle engine. This system is intended to provide no-idle cooling for the cab.
  • Page 4 This specific set of instructions is intended for use only on a Ford Explorer. For another vehicle’s instructions or for a universal set, contact a Bergstrom employee or visit: https://us.bergstrominc.com/nite-manuals-support/ A typical installation of the eCoolPark 1.0 system takes between 6 and 10 hours. This...

  • Page 5: Before You Start

    Under certain circumstances, failure to comply with these instructions can cause severe or life- Under any condition Bergstrom Inc. is committed to threatening impairment. protecting the health and safety of all working individuals at or visiting our site. We strategize,...
  • Page 6 Before You Start Precautions for working with HFC134a Note (R134a) Refrigerant and Polyalkylene Glycol All equipment must be serviced by trained (PAG) Refrigerant Oil professionals only. R134a service equipment and/or vehicle air Warning conditioning systems should not be pressure or •...
  • Page 7 Before You Start Important Safety Notices • Warning When handling corrosion inhibitors and lubricating oils avoid exposure to eyes and repeated contact to Ill-advised practices, negligence, and/or ignoring warning skin for they may contain alkali. In case of contact, signs may cause death, personal injury, equipment or property immediately wash skin with soap and water.
  • Page 8 Before You Start The eCoolPark Unit Must Remain Upright at All Times. The refrigerant inlet/outlet at the bottom of the unit should be capped at all times.

  • Page 9: Parts List

    Parts List Ford Explorer Kit - #1002386000 Part Number Description Quantity in Kit 1002904433 eCoolPark Unit 12V Kit, HVAC – Hose Routing 1002694868 Kit, HVAC – Spare Parts 1002777315 Kit, HVAC – eCool 1.0 M2 1002698610 Mounting Bracket Washer - #10 – M5 Flat 514100 600283 Screw, Self-Drill...
  • Page 10 Parts List 0-10 Electrical Kit - #1002407230 B223109 Fuse Holder B360113 Tie - Plastic 520260 Grommet, Flexible 600283 Screw, Self-Drill 640377 Bag, 3 x inch Static 640378 Bag, Plain Plastic 12 x 12 651459 Iso-Relay, 12V 651462 Tubing Heat Shrink 670136 Terminal Ring 5/16 4 AWG 670137...

  • Page 11: Tools List

    Tools List 0-11 This list is subject to change. Some tools may not be used. • Drill Bit Set • Electrical Tape • Hole Saws (up to 2”) • Hose Cutters • Electric/Air Drill • #4 Professional Grade Cable Crimpers •...

  • Page 12: Installation Procedures

    Section 1 Installation Procedures eCoolPark 1.0 12V Ford Explorer Installation Manual...
  • Page 13 Installation Procedures PLEASE READ! The installation of this no-idle A/C system is done in several parts: • The eCoolPark 1.0 unit includes a compressor, an ECU (electric control unit), and a cooling fan. It is installed in the trunk of the vehicle. •...

  • Page 14: Disconnect Power Source And Reclaim Oem Refrigerant

    Installation Procedures 1. Disconnect Power Source and Reclaim OEM Refrigerant a. Disconnect the desired power source for the duration of the install. The vehicle main start battery can remain connected. b. Reclaim the existing refrigerant in the OEM system using a refrigerant machine or refrigerant reclamation components.

  • Page 15: Prepare And Loose Fit Ecoolpark Unit

    Installation Procedures 2. Prepare and Loose Fit eCoolPark Unit a. Install the 2 mounting feet on the cooling fan side of the eCoolPark unit using the provided 10- 32” screws. Additionally, install 1 more mounting foot on the bottom left corner of the unit. b.

  • Page 16: Run Hoses (Loose)

    Installation Procedures 3. Run Hoses (loose) a. Locate the position where the hoses will exit the interior of the vehicle (marked with X in figure 1.4). b. Verify the opening is large enough for both hose fittings. If not, use an air saw to enlarge the hole.

  • Page 17: Identify Oem Refrigerant Tubing/Hoses And Install T Fittings

    Confirm that the hose in the suction and discharge section of OEM hose is suitable for the fittings provided in the Bergstrom kit. Hose should be Galaxy 4890 ¾ in. and 13/32 in. If not labeled, measure the ID and OD and consult figure 1.16.
  • Page 18 Installation Procedures Assemble Discharge T Fitting and Check Valves Assemble the discharge T fitting and check valves outside of the vehicle. All fittings are bagged with required o-rings and hardware. Be sure to attach o-rings to check valve fittings and add a small amount of oil to lubricate their assembly. Torque Allen bolts to 7 Nm (62 inch-lbs).
  • Page 19 Installation Procedures Suction Line Mockup the T fitting on the hose and use a marker to mark the hose at the end of the barb fitting. Cut the hose and insert fitting into hose using oil lubricant. Make sure to insert hose clamp before attaching hose!!! Figure 1.12: Suction Line T Discharge Line...
  • Page 20 Installation Procedures Check Valves There are a total of 3 check vales inserted into the system. One is attached to the new discharge T fitting and should have been inserted with the previous instruction. The other two check valves are inserted into the hoses of the eCoolPark section using straight hose fittings.

  • Page 21: Connect To Hoses

    Use hose clamps to secure the hoses to the T fittings. Use the racheting tool provided by Bergstrom. Correct procedure is shown in figure 1.21. c. Like shown in figure 1.12, the suction line eCoolPark hose will route around to the left of the metal component.
  • Page 22 Installation Procedures 1-11 Green Figure 1.15: Ratcheting Refrigerant Hose Crimpers Figure 1.17: Hose Clamp Color Code Figure 1.18: Compression T Barb (hose must be inserted all the way to here) Clamp Tool Clip Alignment Location Figure 1.16: Hose ID/OD Figure 1.19: Hose Clamp Procedure...

  • Page 23: Secure Hoses And Connect To Unit

    Installation Procedures 1-12 6. Secure Hoses and Connect to Unit a. The loose hoses in the engine bay should now be connected to the refrigerant T’s. If not already completed, secure the hoses down to the bottom of the vehicle, along the rail or OEM lines, and up to the unit.
  • Page 24 Installation Procedures 1-13 Note: Use ratcheting style hose clamp plyers. Use of the non-ratcheting style may cause leaks in the system. Figure 1.23: Air-o-crimp Assembly Instructions...

  • Page 25: Leak Check And Charge System

    Installation Procedures 1-14 7. Leak Check and Charge System a. Vacuum the system for 30 minutes. Use of a refrigerant machine is suggested. Additionally, a standalone vacuum pump may be used with a gauge set. b. BE SURE TO VACUUM FROM BOTH CHARGE PORTS (HIGH AND LOW SIDE). c.

  • Page 26: Checking For A Leak

    Installation Procedures 1-15 8. Checking for a Leak i. If there is a leak in the system, first try going through all the alteration made during the install and checking to make sure every nut and bolt is torqued to specification. j.

  • Page 27: Electrical Installation

    Section 2 Electrical Installation eCoolPark 1.0 12V Ford Explorer Installation Manual...
  • Page 28 Electrical Installation 1. Locate Electrical Harnesses a. There should be 3 main harnesses and a small jumper harness included in the kit. b. Main vehicle harness, Ignition harness, condenser harness and a small CAN jumper harness. c. Connect the main eCoolPark harness to the unit (round and square Deutsch/Amphenol). Figure 2.2: Ignition Harness Figure 2.1: eCoolPark Vehicle Harness...
  • Page 29 Electrical Installation 2. Routing Vehicle Harness a. Drill another pass through hole for the power cables near the eCoolPark unit where there is no obstruction underneath. b. Route the 4 AWG power cable and the 18 AWG 12/24 VDC remote (labeled as 12 REM) in the vehicle harness to the desired power source.
  • Page 30 Unbolt the OEM OBD2 connector from the vehicle trim and connect to OBD2 jumper harness from Bergstrom. Connect the 2-way connector on the CAN jumper harness to the compatible 2- way connector on the ignition harness.
  • Page 31 Connect the provided condenser harness to the proper connector on the ignition harness. Route the harness through the engine bay, through the firewall, and to the OEM condenser. Secure along the way. Disconnect the OEM condenser fan connectors and splice in the Bergstrom harness.
  • Page 32 Electrical Installation 5. Electrical Connection a. Make sure the 80 Amp fuse is installed in the fuse holder. b. Connect the open side of the main 80 Amp fuse holder to the positive side of the power source using 4 AWG cable and the provided 4 AWG ring terminals. c.
  • Page 33 Electrical Installation Figure 2.15: eCoolPark 1.0 Electrical Block Diagram Electrical wiring diagram is subject to change. It may not be identical to the wiring for your specific vehicle.
  • Page 34 Electrical Installation...

  • Page 35: Operating Instructions

    Section 3 Operating Instructions eCoolPark 1.0 12V Ford Explorer Installation Manual...
  • Page 36 Operating Instructions The eCoolPark system has field configurable parameters that must be adjusted for each install using the Bergstrom field commissioning tool. Installation Procedure (Only need to complete 1 time per upfitter): Necessary Tools: • Laptop • Internet Connection Open the zip folder for the tool using this link: https://www.bergstrominc.net/files/Tools/FieldCommissioningTool.zip...
  • Page 37 Operating Instructions Locate and run the executable file in the folder where the tool was saved. Go through the installation process and save to the created eCoolPark folder.
  • Page 38 Operating Instructions Confirm that the base configuration file is in the following location: C:\Bergstrom_Commissioning Download PCAN USB Drivers: Relocate to: https://www.peak-system.com/Drivers.523.0.html?&L=1 Download the drivers for your respective system. Go through the installation process and make sure the download is successful.
  • Page 39 Make sure the system is getting proper power (12 or 24 VDC) when requested. Use multi-meter to check pin 1 power on 6-way Deutsch connector at the eCoolPark unit (square connector pin If necessary, contact a Bergstrom employee at: 1-866-204-8570...
  • Page 40 Operating Instructions Connect the provided CAN to DB9 jumper harness to the ignition harness located in the driver under dash compartment using the 2-way CAN connector (Green and Yellow). Then connect your PCAN adapter to the harness via DB9 and to your computer via USB. Use termination resistors on the PEAK adaptor (provided).
  • Page 41 Operating Instructions The default configuration file should open as shown. If another configuration file is required (provided by Bergstrom upon request): Use file -> Load Configuration to open the correct configuration file. (The tool will default to this configuration file, the correct file must be loaded in every time the tool is re-opened)
  • Page 42 Make sure PEAK CAN USB is selected. Power on the eCoolPark system using the proper means for the vehicle (ex. rocker switch). Press “Connect” to connect to the Bergstrom ECU. The Application Response window should now display “Connect: Device Initialized” on top.
  • Page 43 Operating Instructions Press “Read Table from ECU”. Let the tool update and wait until the Application window prompts “Reading completed”. Upon success, this will fill in green data in the ECU data column. This data represents the current state of the parameters on the ECU.
  • Page 44 To change a parameter: double click the parameter row in the “User Data” column. You can view the possible entries for the parameter and a description by double clicking the right key on the mouse (Do not need to change any parameters if using requested configuration file from Bergstrom).
  • Page 45 Operating Instructions 3-11 Click “Validate Table” to verify all the entries made are valid. Upon success, click “Write Table to ECU”. Let the tool update and wait for the Application window to prompt “Writing Data completed”. Upon success, the ECU parameters have been updated. Cycle power to the system to complete the process.
  • Page 46 If without requested configuration file: If the vehicle has any of the following, the configuration parameters must be altered as described below. Vehicle has external Bergstrom enable (ex. Auto stop/start OR Miller EnCab System): ConsiderEngRPM – “0 = No” ConsiderRPMTimeout – “0 = No”...
  • Page 47 Operating Instructions 3-13 Testing eCoolPark Normal Operation: 1. Set the parking brake and turn the engine off – unit will only run if engine RPM is 0 2. Turn the key to the ignition ON position (do not start engine) 3.
  • Page 48 Operating Instructions 3-14 Breakdown of eCoolPark Logic: 1. ECU Operation – will verify proper conditions are set before running compressor/condenser a. Battery voltage b. Engine RPM c. Cab air temperature range d. Low pressure transducer range e. High pressure transducer range 2.

  • Page 49: Troubleshooting

    Section 4 Troubleshooting eCoolPark 1.0 12V Ford Explorer Installation Manual...
  • Page 50 Troubleshooting If the eCoolPark unit won’t run the following steps should be performed to check the wiring. 1. Start with the ignition harness and ensure power is being transmitted from the ignition harness into the main vehicle harness (from start battery add-a-fuse) – all steps should result in a reading of 12V.
  • Page 51 PCAN-USB Drivers – https://www.peak-system.com/ • Peak PCAN-USB with termination resistors • CAN service jumper – purchased from Bergstrom Inc. • System power Complete the following: 1. Connect the CAN service jumper in-between the ignition harness and the main vehicle harness 2.
  • Page 52 Troubleshooting...
  • Page 53 Troubleshooting • Find the Config_Overrides row, select checkbox under “Repetition” column • Under Signal Details, column “Physical Value”, change the corresponding row to a 1 to enable the compressor or condenser...
  • Page 54 Troubleshooting Fault Code List – Blinks on Green Indicator Light: Code Failure Description No faults – light solid green None System operation normal Low Voltage Battery voltage fell below set low voltage disconnect parameter Low side pressure fell below set Low Side Pressure Short Low/High Fault LS low cutoff (default: 20 psi) Low side pressure rose above set...

  • Page 55: Appendix

    Section 5 Appendix eCoolPark 1.0 12V Ford Explorer Installation Manual...
  • Page 56 Appendix GRAPHIC DESCRIPTION N-m In-lb Ft-lb PART NUMBER Nut – Lock, 610099 2.3±0.23 20±2 1.67±0.16 Nut – Keps, 621490 2.3±0.23 20±2 1.67±0.16 #10-32 1001239680 2.3±0.23 20±2 1.67±0.16 Screw - #10-32 x ½” Machine Nut – M5 x 0.8 1001520264 2.3±0.23 20±2 1.67±0.16 Belleville...
  • Page 57 Appendix GRAPHIC DESCRIPTION N-m In-lb Ft-lb PART NUMBER Screw – Soc Hd 1002076692 7.0±0.7 62±6 5.17±0.5 Cap Screw M6- 1.0x16 SS 1002160852 Transducer, 7.0±0.7 62±6 5.17±0.5 Pressure – High Side 1002410443 Check Valve, 0.45±0.045 4±1 0.33±.08 Refrigerant – Schrader Core 1002248234 5.6±0.5 50±5...
  • Page 58 Appendix...

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