Bergstrom eCLIMACOACH Installation Manual
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Bergstrom eCLIMACOACH Installation Manual

Vanhool cx45
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Installation Manual
eCLIMACOACH – VANHOOL CX45
Developed by: Bergstrom Inc.
Updated 5/14/2020
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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  • Page 1 Developed by: Bergstrom Inc. Updated 5/14/2020 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…………………………………………………………..….0-8 Tools List……………………………………………………………..0-9 Battery Installation……………………………………………………1-1 Installation Procedures – General…………………………………….2-1 ………………………………………………………..2-2 Overview ………………………………………………..…..2-3 Condenser Unit …………………………………………..2-4 Hose Routing Preparation …………………………………2-10 Evaporator Mounting Preparation …………………………………………………….2-11 Hose Routing ………………………..2-15 Evaporator Drain and Electrical Installation …………………………………………..2-16 Evaporator Installation ……………………………………...…..2-18 System HMI Installation...

  • Page 3: Introduction

    Introduction Congratulations! You have chosen the premier no-idle climate control system on the market today – the Generation 2 - eCLIMACOACH from Bergstrom Inc. The Generation 2 - eCLIMACOACH is a NOTE: The Generation 2 – eCLIMACOACH A/C powerful 24 VDC system that keeps the...
  • Page 4 Introduction This specific set of instructions is intended for the installation of a Bergstrom Generation 2 – eCLIMACOACH system on a Van Hool CX45 model bus with a contoured parcel rack. The following instructions are developed from an installation on a Van Hool 2019 CX45.

  • 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 Polyvinyl Ether All equipment must be serviced by trained (PVE) 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: Parts List

    Parts List Part Number Description Quantity in Kit 1002606323 Parcel Rack Unit Gasket, Parcel Rack Rivet, Parcel Rack Mount 1001841526 1000256319 Template, HMI 1000214538 Screw #10 HMI Mount 1002631805 Condenser Unit 1001823237 Condenser Mounting Feet 1002186957 Mounting Hardware Condenser 1001239680 Screw, Mounting Feet 1001863071 Cover, Hose...
  • Page 9 Parts List 1000230085 Fuse, 5A ATO Terminal 3/8” Ring 14-16 AWG 1000247777 Sealed Terminal 3/8” Ring 18-22 AWG 1000247778 Sealed 1000247779 Butt Connector, Step 14-16 to 18- 20 AWG 651462 Tubing, Heat Shrink Terminal, 2 AWG 5/16” 1002457289 1001452271 Holder, Fuse Mega SN Series 1001863071 Kit, Hose Cover Tee, Plastic 5/8”...

  • Page 10: Tools List

    Tools List 0-10 This list is subject to change. Some tools may not be used. • Drill Bit Set • Electrical Tape • Hole Saws (2”, 2 ½”, 3”) • Hose Cutters • Electric/Air Drill • #4 Professional Grade Cable Crimpers •...

  • Page 11: Battery Installation

    Section 1 Battery Installation Generation 2 – eCLIMACOACH Van Hool CX45 Installation Manual...
  • Page 12 Battery Installation The battery installation procedures below are what is recommended at this time by Bergstrom Inc. The location of the batteries is optional but optimal with the space available in this CX45. If another location is chosen, use the following procedure as a reference when connecting cables.
  • Page 13 Battery Installation 3. Replace Batteries a. Remove the existing batteries (heavy). Set aside b. Replace with two (2) new AGM batteries using the reverse of the procedure described previously. 4. Install 2 new AGM batteries a. Remove the back pressure control panel in the area behind the batteries (figure 1.3). Cut the panel in half.
  • Page 14 Battery Installation 5. Battery Connection a. Drill a 2 ½” hole in the corner of the electrical panel to allow wire access from the new batteries to the old batteries (figure 1.6). b. Install the battery terminal lugs onto the positive terminal of the front battery and the negative terminal of the back battery.

  • Page 15: Installation Procedures - General

    Section 2 Installation Procedures Generation 2 – eCLIMACOACH Van Hool CX45 Installation Manual...

  • Page 16: Overview

    Installation Procedures PLEASE READ! The installation of this no-idle A/C system is done in several parts: • The condenser unit includes 2 compressors, a condenser, a condenser fan, and electronic controllers. It is installed curbside in the last cargo bay (next to the existing batteries).
  • Page 17 Installation Procedures 1. Install Condenser Unit a. Using the provided template, line up the edge of the template with the bus and in the back corner (figure 2.1). Check that none of the drain holes will hit a cross member underneath in which case you may have to move the template up an inch or two.
  • Page 18 Installation Procedures 2. Prepare for Hose Routing (luggage bays) a. In the 2 curbside luggage bay remove the two (2) P-clamps and cable ties for the air hose away from the sheet metal (figure 2.5). b. From the post towards the front of the bus, cut a 6” section out of the sheet metal piece and apply trim lock to the edges once cut (figure 2.6).
  • Page 19 Installation Procedures 3. Prepare for Hose Routing (luggage bays) a. In the new condenser unit bay cut the cable tie that secures the wires and hoses in the top inner corner above the ground stud (figure 2.7). b. Cut the sheet metal plate like it is shown in figure 2.8 and attach trim lock to the edges of the cut. c.
  • Page 20 Installation Procedures 4. Prepare for Hose Routing (parcel rack internal) a. Remove driver’s side window 5 and curbside window 2. Refer to the bus manual on removal process. b. Using an air saw, cut a 2 ½” x 5” hole next to the post in the aluminum parcel rack (right above tiny holes).
  • Page 21 Installation Procedures 5. Prepare for Hose Routing (bus internal) a. Loosen the three (3) wall track nuts for driver’s side seat set 8 and curbside seat set 4. b. On the same seat sets, loosen the three (3) floor track nuts and slide the seats forward. c.
  • Page 22 Installation Procedures 6. Prepare for Hose Routing (bus internal) a. Locate the U-channel provided and insert zip ties into the square holes ensuring the locking end of the tie are close to the channel. b. Drill six (6) 3/16” holes alternating down the U-channel. Drill the holes no more than a ½” from the center of the channel (figure 2.17).
  • Page 23 Installation Procedures 7. Prepare for Hose Routing (bus internal) a. Locate all three (3) pieces of the plastic post covering. Included is a long main section, a 45 degree angled section, and a tapered section (figure 2.19). b. Connect the tapered piece to the angled piece and connect the angled piece to the main long piece.
  • Page 24 Installation Procedures 2-10 8. Prepare for Evaporator Mounting a. Locate the evaporator templates and cut off the outside edges. parcel rack on the driver’s b. Place the templates in the 2 parcel rack on the curbside and the 6 side. Use tape to secure the template to the floor following the directions described on the template.

  • Page 25: Hose Routing

    Installation Procedures 2-11 Throughout the hose routing steps in the installation, ensure that no refrigerant hose is ever kinked or twisted at any point. This can cause permanent damage to the hose. Additionally, tape the ends of the hoses to avoid contamination inside. 9.
  • Page 26 Installation Procedures 2-12 10. Hose Routing (condenser unit) a. Ensure you have enough hose length for the entire run before cutting. Use the T fittings (figure 2.28) to connect the hoses in the rearmost luggage bay together. Use the two symmetric arms of the T fitting, not the lone arm.
  • Page 27 Installation Procedures 2-13 Note: Use ratcheting style hose clamp plyers. Use of the non-ratcheting style may cause leaks in the system.
  • Page 28 Installation Procedures 2-14 11. Hose Routing (evaporators) a. Cut both hose jumpers (13-mm) provided in the kit 6” away from the 180 degree fitting. b. Attach and crimp a 13-mm splice fitting onto both of the ends previously cut (figure 2.31). c.

  • Page 29: Evaporator Drain And Electrical Installation

    Installation Procedures 2-15 12. Evaporator Drain and Electrical a. Route the ½” clear drain hose from the evaporator unit down to the lower luggage bays on both sides of the bus. This route is identical to the refrigerant hoses. Ensure no part of the hose is pinched.

  • Page 30: Evaporator Installation

    Installation Procedures 2-16 13. Evaporator Installation (drain) a. Remove the brackets on the curbside evaporator unit and locate the black drain hose, small drain T, and the spring clamps. b. Cut two (2) small sections of drain hose and attach them to the drain outlets of the evaporator unit, securing them with the small spring clamps.
  • Page 31 Installation Procedures 2-17 14. Evaporator Installation (mounting) a. With the curbside evaporator unit in the overhead bay, reinstall the mounting brackets. Ensure the unit is oriented with the duct over the hole in the floor. If needed, drill new mounting holes. Mount the unit to the floor with four (4) 25-mm M6 x 1.00 bolts (nylon nuts with washers).

  • Page 32: System Hmi Installation

    Installation Procedures 2-18 15. System HMI Installation a. Locate the HMI electrical harnesses provided in the kit. Make sure the gray connector is at the condenser unit and route the harness from the condenser unit to the driver’s overhead by following the driver’s side refrigerant hoses until you reach the parcel rack.

  • Page 33: Hose Cover Installation

    Installation Procedures 2-19 16. Hose Cover Installation a. Locate the post cover assembly and drill eight (8) 3/16” holes down both sides of the long piece approximately ½” from the edge. b. Test fit the assembly onto the curbside post and ensure all is hidden by the cover. Mark the previously drilled holes in the cover onto the steel post with a marker.

  • Page 34: Miscellaneous

    Installation Procedures 2-20 17. Miscellaneous a. Slide all bus seats back into place and re-tighten the lock nuts. Torque to 45 ft-lbs. b. Connect the evaporator electrical harness to the evaporator on both sides of the bus. c. Ensure all refrigerant hoses, electrical harnesses, and drain hoses are taut. Zip tie anything that needs it and tighten/snip all zip ties.

  • Page 35: Condenser Unit Power

    Installation Procedures 2-21 18. Condenser Unit Power a. Locate the voltage sense harness and the small orange fuse holder. b. Connect the voltage sense harness to the 4-pin plug at the condenser unit. Route the harness around the back of the unit and over to the batteries. c.

  • Page 36: Refrigerant Charging

    Installation Procedures 2-22 Any refrigerant related steps must be completed by a Section 609 certified technician. 19. Refrigerant Charging a. Connect an R-134a certified gauge set to the condenser unit by connecting the low side gauge to the low side fitting (larger fitting) and the high side gauge to the high side fitting. b.
  • Page 37 Section 3 Solar Installation Generation 2 – eCLIMACOACH Van Hool CX45 Installation Manual...
  • Page 38 The solar installation for this coach bus is an optional feature provided by Merlin Solar Technologies Inc., not Bergstrom Inc. It consists of 3 or 6 solar panels mounted on top of the bus, a charge controller, and an optional remote display. Please refer to the solar installation manual provided by Merlin Solar Technologies Inc.
  • Page 39 Solar Installation 2. Solar Panels a. Follow the instructions provided by Merlin to mount the solar panels to the top of the bus. b. Connect the panels and run the wire lead down to the battery compartment.

  • Page 40: Wiring Diagrams

    Section 4 Wiring Diagrams Generation 2 – eCLIMACOACH Van Hool CX45 Installation Manual...
  • Page 41 Wiring Diagrams...
  • Page 42 Wiring Diagram...
  • Page 43 Wiring Diagram...

  • Page 44: Operating Instructions

    Section 5 Operating Instructions Generation 2 – eCLIMACOACH Van Hool CX45 Installation Manual...
  • Page 45 Operating Instructions...
  • Page 46 Operating Instructions...
  • Page 47 Operating Instructions...
  • Page 48 Operating Instructions Fault codes are shown in the table below: Code Description Comments No Faults Left parcel rack outlet sensor missing or shorted Compressor/condenser disabled high Left parcel rack outlet sensor shorted low Compressor/condenser disabled Right parcel rack outlet sensor missing or Compressor/condenser disabled shorted high Right parcel rack outlet sensor shorted low...

  • Page 49: Testing Normal Operation

    Section 6 Testing Normal Operation Generation 2 – eCLIMACOACH Van Hool CX45 Installation Manual...
  • Page 50 Testing Normal Operation System Operation The unit can be operated with the key in any position. The unit will not turn off when the position of the key is changed. If system ON or OFF is desired, the HMI controller head will need to be manually operated upon.

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