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Bergstrom NITE Phoenix T2000, Installation Manual

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Bergstrom NITE Phoenix T2000 Installation Manual Download Page 43

Electrical Installation

 

 

 

 

 

43 

  

2-19

 

 

 

 

 

35 

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

– Solenoid common (White wire)  

2

– Solenoid engage (Orange wire) 

 
 

After Wires are Installed

  

Slide the terminal lock into place, inside the 
connector.

 

 

36 

37 

38 

Summary of Contents for NITE Phoenix T2000

Page 1: ...70 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: ... 1 4 1 5 1 6 1 7 1 Refrigerant Charging Battery Management Operating Instructions Wiring Diagrams Espar Heater Install Electrical Installation Installation Procedures Tools Required Before You Start EPA Introduction Unit Exploded View Warranty Website ...

Page 3: ...ficiently power the system for 7 to 9 hours The batteries are then fully recharged after just 4 to 6 hours of driving Add it all up and you have a revolutionary no idle system that will save you money and fuel year after year the NITE Phoenix from Bergstrom NOTE The NITE Phoenix A C system is designed to maintain a comfortable temperature inside the sleeper without running the engine For optimal c...

Page 4: ...wing to help make your installation as easy as possible 1 Lay out all parts and check to make sure you have all parts listed on the parts list Depending on truck some hardware may not be used 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 ...

Page 5: ...ulations when disposing of any resources It is under our obligation to put in place a series of practices and procedures that when taken together result in an environmental management system Disclaimer of Liability Descriptions and specifications within this manual were in effect at the time of production Models and specifications are subject to change Refer to nitesystem com for more information ...

Page 6: ...34a fluorescent dye to determine leak detection Examine with a high intensity ultraviolet light system Specified labels on unit will identify systems that contain fluorescent dye 1 4 Note The air conditioning system is designed only for certain polyvinyl ether PVE refrigerant oil for HFC134a R134a A C systems and HFC134a R134a components The only recommended oil for this particular system is Idemi...

Page 7: ...diately wash skin with soap and water When cases are severe please contact a physician Store toxic products and substances out of reach of children Naptha and Methyl Ethyl Ketone MEK are flammable and hazardous materials and must be used with attentiveness Follow manufacture guidelines to ensure safety when handling materials Store toxic products and substances out of reach of children When operat...

Page 8: ...8 1 6 Before You Start EPA ...

Page 9: ...9 1 7 Cardboard Template Layout Unit Exploded View ...

Page 10: ...NTY 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 Warranty Website WARRANTY ...

Page 11: ...Head T20 T25 Bit Set 8 Metric Wrenches 9 SAE Wrenches 10 1 4 3 8 Drive Ratchets 11 SAE Socket Set 12 Metric Socket Set 13 Wire Cutters 14 Terminal Crimpers 15 Wire Strippers 16 Razor Knife 17 Electrical Tape 18 Cable Cutters 19 4 Professional Grade Cable Crimpers 20 Cable Strippers 21 Work Light 22 Torque Wrench up to 50 in lb 23 U barrel Crimper 24 Pop Rivet Gun 25 Deutsch Crimpers Tools Required...

Page 12: ...Bend or remove the end tabs of the template and position the template close to the front bunk support see photo The Phoenix unit will fit snug between the front support and the rear wall Check under the truck for any obstructions Do not cut through cross members Mark Area in Truck Floor to be Cut Mark the rectangular opening in the template Opening should be large enough for the condenser air brac...

Page 13: ...tions but you will only use 4 Use equal spacing to provide adequate stability of the Phoenix unit Predrilling holes for the mounting screws will aid in keeping the unit square with the condenser openings Optional Heater Use the heater mounting plate as a guide check for clearance around heater Mark center of the plate Using a 4 hole saw cut the opening in the floor Place silicone sealant around he...

Page 14: ...r flow Attach Assembled Condenser Air Inlet Weldment to Underside of Truck Use silicon sealant on sides and edges Insert weldment into hole from below truck floor and fasten from underneath using 1 x 5 16 head self drilling screws through the predrilled holes Cut Hole for Wiring Grommet Using a 2 hole saw drill a hole for the wiring grommets One flanged grommet will be installed from under the tru...

Page 15: ...round wires and grommet with silicone sealant Cut Opening For the Recirculation Grill Using provided template mark area to be cut Also mark the 2 inch hole for the optional heater See photo If this area is already open disregard this step Failure to use the proper cable loom and or grommet will result in damage to cables unit and or vehicle Always seal all open areas in grommet with silicone when ...

Page 16: ...h Seal Strip to Duct Bracket and Elbow Prepare to Install Unit Install the duct elbow mounting bracket to the Phoenix unit using 3 10 x 1 2 T20 elbow bracket screws Install the Left Half of the Elbow Support Ring Using 2 8 x 3 4 T20 elbow flange screws Do not completely tighten screws at this time 14 15 17 16 ...

Page 17: ...Test Fit the NITE Phoenix Unit Elbow Duct and Flange Set the NITE Phoenix unit in place as shown Test fit the elbow With elbow pointing towards the rear of the truck mark hole to be cut for the air duct Using a 4 hole saw cut a hole in the bunk support wall See photo Mark the OE Duct at Center of Hole Remove this OE section of duct and prepare to cut the hole Mark Elbow to Attach to OE Duct It wil...

Page 18: ... the bottom corner of the OE duct Mark and cut flanged elbow adapter Measure approximate 2 inches from one of the sides with no holes Cut both sides Install Modified Flanged Elbow Bracket Secure the bracket to the elbow using 3 inch black Phillips head screws Seal Around Elbow and Adapter With Silicone 22 23 24 25 ...

Page 19: ...19 1 17 Installation Procedures Cut OE Duct For Modified Elbow Place modified duct elbow centered over mark and outline the area to be cut as seen in photo Cut OE Duct as Marked 26 27 ...

Page 20: ...ealant Reinstall the Assembled OE Duct Install the Phoenix Unit Now secure the unit using eight 1 x 5 16 head self drilling screws in the predrilled holes Install Edge Guard Around Hole see arrow Install Elbow and Support Ring Slide elbow into place and install the second half of the support ring using elbow flange screws 8 x 3 4 T20 Tighten all screws at this time 28 29 30 31 ...

Page 21: ...Control Panel For this application we chose to relocate the factory installed Espar heater controller It was raised allowing enough room for the Phoenix controller to mount below the heater control Mounting location can be changed but always check the harness length before cutting For applications with no factory installed heater see instructions page 20 Remove OE Control Panel Disconnect all OE w...

Page 22: ...ontroller template in acceptable location and mark the area inside the template to be cut out Drill Starter Holes with Air Saw Cut out marked section Attach Control Panel to the sleeper control center Carefully depress the lock and remove the controller cover 35 36 37 ...

Page 23: ...ghten Replace cover Connect the Phoenix Control Harness to the Controller and Reinstall Bezel If necessary install the harness extension to the controller harness Reconnect all OE Wires and Cables Reinstall the OE panel Install Drip Tube Under Truck All drip tubes are the same but photo may not represent actual application 38 39 40 41 ...

Page 24: ...24 Section 2 Electrical Installation ...

Page 25: ...attery Boxes Options Refer to www nitesystem com for styles and part numbers Aluminum clamp on boxes include between rail and vertical box styles Install box as suggested by box manufacturer Steel battery boxes require frame drilling and must be attached to the frame rail with bolts see instructions in steps 1 and 2 below Steel Battery Box Between Rail Clamp On Box 2 required Vertical Clamp On Box...

Page 26: ... corner area where you have double walled steel Of the 3 holes available on each side of the outer most edge of box choose the top and center holes on each side see photo A Drill frame rail using HS bit Install box with grade 8 bolts and hardware provided Tighten securely Attach the Hold down Brackets Set two batteries side by side in the battery box and place a hold down bracket on top with the u...

Page 27: ...stallation 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 3 4 ...

Page 28: ...o each end using a professional grade crimper Place heat shrink around each terminal and heat Then loom it Use this cable to connect the positive of one bank of batteries to the positive of the other bank of batteries Step 3 Repeat Procedure for the negative to negative connection using black cable Then loom it Use this black cable to connect the negative of one bank of batteries to the negative o...

Page 29: ...ink around each terminal and heat Then loom it Use these cables to connect all positive terminals on all 4 NITE Batteries Step 2 For the negative to negative connections repeat procedure using black cables Then loom it Connect all negative terminals of the 4 NITE Batteries together Do NOT use truck frame as a ground Battery Set Battery Set Connect positives here AC unit Heater and Separator Connec...

Page 30: ...ble Route the cables from the NITE Phoenix unit down through the floor grommet and along the frame rails to the NITE Batteries HARNESS CHANGE Beginning 6 26 2017 all Phoenix unit use the new power connector shown in photo B Please continue to loom and support the harness using the provided loom and cable ties Secure harness at the unit to prevent stress on harness connectors 6 ...

Page 31: ...rawn from the batteries as well as the charging current to the batteries It also controls the separator solenoid 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 auxiliary battery positive terminal of the NITE Batteries Trim end ...

Page 32: ...2 8 KISSLING TERRA POWER LITTLE FUSE 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 ...

Page 33: ...oles in the bottom of the box and route the cables through the holes to the separator Securely fasten the separator and box using the provided bolts washers and lock nuts Note The separator ties to the truck s starting batteries and allows charging priority to the starting batteries The NITE Batteries begin charging after the starting batteries reach 13 2 volts Run Cables from Truck Batteries Loom...

Page 34: ...eries orange tan white go to separator green yellow go to can bus on Phoenix unit inside the truck All three must be loomed Install Y Connector at BMS Connection D Wires Green and Yellow Systems built after 9 1 2013 do not use a Y connector and resistor Install Resistor Plug E Into Y Connector Connect Can Bus Harness From the Battery Management System Wiring Harness This harness must be loomed F R...

Page 35: ... 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 The black connects to any 12 volt NEGATIVE post in the battery box It is vital that these wires connect in each box Attach Can Bus Cable to Unit Connect can bus harness coming from the BMS into connector at the NITE Phoenix unit it only f...

Page 36: ...he starting batteries It closes when the truck batteries are at or above 13 2 and opens at 12 5 volts Location can be in the AUXILIARY battery box truck starting battery box or the supplied plastic enclosure This harness must be loomed Notice the terminal connecting points are printed on each wire Terminals are marked as 88 Starting battery cable POS 88A Auxiliary battery cable POS 85 Solenoid com...

Page 37: ...r Place the separator mounting bracket centered on the inside of the cover Mark and drill 4 holes to secure the bracket to the cover Before Installing the Bracket Secure the separator to the bracket with four 10 x 32 x screws and lock washers provided Disregard the enclosure instructions if you mount the separator inside the battery box ...

Page 38: ...n Install the Assembly to the Cover Using 4 10 x 32 x 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 slot Install Enclosure on Truck ...

Page 39: ...um inch lbs The black negative will connect the truck negative to the threaded stud D of the BMS Connect NITE Batteries to the Battery Separator Using red battery cable measure and cut to proper length Crimp ring terminals and heat shrink Connect one end to the most appropriate positive terminal of the NITE Batteries Connect the other end to the AUXILIARY terminal B of the battery separator See to...

Page 40: ...ree must be loomed Install Y Connector at BMS Connection D Wires Green and Yellow Systems built after 9 1 2013 do not use a Y connector and resistor Install Resistor Plug E Into Y Connector Connect Can Bus Harness From the Battery Management System Wiring Harness This harness must be loomed F Route this harness inside the truck through the floor grommet and connect at the Phoenix unit Attach Can B...

Page 41: ...ny 12 volt NEGATIVE post in the battery box It is vital that these wires connect in each box Connect Battery Management System to Battery Separator This 2 wire harness from the 6 pin connector routes to the battery separator solenoid This harness must be loomed Notice the terminal connecting points are printed on each wire Deutsch connector kit This connector connects the orange and white control ...

Page 42: ...42 2 18 Electrical Installation ...

Page 43: ...ction 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 Solenoid common White wire 2 Solenoid engage Orange wire After Wires are Installed Slide the terminal lock into place inside the connector 36 37 38 ...

Page 44: ...n the 4 pin connector will disable the Phoenix system Example this can be an input from a park brake or ignition switch to disable the system while vehicle is being driven This connector is provided with your kit Complete Electrical Wiring Recheck and tighten all battery and separator connections Zip tie the cables where necessary Your wiring should match the diagram on page 5 1 39 Electrical Inst...

Page 45: ...ation 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 IF you choose to wire the existing factory installed heater to the SSI controller YOU WILL VOID THE FACTORY WARRANTY OF THE HEATER Electrical Installation ...

Page 46: ...46 Section 3 ESPAR Fuel Operated Heater Installation ...

Page 47: ...xisting factory installed Espar heater to the SSI controller YOU WILL VOID THE FACTORY WARRANTY OF THE HEATER 1 2 Espar Heater Install Unpack Heater Parts Take out the parts to the heating unit Prepare Heater Mounting Location Choose the most appropriate location to install the heater in this case we have chosen a side box floor location Check underneath truck for any obstructions or supports Use ...

Page 48: ...e for the heater intake exhaust and pickup tube Also drill a 1 2 hole approximately 1 to 2 from mounting plate corner NOTE DO NOT USE PHOENIX DUCT FOR HEATER VENT Install Sleeper Heat Vent Select location for the vent in the lower left side of the center support wall closest to heater Drill a 2 hole A to allow distribution of heat into the sleeper After hole is drilled use self tapping screws to a...

Page 49: ...nection Peel off backing from gasket and place gasket over mounting plate edges sticky side down Place small black rubber fuel line connector over the fuel intake tube and push down Place a small clamp over connector push to bottom and tighten Heater Unit Assembly Attach Fuel Line Now take the clear pick up tube place a small clamp over it and push the tube all the way to the bottom of the fuel in...

Page 50: ...e Heater Unit Assembly Attach Exhaust Hose Take the heavy duty silver metal hose and place a large heavy duty clamp over the end of it Place the hose and clamp over the exhaust tube push all the way down and tighten securely Heater Unit Assembly Attach Intake Hose Take the black flex hose and place a small clamp over the end of it Place the hose and clamp over the intake tube push all the way down...

Page 51: ...ngled or caught on anything Run Lines Through Cab Floor Feed exhaust hose intake hose and fuel line through the 4 hole making sure they are not bent crimped or rubbing on the side of the hole Mount Heater Unit to Cab Floor Make sure that the heater unit is set with the fan intake end opposite the 2 hole for the vent louver drilled earlier Set unit flush to floor and attach with a self tapping scre...

Page 52: ...Grill onto intake end of heater B Keep this area clear of debris or install return air hose Attach Wiring Harness Attach plug end of wiring harness into wiring plug at bottom of heating unit Be sure the lock in pin seats securely Run Power and Fuel Pump Wires Through Floor Run the power wire and fuel pump power wire through the grommet installed in section 1 to the underside of the truck If the fu...

Page 53: ... included in the heater kit Route the control cable along the bed towards the heater control panel Use zip ties as needed Strip off 6 of black outer jacket from cable coming from heater Fold all wires back and cut off the outer jacket the blue solid gray and solid brown wires Save the brown wire and make a jumper wire Strip down ends of solid brown wire Connect one end of solid brown jumper to bro...

Page 54: ...e sure exhaust exits behind the vehicle Assemble the Fuel Pump Mount and Hoses Take rubber mount bushing and L bracket and put them together to make mounting bracket for fuel pump Slide fuel pump into rubber bushing A Take plastic caps off both ends of fuel pump Attach large fuel hose to larger diameter end B figure out length needed to connect to pick up tube and cut off excess Secure with clamp ...

Page 55: ... rubber seal and place metal washer on top of pickup tube followed by pump mounting bracket and nut Tighten slightly Put clamp over end of large fuel line from fuel pump attach to pick up tube and clamp down Finish snugging up large nut but do not over tighten Cut off excess from small feeder tube fuel line and attach to fuel pump Secure with clamp Prepare and Attach Fuel Pump Harness Measure and ...

Page 56: ...w 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 If you choose not to connect the heater to the Phoenix unit proceed to Option 2 Espar Heater Install Heater power option Heater control connection 22 ...

Page 57: ...ing of the fuse holder on and pull the red wire through Now strip the end of the red wire attach terminal and crimp Pull red wire back into fuse holder Push rubber seal into place Attach ring terminal to ground wire and crimp Attach Wires to NITE Batteries Connect auxiliary heater ground wire to ground terminal threaded stud of Battery Management System Connect heater unit positive wire to positiv...

Page 58: ... 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 59: ...59 4 1 Wiring Diagrams New Phoenix wiring for units built from 6 26 2017 to current Optional Heater Power 12 volts applied here disables Phoenix system ...

Page 60: ...60 New Phoenix wiring for units built from 6 26 2017 to current 4 2 Wiring Diagrams ...

Page 61: ...61 Use for units manufactured from 2 08 2012 to 6 26 2017 4 3 Wiring Diagrams ...

Page 62: ...62 Use for units manufactured from 2 08 2012 to 6 26 2017 4 4 Wiring Diagrams ...

Page 63: ...63 Use for units manufactured prior to 2 08 2012 4 5 Wiring Diagrams ...

Page 64: ...64 Use for units manufactured prior to 2 08 2012 4 6 Wiring Diagrams ...

Page 65: ...65 Section 5 Operating Instructions ...

Page 66: ...ows 4 bars for fully charged and 1 bar equals low batteries In most cases 1 bar will remain visible when system reaches the LVD low voltage disconnect Changing MODE press ENTER while mode is flashing use up or down arrows to select AUTO COOL HEAT After 5 seconds selection will be set Changing BLOWER SPEED press ENTER until display shows FAN and SPEED Press up or down arrows to select 1 2 3 speed A...

Page 67: ...t back to 72 F degrees on restarts To view system runtime hours press ENTER until Hrs show on display When hours are displayed pressing ENTER for 7 seconds will reset the hours to zero To change from F to C press ENTER until temperature symbol only shows push the up or down arrow to change After 5 seconds selection will be locked Anytime the control is idle for 5 seconds the screen will return to ...

Page 68: ...igh pressure switch open or shorted high Press the ENTER button to proceed through the available service screens Use up down arrows to scroll through voltages and amps 1 SV Starting batteries Voltage 2 AV Auxiliary batteries Voltage 3 AA Unit Amperage draw Pressing ENTER arrow after viewing service screen will return you to the fault code screen Pressing the ON OFF button will return you to the Te...

Page 69: ...69 Section 6 Battery Management System BMS Installation ...

Page 70: ...70 6 1 Bergstrom NITE System BMS 100 Installation Battery Management ...

Page 71: ...71 6 2 Battery Management ...

Page 72: ...72 6 3 Battery Management ...

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