Bergstrom NITE Phoenix Installation Manual Download Page 53 | Manualshive

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Section 4

WEBASTO Fuel Operated Heater

Installation

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Summary of Contents for NITE Phoenix

Page 1: ...Installation Manual Classic Sleeper including T600 T660 T800 and W900 2390 Blackhawk Road P O Box 6007 Rockford IL 61125 www nitesystem com 1 866 204 8570 ...

Page 2: ...s Table of Contents Introduction Before You Start Parts List Tools Required Installation Procedures Electrical Installation Espar Heater Install 1 3 1 4 1 5 1 8 1 9 2 1 3 1 4 1 5 1 6 1 7 1 Wiring Diagrams Operating Instructions Battery Management Webasto Heater Install ...

Page 3: ...ntly 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 Introduction NOTE The NITE Phoenix A C system is designed to maintain a comfortable temperature inside the sleeper without running the engine For o...

Page 4: ...hly recommend doing the following 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 ba...

Page 5: ...05 LOUVER CARY 633 WITH 631 BEZEL 2 500198 GRILLE AIR RETURN 1 560235 HOSE DEFROST 4 X 45 INCHES 1 584510 PLUG BUTTON 5 IN HLE 3L4566 2 1000007617 DUCT STEALTH 1 1000168631 COLLAR DUCT 2 1000183274 BRACKET UNIT MNT 4 1000184211 DUCT UPPER PHOENIX 1 1000185196 COLLAR SIDE 1 1000186017 DUCT ASSY 1 1000218364 DUCT INTAKE 1 1000219677 DUCT INTAKE 1 1000224619 GASKET STRIP 2 1000230622 BRACKET INTAKE S...

Page 6: ...RINK 22 660706 ASSY WIRE BATT CABLE 5300MMBL 2 660707 ASSY WIRE BATT CABLE 5000MMRE 3 670136 TERMINAL RING 5 16 4 GA 2 670137 TERMINAL RING 3 8 4 GA 20 1000049325 ENCLOSURE ELECTRICAL 1 1000173480 HARNESS DAYCAB POWER 4 GA 1 1000174251 FUSE MEGA 100A YELLOW 1 1000174286 FUSEHOLDER MEGA BOLT ON 1 1000230085 FUSE 5A ATO 1 1000235371 WIRE LOOM 413 ID X 140 FT 1 1000247777 TERM 3 8 RING 14 16GA SEALE ...

Page 7: ...own Bergstrom Part Bergstrom Bergstrom 585414 Bergstrom Bergstrom Bergstrom Bergstrom Bergstrom Bergstrom Bergstrom Bergstrom Bergstrom Bergstrom Bergstrom Bergstrom Bergstrom Bergstrom Bergstrom Bergstrom Bergstrom Bergstrom Bergstrom Bergstrom Parts List Cardboard Template Layout ...

Page 8: ...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 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 lbs 23 U barrel Crimper 24 Pop...

Page 9: ...se items and remove the divider curtain if there is one Then remove the mattress Remove Aluminum Bunk Decking Remove the screws securing the center panel of the bunk deck A exposing the center storage area B Roll Floor Insulation Back Pull up the floor insulation and roll it back out of your way as shown 1 3 A B Attention The evaporator blower in the Phoenix will not rotate This unit will always b...

Page 10: ...mplate must be placed against the front bunk support wall to allow clearance for the elbow on the back of the unit Apply Trim Lock Protector to Cut Edge Cover the sharp edge of the cut opening Determine Location for NITE Phoenix Unit Mounting Plate After the side wall is cut out fold the two mounting tabs on the template opposite the AIR outlet arrow and position the template close to the front wa...

Page 11: ...n 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 Pre assemble the air intake using 10 X 1 2 T20 screws see below Place assembled unit in the condenser hole Fasten with 1 screw with 5 16 head self drilling Mod...

Page 12: ...ening 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 Cut Opening for Recirculation Grill Cut an opening A with a metal cutting air saw or jigsaw for the recirculation grill in the support wall Attach grill B to the center wall using black Phillips head screws NOTE Take precautions not to damage car...

Page 13: ...the bottom of duct A remove duct and cut opening B Attach Control Panel to the NITE Phoenix Duct Carefully depress the lock and remove the controller cover Install the controller to the duct using 10 x 1 2 T 20 torque head screw PN 600129 Do not over tighten Replace cover Installation Procedures 12 13 B A The following steps vary based on whether the sleeper has a window or not If the sleeper has ...

Page 14: ...lled slide NITE Phoenix duct and wiring down through the slot in the decking enough to fasten the elbow to the duct using two 1 X 5 16 self tapping screws Seal around stealth with silicone sealant Now raise duct back up to proper location Attach NITE Phoenix Duct to Back Wall of Sleeper Press the top of the duct up against the back wall Make sure the duct is square and level against the back wall ...

Page 15: ...o 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 T20 Do not completely tighten screws at this time Slide the elbow into the support ring and install the second half Once it s installed you can snug all screws 19 ...

Page 16: ...ance against the rear wall Rotate the elbow towards the driver s side Now secure the unit using eight 1 X 5 16 head self drilling screws in the predrilled holes Attach Assembled Elbow to the Flexible Duct Insert flexible duct onto the round end of the elbow unit Tighten hose clamp to secure flex duct to elbow Attach Flexible Duct to Transition Duct Run flexible duct through support wall to the NIT...

Page 17: ...minum flange between the two seat belt straps a minimum of 13 1 2 flush against back wall B Determine Location for Recirculation Grill Install the grill in the center support wall 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 m...

Page 18: ...ng eight 1 X 5 16 head self drilling screws in the pre drilled holes drilled in step 8 page 1 11 Attach Control Panel to NITE Duct Carefully depress the lock and remove the controller cover Install the controller to the duct using 10 x 1 2 T 20 torque head screws PN 600129 Do not over tighten Run Wiring behind NITE Duct Loom the control harness Connect it to the back of the controller Place the wi...

Page 19: ...one sealant is not included in kit Attach NITE Phoenix Duct to Back Wall of Sleeper Press the top of the duct up against the back wall Make sure the duct is square and level against the back wall Use 1 X 5 16 hex head self tapping screws to attach top of duct to back wall Place 3 5 screws in each duct opening and install at different angles A Take care not to over tighten Snap both louvers into pl...

Page 20: ...rommet Chose a good location for the flanged grommet provided Drill a 2 hole and install provided grommet in the floor Route all Phoenix and heater cables through this grommet Secure harness with provided zip ties Install Drip Tube Under Truck Notice deflector pan has be modified to allow proper air flow 35 36 37 Failure to use the proper cable loom and or grommet will result in damage to cables u...

Page 21: ...Section 2 Electrical Installation Rev 9 25 2013 ...

Page 22: ...ing within 2 of top or bottom of frame rail Check truck manufacturer guidelines prior to drilling Using box as template mark and drill a minimum of 4 holes Always use the holes in the rear outer 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 Ins...

Page 23: ... bolts through the outer holes Tighten each bolt securely from under neath using the supplied nuts and washers Repeat the procedure for the other two batteries Preparing Cables The batteries are wired series parallel for 6 volt or parallel only for 12 volt See diagrams on pages 2 3 and 2 4 Make and Install All Cables described in steps 6a or 6b depending on which batteries you are using NOTE Befor...

Page 24: ...e crimper Place heat shrink around each 6a 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 Step3 Repeat procedure for the negative to negative connection using a black cable Then loom it Use this black cable to connect the negative of one bank of batteries to the negative of the other bank of batteries Do...

Page 25: ... Batteries Step2 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 6b b Directions for Wiring A 12 Volt Parallel 4 Battery NITE Phoenix Parallel is all positives connected together and all negatives connected together Battery Set Battery Set Connect positives h...

Page 26: ... 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 stress on harness connectors 7 ...

Page 27: ...rging 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 battery cable to go from the fuse to the Aux battery positive terminal of the NITE Batteries Trim end of lug ...

Page 28: ...2 7 Electrical Installation STOP FOLLOW STEPS 10 19 FOR KISSLING SEPARATOR PROCEED TO PAGE 2 10 STEPS 20 41 FOR THE TERRA POWER SEPARATOR TERRA POWER KISSLING ...

Page 29: ...eries 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 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 88 of the battery separator The black neg will connect the truck neg to the threade...

Page 30: ...o separator green yellow go to can bus on Phoenix unit inside the truck All three must be loomed Install Y connector at BMS connection A wires green and yellow Install resistor plug B into Y connector Connect Can Bus harness from the Battery Management System wiring harness This harness must be loomed C Route this harness inside the truck through the floor grommet and connect at the Phoenix unit 1...

Page 31: ...rough the supplied field installed 5 amp mini fuse and holder A to any 12 volt POS post in the truck starting battery box The black connects to any 12 volt NEG 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 fits one way Also connect the digital controll...

Page 32: ...es the Aux batteries from the 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 AUX 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 Aux battery cable POS ...

Page 33: ... 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 WIRING THE TERRA POWER SEPARATOR Disregard the enclosure instructions if you mount the separator inside the battery box 20 21 ...

Page 34: ...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 22 23 24 ...

Page 35: ...ack neg will connect the truck neg to the threaded stud C of the BMS Connect NITE Batteries to 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 AUX terminal B of the battery separator See top photo You must use the provided 90 d...

Page 36: ...separator green yellow go to can bus on Phoenix unit inside the truck All three must be loomed Install Y connector at BMS connection A wires green and yellow Install resistor plug B into Y connector Connect Can Bus harness from the Battery Management System wiring harness This harness must be loomed C Route this harness inside the truck through the floor grommet and connect at the Phoenix unit C C...

Page 37: ...stallation 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 34 ...

Page 38: ...ack connects to any 12 volt NEG 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 wh...

Page 39: ...2 18 Electrical Installation ...

Page 40: ...nals 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 37 38 39 40 ...

Page 41: ...ou are installing the ESPAR heater proceed to section 3 If you are installing the WEBASTO heater proceed to section 4 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 Phoenix install you can continue to operate the heater with the exist...

Page 42: ...Section 3 ESPAR Fuel Operated Heater Installation ...

Page 43: ...hoose to wire the existing factory installed Espar heater to the Phoenix controller YOU WILL VOID THE FACTORY WARRANTY OF THE HEATER 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 th...

Page 44: ...ter 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 5 16 x 1 self tapping screws to attac...

Page 45: ... 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 intake tube Pl...

Page 46: ...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 and tigh...

Page 47: ...ught 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 screw at each c...

Page 48: ...ke 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 fuel pump wire wi...

Page 49: ...ess is 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 ...

Page 50: ...ust 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 Attach smal...

Page 51: ... nut Tighten slightly Put clamp over end of large fuel line from fuel pump attach to pickup 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 cut fuel pump harness wires to appropriate length Strip wires put on rubber boots then attach en...

Page 52: ...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 Aux heater ground wire to ground terminal threaded stud of Battery Management System Connect heater unit positive wire to positive terminal of NITE Bat...

Page 53: ...Section 4 WEBASTO Fuel Operated Heater Installation ...

Page 54: ... WARRANTY OF THE HEATER DONOTUSEPHOENIXDUCTFOR HEATVENT ATTN Refer to Webasto manual for all heater installation instructions then proceed to steps below for connecting Webasto heater to the Phoenix unit Attach Webasto heater control harness to Phoenix Unit Route the control cable along the bed towards the Phoenix unit Use zip ties as needed Now connect the heater control harness to the Phoenix un...

Page 55: ...Rev 7 10 14 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 ...

Page 56: ...5 1 External Wiring Diagram Use for units manufactured after 2 08 2012 ...

Page 57: ...5 2 Internal Wiring Diagram Use for units manufactured after 2 08 2012 ...

Page 58: ...5 3 External Wiring Diagram Use for units manufactured prior to 2 08 2012 ...

Page 59: ...5 4 Internal Wiring Diagram Use for units manufactured prior to 2 08 2012 ...

Page 60: ...Section 6 Operating Instructions ...

Page 61: ...t setting is blower speed 1 AUTO MODE 60 F 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 After 5 seconds selection will be set ON OFF ENTER ENTER ...

Page 62: ...e last setting when the unit is turned on 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 ret...

Page 63: ...gh Press the ENTER button to proceed through the available service screens 1 SV Starting batteries Voltage 2 AV Auxiliary batteries Voltage 3 AA Unit Amperage draw 4 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 Temperature Display screen When necessary Check Filter light will notify you that the Phoenix...

Page 64: ...Section 7 Battery Management System BMS Installation ...

Page 65: ...7 1 Battery Management Bergstrom NITE System BMS 100 Installation ...

Page 66: ...7 2 Battery Management ...

Page 67: ...7 3 Battery Management ...

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