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Installation Manual

Kenworth T680

without factory installed heater

For Phoenix Gen 4 units built after 6/26/2017

2390 Blackhawk Road ● Rockford, IL 61109 ●

www.nitesystem.com

● 1-866-204-8570

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.

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Содержание NITE Kenworth T680

Страница 1: ...com 1 866 204 8570 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...

Страница 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 EP...

Страница 3: ...iciently 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...

Страница 4: ...ing 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 ar...

Страница 5: ...lations 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...

Страница 6: ...4a 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 condi...

Страница 7: ...iately 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...

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

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

Страница 10: ...TY 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...

Страница 11: ...ead 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 Electrica...

Страница 12: ...condenser openings will be centered above the floor cross member Remove the floor insulation as shown exposing the floor of the sleeper Mark Area in Truck Floor to be Cut Bend or remove the end tabs o...

Страница 13: ...enings over the holes cut in the truck floor Mark 4 mounting feet locations as indicated in photo The unit has 8 possible locations but you will only use 4 Use equal spacing to provide adequate stabil...

Страница 14: ...tion next to the Phoenix where the wiring will drop through the floor inside the frame rail Choose the best location for routing the cables away from heat and sharp edges Install Wiring Grommet Fasten...

Страница 15: ...t the Phoenix Duct to the OE Photo to the right shows duct adapter already cut and ready for installation Before removing cross car duct mark the location for the duct adapter Line up the side of the...

Страница 16: ...in step 14 Cut OE Duct Section as shown Using an air saw remove the marked section Use caution do not cut too much The opening must be inside the adapter when reinstalled Slide the Adapter Onto the OE...

Страница 17: ...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 s...

Страница 18: ...se 1 x 5 16 hex head self drilling screws Do not install feet where the case is not dimpled or you will damage the unit Install Phoenix Unit Now secure the unit using eight 1 x 5 16 head self drilling...

Страница 19: ...s stamped in the back of the OE panel Place the controller template in the area to be cut to make sure the dimensions and area are ok to cut Drill Starter Holes for Air Saw Cut out marked section Atta...

Страница 20: ...ll Phoenix Control Harness Route the controller harness from Phoenix unit to control center area Connect harness to controller Install the OE Control Center Gravity door The purpose of this door is to...

Страница 21: ...h side closer to the top of the OE duct Make sure the holes are 20 4 mm from the top side of the duct and 50 mm from the rear edge Dimension of the pivot holes are 6 mm Door Stop Measure 56 5 mm on th...

Страница 22: ...ble the photo to the right It should swing freely inside the duct If the door binds it could block air from the OE bunk unit Please operate the bunk unit when finished to check gravity door operation...

Страница 23: ...23 Section 2 Electrical Installation...

Страница 24: ...ttery 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 batt...

Страница 25: ...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 bi...

Страница 26: ...tallation 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 dep...

Страница 27: ...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 b...

Страница 28: ...nk 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 ca...

Страница 29: ...le 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 conn...

Страница 30: ...awn 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...

Страница 31: ...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 1...

Страница 32: ...les 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...

Страница 33: ...arting batteries 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 Sy...

Страница 34: ...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 NEGAT...

Страница 35: ...e 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 enc...

Страница 36: ...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 wi...

Страница 37: ...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 creat...

Страница 38: ...m 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...

Страница 39: ...ee 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...

Страница 40: ...y 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 t...

Страница 41: ...41 2 18 Electrical Installation...

Страница 42: ...tion 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 commo...

Страница 43: ...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 wi...

Страница 44: ...tion 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 heat...

Страница 45: ...45 Section 3 ESPAR Fuel Operated Heater Installation...

Страница 46: ...isting 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...

Страница 47: ...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 locat...

Страница 48: ...ection 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...

Страница 49: ...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 do...

Страница 50: ...gled 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 Hea...

Страница 51: ...rill 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 th...

Страница 52: ...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...

Страница 53: ...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...

Страница 54: ...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 clam...

Страница 55: ...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 conne...

Страница 56: ...ng 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...

Страница 57: ...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...

Страница 58: ...58 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...

Страница 59: ...59 New Phoenix wiring for units built from 6 26 2017 to current 4 2 Wiring Diagrams...

Страница 60: ...60 Use for units manufactured from 2 08 2012 to 6 26 2017 4 3 Wiring Diagrams...

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

Страница 62: ...62 Use for units manufactured prior to 2 08 2012 4 5 Wiring Diagrams...

Страница 63: ...63 Use for units manufactured prior to 2 08 2012 4 6 Wiring Diagrams...

Страница 64: ...64 Section 5 Operating Instructions...

Страница 65: ...ws 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 u...

Страница 66: ...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...

Страница 67: ...gh 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...

Страница 68: ...68 Section 6 Battery Management System BMS Installation...

Страница 69: ...69 6 1 Bergstrom NITE System BMS 100 Installation Battery Management...

Страница 70: ...70 6 2 Battery Management...

Страница 71: ...71 6 3 Battery Management...

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