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BERGSTROM Manual Instalación Freightliner
BERGSTROM Manual Instalación Freightliner
TABLE OF CONTENTS
SECTION
INTRODUCTION
OPERATION MANUAL
PARTS LIST
TOOLS LIST
INSTALLATION INSTRUCTIONS
ELECTRICAL SYSTEM
WIRING SCHEMATICS
ELECTRICAL CHECKLIST
INTRODUCTION
The NITE system is a compact electrical 3,000 BTU air conditioning system. This unit is
quality engineered to provide a dependable means of air conditioning to the cab area
without idling the engine. The NITE unit is completely self-contained and runs on 12
volts using the greatest deep cycle battery technology.
This no-idle air conditioning system is designed to provide cool air to the cab interior in
order to maintain passenger comfort. In order to conserve battery power and life, this
system is not designed to instantly cool down a hot cab that has been sitting under an
extreme solar load. If these kind of conditions occur, it is recommended to start the
trucks engine and let the OEM a/c system help cool the cab for a few minutes. Then
the truck can be shut off and the NITE system will continue to keep the cab cool and the
driver comfortable.
The NITE system operates independently off of it’s own deep cycle batteries and is
completely isolated away from the trucks starting batteries. The A/C is operated by its
own 3-speed control. It cycles through 3 blower settings (low, medium, and high). On
high speed, the system will run for 1 hour and then automatically switch the blower to
medium speed in order to conserve battery power. The control has a battery indicator
light so the driver always knows how much charge he has. A green light equals full
charge, a yellow light equals half charge, and a red light means the batteries need to be
recharged. The NITE batteries will be fully recharged after about 4-6 hours of driving.
NITE INSTALLATION PROCEDURE
GENERAL COMMENTS
A mounting plate and the hardware are provided with the NITE kit.
• For ease of installation, make sure the condenser openings do not interfere with any
support structures underneath the floor.
A/C DUCTING INSTALLATION
Ducting kits are application specific. Depending on the application, some kits are
designed to tie into the OEM ducting and others are universal and supplied with a 4” flex
hose. In routing and installing the systems ducting, the following criteria must be
observed:
• Route the ducting with smooth bends and transitions. Avoid crushing the duct work
with tools and etc.
• Be sure all of the treated air is routed above the mattress as close to the driver’s
body as possible.
• Kits can be supplied with either a Tower Duct or a T-Duct.
BATTERIES
The NITE system is powered by two 6 volt batteries running in series to give you 12
volts. The batteries are a sealed, deep cycle, dry cell battery. They need to be
mounted inside the provided battery box. The battery box is generally mounted on the
frame rail of the truck. However, if there is no room on the frame rail, the batteries may
be mounted inside on of the trucks side storage compartments. Since the batteries are
sealed and dry celled, there is no hazard in doing this. Things to observe when
mounting the battery box:
• Find a general location on the frame rail, usually just behind one of the fuel tanks.
• Be sure to have at least 4 inches of free space on both sides of the battery box to
allow room for wiring and the rubber latches.
• Try to locate existing holes or bolts in the frame rail to capture. It is difficult to drill a
½” hole into the frame, so this will help ease the installation.
SEPARATOR
Depending on the truck isolator the system can require a separator in place of an
isolator. It has the same purpose as the isolator but acts differently.
• The separator is mounted in the sleeper, under the mattress
• It is electrically connected between the truck batteries and the NITE batteries
CONTROLS
• The heater ventilation mode is to be used for continuous operation of the heater at a
pre-selected temperature setting. The temperature control knob has no function
while in ventilation mode.
• The Green battery light indicates normal operation. When the battery light changes
to Yellow, it indicates the batteries are at about half charge. The light will change to
Red and the system will shut down automatically when the engine needs to be
started in order to recharge the batteries.
OPERATION NOTES
• For optimal comfort Bergstrom recommends to close the curtain between the cab
and the sleeper when using the NITE A/C and heating system.
• The NITE A/C system is designed to maintain a comfortable temperature inside the
cab without the engine running.
• The A/C unit will not pull down a hot cab that has been sitting in the sun without the
factory A/C running. To assist the NITE system in cooling down the cab, start the
engine and run the factory A/C system for a few minutes. This will help cool the cab
to a respectable temperature. Once the cab is pulled down, the NITE system will
maintain a comfortable temperature.
• The system must be turned off every time the system is not in use or the batteries
May not charge properly. After use of the system be sure to turn the control knob to
the off position, even if the unit is not running.
• The system must be turned off every time the system is not in use or the batteries
may not charge properly.
After using the system turn the control back off, even if the unit is not running.
• The NITE A/C and heating system uses its own batteries. A battery isolator or
separator keeps the starting batteries from being drawn down.
• The NITE A/C and heating system switches off automatically when batteries charge
level is low.
• The A/C fuses (2) are located next to the NITE A/C unit, under the bunk.
• The parking heater fuse (1) is located inside the battery box.
SERVICE
• The NITE A/C unit is not serviceable. If problems are encountered please contact
the NITE line at 1-866-204-8570.
GENERAL DESCRIPTION OF THE INSTALLATION
3) ELECTRIC/AIR DRILL
5) IMPACT GUN
8) METRIC WRENCHES
9) ENGLISH WRENCHES
REMOVE THE STORAGE CABINET LOCATED NEXT TO THE MATRESS ON THE DRIVERS SIDE OF
THE TRUCK:
• FIRST REMOVE THE TOP DRAWER OF THE CABINET BY UNFASTENING THE 2 CLIPS
LOCATED ON THE SIDE OF THE DRAWER.
• TAKE OFF THE FRONT FACIA OF THE CABINET BY REMOVING THE 6 TORX HEAD
SCREWS LOCATED INSIDE THE FACIA.
• NOW REMOVE THE 4 NUTS/WASHERS AT THE BACK OF THE CABINET AND THE 2
NUTS/WASHERS ON THE FLOOR OF THE CABINET. THE CABINET CAN NOW BE
REMOVED FROM THE TRUCK.
•
NOTE: IF THERE IS A REFRIGERATOR POWER HARNESS & PLUG INSIDE THECABINET, IT MUST
BE REMOVED PRIOR TO REMOVING CABINET.
REMOVE THE ALUMINUM SUPPORT FROM THE BACK OF THE CABINET BY REMOVING THE 2
TORX HEAD SCREWS.
NOTE: THIS PART WILL NOT BE RE-INSTALLED BECAUSE IT INTERFERS WITH THE MOUNTING
OF THE A/C UNIT.
PLASTIC RIBS NEED TO BE CUT IN THE INSIDE OF THE CABINET TO MAKE CLEARANCE FOR
THE A/C UNIT. USE AN AIRSAW OR DREMEL TO REMOVE TWO TRIANGLE PIECES ON THE
RIGHT AND LEFT SIDE OF THE BACK OF CABINET. ALSO ON THE RIGHT SIDE, CUT OFF THE
ROUNDED PIECE LOCATED ABOVE THE TRIANGLE.
NOW IS TIME TO INSTALL THE DUCTING, THE LOUVERS, AND THE CONTROL ON THE CABINET
(TOP)
TWO HOLES NEED TO BE DONE ON TOP OF THE CABINET TO MOUNT THE DUCT AND ROUTE
THE CONTROL HARNESS. MARK THE HOLE CENTERS AS SHOWN ON THE FOLLOWING
DRAWING
59 mm ¾” HOLE
14 mm
59 mm
4” ¼ OR
101 mm 4” 1/8
HOLE
HOLES
FOR BOLTS
INSTALL THE DUCT ON TOP OF THE CABINET. FROM INSIDE THE CABINET MARK ON THE DUCT
BOTTOM TRIANGLE PIECE THE LOCATION OF THE ¼” HOLES THAT WERE JUST DONE ON TOP
OF THE CABINET
REMOVE THE DUCT AND DRILL (2) ¼” HOLES IN THE DUCT WHERE MARKED.
REINSTALL THE DUCT ON TOP OF THE CABINET AND SECURE IT ON THE CABINET WITH THE
BOLTS, WASHERS AND NUTS PROVIDED IN THE KIT.
BOLTS
ROUTE THE CONTROL HARNESS (660724) WITH THE L SHAPE BLADE TERMINALS FROM INSIDE
THE CABINET, THROUGH THE ¾” HOLES IN THE CABINET TOP AND THE DUCT, THEN TROUGH
THE RIGHT HOLE OF THE DUCT FACE.
TAKE THE CONTROL + LOUVERS PANEL (880055) AND CONNECT THE CONTROL HARNESS
BLADE TERMINALS ON THE BLOWER SWITCH AS SHOWN ON THE FOLLOWING DRAWING
GREEN
WHITE BROWN
SECURE THE CONTROL + LOUVERS PANEL TO THE DUCT FACE, USING (6) BLACK SELF TAP
SCREWS.
THE MOUNTING OF THE DUCT / LOUVERS / CONTROLS IS NOW COMPLETED
THE DRAWER NOW MUST BE MODIFIED. THE PURPOSE IS TO GIVE CLEARANCE TO THE 4”
HOSE THAT WILL BE CONNECTED TO THE PLASTIC DUCT, INSIDE THE CABINET.
ON THE BACK LEFT CORNER OF THE CABINET USE THE L SHAPE BRACKET (454991) TO MARK
THE SQUARE THAT NEEDS TO BE CUT OUT OF THE DRAWER. USE AN AIR SAW TO CUT THE
DRAWER AND SECURE THE BRACKET, USING THE SELF-DRILL SCREWS PROVIDED IN THE KIT.
INSTALL THE CABINET BACK IN THE SLEEPER AND MOUNT THE NITE UNIT NEXT.
RE-INSTALL THE CABINET INSIDE THE TRUCK, IN ITS ORIGINAL LOCATION INSIDE THE
SLEEPER. SECURE THE NUT AND WASHER INTO PLACE ON THE RIGHT BACK SIDE. INSTALL
THE OTHER 3 NUTS AND 3 WASHERS AND LEAVE THEM LOSE.
INSERT THE FLOOR TEMPLATE (454377) INSIDE THE CABINET. BE SURE TO STRETCH THE
CABINET SO THE TEMPLATE LIES FLAT ON THE FLOOR.
NOTE: MAKE SURE THE TABS ON THE FRONT OF THE TEMPLATE SIT FLUSH AGAINST THE
FRONT OF THE CABINET.
TABS
ONCE THE TEMPLATE IS IN PLACE, TIGHTEN THE NUTS OF THE CABINET DOWN.
MARK THE 2 RECTANGULAR OPENINGS AND THE 2 HOLES AT THE BACK USING A MARKER.
REMOVE THE TEMPLATE AND CUT OUT THE 2 RECTANGLES USING AN AIRSAW OR JIGSAW.
DRILL OUT THE 2 HOLES WITH A ¼” DRILL BIT.
REMOVE THE NUTS AND WASHERS FROM THE BACK OF THE CABINET AND TAKE OUT THE
TEMPLATE.
SLIDE THE ALUMINUM CONDENSER DUCT (869998) UNDER THE FLOOR FROM INSIDE THE
CABINET. SECURE THE CONDENSER DUCT INSERTING (2) PROVIDED M6 BOLTS INTO THE ¼”
HOLES IN THE FLOOR, ON THE DRIVER SIDE
NOTE: BE SURE THE DUCT OPENING IS FACING THE DRIVERS SIDE.
ALUMINUM
CONDENSER
DUCT
DRIVER SIDE
BOLTS TO BE
INSERTED AT
THIS TIME
SLIDE THE A/C UNIT MOUNTING PLATE (WITH GASKET) (869997) INSIDE THE CABINET. WE
SUGGEST INSERTING THE RIGHT REAR CORNER FIRST THEN PUSHING FORWARD.
ONCE THE MOUNTING PLATE IS IN POSITION, FASTEN THE NUTS AND WASHERS BACK INTO
PLACE ON THE BACK OF THE CABINET.
NOTE: PUSH THE LEFT SIDE OF THE CABINET LIGHTLY AGAINST THE MOUNTING PLATE
WHILE FASTENING THE REAR NUTS.
DRILL OUT THE 4 HOLES OF THE MOUNTING PLATE WITH A ¼” DRILL BIT. USE 2 PROVIDED M6
BOLTS TO FASTEN THE MOUNTING PLATE AND THE BACK OF THE CONDENSER DUCT
TOGETHER. USE 2 MORE M6 BOLTS WITH LOCKNUTS AND FASTEN THE FRONT OF THE
MOUNTING PLATE TO THE FLOOR.
BEFORE THE NITE A/C UNIT IS INSTALLED INSIDE THE CABINET IT NEEDS TO BE PREPARED.
REMOVE THE (3) NOTED TORX HEAD SCREWS (2 ON THE SIDE ARE FOR CLEARANCE, AND 1
ON TOP FOR MOUNTING TO THE MOUNTING PLATE).
ELECTRICAL
BOLTS TO BE
REMOVED
ON TOP OF THE UNIT SECURE THE DUCT COLLAR (454651) USING (4) TORX HEAD SCREWS.
THE COLLAR WILL SUPPORT THE PLASTIC ELBOW (530724).
INSERT THE RUBBER DRAIN TUBE INTO THE DRAIN HOLE LOCATED ON THE BOTTOM OF THE
UNIT.
LIFT THE UNIT INSIDE THE CABINET WITH THE ELECTRICAL CONNECTION ENTERING FIRST
TOWARDS THE BACK OF THE CABINET.
NOTE: MAKING SURE THE DRAIN TUBE ENTERS THE DRAIN HOLE OF THE MOUNTING PLATE.
ONCE THE UNIT IS IN POSITION, SECURELY FASTEN THE UNIT TO THE MOUNTING PLATE. USE
(2) TORX SCREWS TO SECURE THE FRONT AS SHOWN ABOVE. USE (1) TORX SCREW TO
SECURE THE BACKSIDE OF THE UNIT TO THE MOUNTING BRACKET.
MOUNTING
POINTS
INSIDE THE CABINET PLUG THE CONTROL HARNESS (660724) TO THE UNIT WHITE PLUG
CONNECT THE 4” FLEXIBLE HOSE (B310000) TO THE DUCT AND THE PLASTIC ELBOW, AND
SECURE IT WITH THE (2) PROVIDED CLAMP (B290303)
CLAMPS
4” HOSE
CONTROL
HARNESS
PLUG
INSTALLATION NOTE:
IF YOU HAVE THE HEATER OPTION, NOW IS A GOOD TIME TO REVIEW THE
HEATER INSTRUCTIONS AND BEGIN THE HEATER INSTALL. THIS WILL SAVE
YOU SOME TIME BEFORE STARTING TO INSTALL THE POWER SYTEM OUTSIDE
OF THE CAB.
ELECTRICAL SYSTEM
BATTERY SEPARATOR
16 GA
STARTER
ALTERNATOR
4 GA
4 GA
NITE UNIT +
SEPARATOR 16 GA HEATER
STARTER
ALTERNATOR
NITE BATTERIES
TRUCK BATTERY
NITE BATTERIES
BATTERY BOX INSTALLATION INSTRUCTIONS
4) USE THE PROVIDED ½” BOLTS AND LOCKNUTS TO BOLT THE BATTERY BOX
TO THE FRAMERAIL USING AN IMPACT GUN.
5) PLACE THE TWO BATTERIES SIDE BY SIDE INSIDE THE BATTERY BOX.
NOTE: BE SURE TO POSITION THE BATTERIES POWER AND GROUND
OPPOSITE OF ONE ANOTHER. ONE BATTERIES GROUND WILL BE NEXT TO
THE OTHER BATTERIES POSITIVE.
The control of the NITE unit has 3 positions: Low, Medium and High. For each control
position the compressor speed and the evaporator blower are set differently. The
following table shows how the compressor and the blower are set for each control
position:
Compressor
Control position Capacity setting Blower speed
speed
1 Low Low Low
2 Medium High Low
3 High High High
Note 1: there is no change of airflow when switching from position 2 to position 3. Only
the compressor speed changes.
Note 2: in addition to the evaporator blower and to the compressor there is another
electrical device that makes the NITE system work: the condenser fan. As well as the
compressor and the evaporator blower, the condenser fan is located inside the NITE
unit. It sucks air from underneath the sleeper floor and blows it to the outside as well.
Whatever the position of the control (low, medium or high), the condenser fan speed
remains the same.
Note 3: When the control is set on HIGH (position 3) the system will automatically
switched to the MEDIUM setting after an hour of operation. This permits to increase the
NITE system running time without affecting the performances. When this automatic
switch is performed the compressor speed changes and the airflow (blower speed)
remains the same.
• No such change occurs for an upgraded 4 battery system.
The following table explains out to check that the different components of the NITE unit
are running correctly when the NITE unit is ON. The next paragraph will explain how to
evaluate that the different components are working fine.
The following instructions list how to check that the NITE unit is working properly.
• check the NITE unit voltage: close to the unit, on the power supply cables (red
and black cables), there is a black connector on which the voltage can be read.
When the NITE batteries are fully charged and when the control position is on
HIGH, you must read between 12 and 12.5 volts
• check the NITE unit current: when the NITE unit control is on HIGH position and
using a clamp-on inductive ammeter, measure the current on the NITE unit
power supply RED cable. You must read between 27 and 35 Amps.
• check the louvers temperature: when the NITE unit control in on HIGH position,
when the sleeper temperature is between 75 and 80 F and when the outside
temperature is between 90 and 95 F, measure the temperature directly at one of
the duct louvers. You must read between 55 and 62 F.
3.2. Condenser outlet temperature
• as described earlier in this document the NITE unit pulls air from outside, under
the sleeper floor to cool down the condenser coil, then the air is rejected to the
outside from the sleeper floor too. When the NITE unit is running in HIGH
position, go under the sleeper and locate the condenser air outlet (rectangle
opening with a screen). The temperature at the condenser outlet must be 10 to
20 F higher than the outside temperature
ELECTRICAL CHECK LIST
2.1. Make sure the 16 ga ground wire is connected to the bottom blade terminal of the
separator on one end, and to any good ground on the other end (truck batteries ground,
or NITE batteries ground, or frame(last choice))
2.2. In case of a 2-battery system, make sure the 2 NITE batteries are connected in
series with a jumper. In case of a 4-battery system, make sure the batteries are
connected in series and parallel. Each battery is a 6 V one, the NITE system runs in 12
VDC.
2.3. Make sure the ground of the NITE batteries is connected to a good ground (truck
batteries ground, or frame (last choice), or alternator ground)
2.4. Make sure the NITE unit power cables are connected to the correct terminals of the
NITE batteries. The red cable goes to the positive terminal; the black cable goes to the
ground.
3.1. Check that the voltage on the truck batteries is the same as the voltage on the
separator (main batteries side). When you check the voltage on the separator, use the
ground terminal on the separator. Both voltages should be the same.
3.2. Check that the voltage on the NITE batteries is the same as the voltage on the
separator (aux batteries side). When you check the voltage on the separator, use the
ground terminal on the separator. Both voltages should be the same (approx. 12 V)
4. Voltage checking engine ON
4.1. Engine ON, check the voltage of the truck batteries. It should be higher than the
voltage when engine is OFF (> 13 V).
4.2 In order to check that the separator works properly, wait for the truck batteries
voltage to reach at least 13.2 V. Increase the engine rpm if necessary. When the
separator closes to start charging the NITE batteries, you can hear an audible “click” of
the separator. Check the NITE batteries voltage. It should be higher than the voltage
when the engine is OFF (approx. the voltage of the truck batteries).
2.3. In order to double check that the separator allows the NITE batteries to be
charged you can measure the Amps going to the NITE batteries, using a clamp-
on type inductive ammeter, on the 4 ga cable that connects the separator to the
NITE batteries positive terminal. It should be > 0 Amp.