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TABLE OF CONTENTS SECTION PAGE INTRODUCTION 3 INSTALLATION PROCEDURES Air Conditioner Location 4 Air Conditioner Mounting 4 A/C Ducting Installation 5 Power Kit Installation (Batteries). 5 Separator... 6 OPERATION MANUAL.. 7-8 GENERAL DESCRIPTION OF INSTALLATION 9 PARTS LIST.. 10-11 TOOLS LIST.. 12 INSTALLATION INSTRUCTIONS 13-23 ELECTRICAL SYSTEM... 24-27 BATTERY BOX MOUNTING... 28 NITE SYSTEM CHECK LIST 29-31 SEPARATOR CHECKLIST.. 32-33 2
INTRODUCTION BERGSTROM S NITE AIR CONDITIONING SYSTEM 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. 3
NITE INSTALLATION PROCEDURE GENERAL COMMENTS AIR CONDITIONER LOCATION Depending on the type of vehicle, the best location for mounting the a/c unit will vary. Generally, the units are mounted underneath the matress in the sleeper; either in the center compartment or one of the side storage compartments. However, the unit can be mounted anywhere else inside the cab of the truck provided you adhere to the following conditions: Unit must be mounted flat on the floor of the vehicle. Do not mount the unit outside of the vehicle to prevent weather damage and lack of performance. The condenser air inlet and exhaust must be diverted out underneath the truck with openings in the floor. For ease of installation, make sure the condenser openings do not interfere with any support structures underneath the floor. Also consider the following when selecting a location: - Ducting - Electrical routing - Condenser inlet/ exhaust openings - Recirculation air AIR CONDITIONER MOUNTING A mounting plate and the hardware are provided with the NITE kit. Choose the air conditioner unit location Use the provided template to mark and cut out the two rectangles needed for the condenser openings. The mounting plate gets mounted to the floor, then the unit attaches to the mounting plate. For ease of installation, make sure the condenser openings do not interfere with any support structures underneath the floor. 4
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. POWER KIT INSTALLATION (BATTERIES, ISOLATOR) 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. 5
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 6
NITE AIR CONDITIONING AND HEATING SYSTEM OPERATION MANUAL CONTROLS NO-IDLE AIR CONDITIONING NO-IDLE HEATING OFF LOW MEDIUM MAX OFF ON TEMPERATURE CONTROL BATTERY INDICATOR VENTILATOR OPERATION NOTES After 1 hour of operation, the MAX A/C setting will automatically switch to the MEDIUM A/C setting. This feature is done to provide optimum system energy efficiency. With the upgraded 4 battery system the max A/C setting remains constant. 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. 7
NITE AIR CONDITIONING AND HEATING SYSTEM 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. BATTERIES & FUSES 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. 8
GENERAL DESCRIPTION OF THE INSTALLATION The unit is mounted under the bed, in the central storage compartment. A ducting device is mounted on the back wall (and slides behind the bed pan) to distribute the cold air to the bunk area. 9
PARTS LIST BERGSTROM# DESCRIPTION QTY 585474 INSTALLATION INSTRUCTIONS 1 585421 OPERATION MANUAL 1 870089 ASSEMBLY, NO-IDLE UNIT (HORIZONTAL OUTLET) 1 651222 BATTERY, 6 VOLT DEEP CYCLE 2 870143 ASSY, MOUNTING PLATE 1 870107 KIT, "T" DUCT (TALL) 1 870158 ASSY, "T" DUCT TALL 1 600138 SCREW, FLAT HEAD 8 870219 KIT, INSTALLATION 454787 TEMPLATE, UNIT LOCATE 1 454556 SCREEN, DUCT MOUNT 2 454651 ANGLE, DUCT COLLAR 1 530718 DUCT, "T" INLET TRANSITION 1 530719 DUCT, UNIT OUTLET 90 4X4 1 530724 DUCT, INLET 90 4X4 1 B316000 HOSE, DEFROST 4" I.D. 3 FT 880031 CONTROL, A/C 1 660679 WIRE HARNESS 1 621820 SCREW, TRUSS HD #10 SELF TAP 25 600059 SCREW, M6 X 16MM TORX HD 4 600283 SCREW, SELF DRILL 25 600157 S-CLIP, TINNERMAN 8 B290303 CLAMP, HOSE 4.12 I.D. 2 509700 WASHER, 1/4" FLAT 8 10
870144 KIT, NITE POWER 1 870055 ASSEMBLY, BATTERY BOX 1 869836 WELDMENT, BATT. HOLD DOWN 1 660706 ASS'Y, WIRE BATT. CABLE 5300MM BLACK 1 660707 ASS'Y, WIRE BATT. CABLE 5000MM RED 2 660694 ASS'Y, WIRE BATT. CABLE 225MM 1 660678 HARNESS, WIRE NO-IDLE POWER 1 651318 SEPARATOR 100 AMPS 1 651225 FUSE, MAXI 50 AMP. 1 B230083 RING TERMINAL, 5/16 2 B300642 WIRE LOOM,.413 I.D. X 600.0 50 FT. B360113 STRAP, CABLE TIE 30 600278 BOLT, 5/16-18 X 11" 1 610102 NUT, 5/15-18 LOCK 1 B202303 WASHER, 5/16 FLAT 2 B201320 BOLT, 1/2-13 X 1 1/2 4 B203603 LOCKNUT, 1/2-13 4 619000 WASHER, 1/2 FLAT 8 660827 WIRE, 16 GA BLACK 1 709860 BLADE TERMINAL 1 708000 RING TERMINAL, 5/16 16 GA 1 11
REQUIRED TOOLS 1) DRILL BITS (1/4, ½, ) 2) HOLE SAWS (4 1/8 OR 4 1/4) 3) ELECTRIC/AIR DRILL 4) SCREWDRIVERS (FLAT HEAD & PHILLIPS HEAD) 5) IMPACT GUN 6) AIRSAW/ JIGSAW (CUTTING SHEETMETAL) 7) TORX HEAD (T30) 8) METRIC WRENCHES 9) ENGLISH WRENCHES 10) ¼, 3/8 DRIVE RATCHETS 11) ENGLISH SOCKET SET 12) METRIC SOCKET SET 13) WIRE CUTTERS 14) TERMINAL CRIMPERS 15) WIRE STRIPPERS 16) RAZOR KNIFE 17) ELECTRICAL TAPE 12
INSTALLATION INSTRUCTIONS THE NITE UNIT IS GOING TO BE MOUNTED UNDER THE LOWER BUNK, IN THE CENTRAL COMPARTMENT. PLACE THE TEMPLATE (454787) ON THE FLOOR, IN THE CENTRAL STORAGE COMPARTMENT, AS SHOWN ON THE FOLLOWING DRAWING: BACK WALL PASSENGER SIDE DRIVER SIDE 2 5 TRUCK FORWARD MARK THE (2) RECTANGLE OPENINGS ON THE FLOOR. REMOVE THE TEMPLATE. USE A ½ DRILL BIT TO DRILL OUT THE OPPOSING CORNERS ON EACH OF THE TWO RECTANGLES USE A JIGSAW OR AN AIRSAW TO CUT OUT THE TWO RECTANGLES. THESE TWO OPENINGS WILL ACT AS THE AIR INLET AND EXHAUST FOR THE A/C UNIT CONDENSER. 13
ONCE THE OPENINGS ARE CUT, PLACE THE ALUMINUM MOUNTING PLATE (870143) INTO POSITION AS SHOWN USE THE PROVIDED 1 TEK SCREWS TO MOUNT THE ALUMINUM PLATE SECURELY TO THE FLOOR. NOW THE A/C UNIT CAN BE PREPARED FOR INSTALLATION THE 90 DEGREE PLASTIC ELBOW (530719) NEEDS TO BE ATTACHED TO THE OUTLET SIDE OF THE UNIT. FIRST MOUNT THE SQUARE METAL BRACKET (454651) TO THE SIDE OF THE UNIT AS SHOWN. USE THE EXISTING 5 TORX SCREWS LOCATED IN THIS SAME LOCATION. 14
MOUNT THE PLASTIC ELBOW TO THE METAL BRACKET AS SHOWN. THE ELBOW WILL NEED TO FACING THE BACK WALL OF THE TRUCK WHEN THE A/C UNIT IS MOUNTED IN POSITION. MAKE SURE ALL FOUR METAL TABS OF THE BRACKET SEAT INSIDE THE WALLS OF THE PLASTIC ELBOW. SECURE USING THE PROVIDED TEK SCREWS OR BLACK SHEET METAL SCREWS. PLACE THE UNIT IN THE ALUMINUM MOUNTING PLATE, WITH THE PLASTIC ELBOW FACING THE BACKWALL. SECURE THE UNIT TO THE MOUNTING PLATE, USING (4) TORX HEAD SCREWS, ONE IN EACH OF THE FOUR CORNERS OF THE PLATE, AT BOTH ENDS BACK WALL TRUCK FORWARD 15
PREPARE THE T SHAPE DUCT THAT WILL BE MOUNTED ON THE BACK WALL. 16
TAKE THE DUCT ASSEMBLY (870158) AND MOUNT THE T DUCT INLET (530718) TO THE BOTTOM OF THE T-DUCT, USING THE PROVIDED SCREWS AS SHOWN: (3) SCREWS ACROSS THE FRONT AND (2) SCREWS IN THE BACK. INSERT THE PLASTIC ELBOW (530719) INSIDE THE SQUARE OPENING OF THE T INLET, AND SCREW IT INTO PLACE AS SHOWN BACK FRONT 17
THE BED PAN SUPPORT BRACKET NOW NEEDS TO BE CUT, SO THAT THE T DUCT ASSEMBLY CAN SLIDE BEHIND THE BED, AND CAN BE CONNECTED TO THE UNIT UNDER THE BED. THE OPENING THAT NEEDS TO BE CUT IN THE BRACKET MUST BE 13 WIDE AND 2 DEEP. 18
THE FOLLOWING DRAWING WHOWS WERE THE OPENING NEEDS TO BE MADE IN THE SLEEPER. VIEW FROM TOP 2 (FROM THE SUPPORT BRACKET DRIVER SIDE EDGE) BACK WALL PASSENGE SIDE DRIVER SIDE 2 5 TRUCK FORWARD 19
THE FOLLOWING DRAWING SHOWS A CUT VIEW OF THE BED PAN SUPPORT BRACKET, FROM THE PASSENGER SIDE, AND THE CUT THAT NEEDS TO BE MADE (USE AND AIRSAW TO CUT THIS OPENING) PIANO HINGE BACK WALL ALUMINUM SUPPORT BRACKET PLASTIC BED PAN 2 ONCE THE OPENING IS DONE PUT THE T DUCT ASSEMBLY + STEALTH + ELBOW IN PLACE ON THE BACKWALL, AND MARK ON THE PLASTIC BACK OF THE STORAGE COMPARTMENT WHAT NEEDS TO BE CUT, SO THAT THE DUCT SEATS ALONGSIDE THE BACL WALL. REMOVE THE DUCT ASSEMBLY, AND, USING AN AIR SAW, CUT THIS OPENING BACKWALL CUT IN PLASTIC BACK WALL FOR DUCT CLEARANCE 20
REMOVE THE (4) TOP RECTANGLE LOUVERS OF THE T-DUCT. PUT THE DUCT ASSEMBLY IN PLACE AND ATTACH (1) SELF DRILL SCREW + (1) WASHER THROUGH THE DUCT AND THE BACK WALL TRIM, IN EACH OF THE (4) LOUVER OPENINGS. PLACE THE LOUVERS BACK IN PLACE, AND USE THE PROVIDED SCREWS TO SECURE THEM ON THE DUCT. ON THE BOTTOM OF THE DUCT SCREW THE SCREEN (454556) AS SHOWN ON THE FOLLOWING PICTURE, IN ORDER TO SECURE THE DUCT BOTTOM TO THE PLASTIC BACK WALL. PERFORATED SCREN 21
CONNECT THE 4 FLEXIBLE HOSE (B310000) TO THE DUCT BOTTOM ELBOW AND THE UNIT PLASTIC ELBOW, AND SECURE IT WITH THE (2) PROVIDED CLAMP (B290303) FIND A LOCATION FOR THE CONTROL ASSEMBLY (880031). IT CAN BE MOUNTED ON THE SLEEPER CONTROL PANEL, OR A WALL CABINET. WHEN THE CONTROL LOCATION IS CHOSEN CUT A 2.5 HOLE, USING A HOLE SAW. ROUTE THE CONTROL HARNESS (660679) FROM THE UNIT TO THE CONTROL LOCATION. PLUG THE BLACK PLUG OF THE CONTROL HARNESS TO THE BOWER SWITCH OF THE CONTROL ASSEMBLY. SLIDE THE BACK OF THE CONTROL AND THE HARNESS THROUGH THE HOLE AND SECURE IT, USING THE (4) PROVIDED SHEET METAL SCREWS. 22
NEXT TO THE UNIT PLUG THE CONTROL HARNESS (660724) TO THE UNIT WHITE PLUG 23
ELECTRICAL SYSTEM INSTALLATION 1. Now begin making the proper electrical connections. First connect white plug of the control harness into the orange plug on the side of the A/C unit as shown below. 2. Now drill a 1-3/8 (1.375 ) hole in the floor next to the A/C unit. This hole will be used for routing the power wires out to the battery supply. 3. Run the black and red wired power harness through the hole in the floor. Connect the black plug of the harness into the black plug on the side of the A/C unit. 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. 24
ELECTRICAL SYSTEM BATTERY SEPARATOR The battery separator ties into the truck starting batteries. The separator puts charging priority to the starting batteries and then charges the Nite batteries. The NITE batteries begin charging after the starting batteries have reached 13.2 volts. 25
SEPARATOR WIRING SCHEMATIC w/ 2 BATTERIES The wiring instructions are written on the separator too 4 GA Use the bottom terminal for ground The 2 other terminals are not used 4 GA SEPARATOR 16 GA NITE UNIT + HEATER ALTERNATOR STARTER TRUCK BATTERY NITE BATTERIES 26
SEPARATOR WIRING SCHEMATIC w/ 4 BATTERIES The wiring instructions are written on the separator too Use the bottom terminal for ground The 2 other terminals are not used 4 GA 4 GA SEPARATOR 16 GA NITE UNIT + HEATER ALTERNATOR STARTER NITE BATTERIES TRUCK BATTERY NITE BATTERIES 27
BATTERY BOX INSTALLATION INSTRUCTIONS 1) THE BATTERY BOX IS DESIGNED AS A UNIVERSAL MOUNTING TO BE BOLTED ON EITHER THE DRIVER S SIDE OR PASSENGER SIDE FRAME RAIL. 2) USE THE 10 MOUNTING HOLES LOCATED ON THE BACK OF THE BATTERY BOX IN ORDER TO CAPTURE 4 EXISTING HOLES OR BOLTS ON THE FRAME RAIL. 3) IF NO EMPTY HOLES OR BOLTS ARE EXCESSIBLE FOR MOUNTING THE BOX, DRILL (4) HALF INCH HOLES INTO THE FRAME RAIL USING THE FOUR OUTSIDE MOUNTING HOLES OF THE BATTERY BOX. CAUTION: WHEN DRILLING INTO THE FRAME RAIL, BE SURE TO STAY AT LEAST 40MM AWAY FROM THE TOP AND BOTTOM EDGE OF THE FRAME. NOTE: MOUNT THE BATTERY BOX ON THE FRAME RAIL CLOSE TO THE LOCATION OF THE FUEL TANK TO INSURE THE BATTERY CABLES WILL BE LONG ENOUGH. 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. 6) PLACE THE H -BRACKET ON TOP OF THE BATTERIES. NOW USE THE PROVIDED 11 BOLT AND RUN THROUGH THE TOP OF THE H-BRACKET BETWEEEN THE TWO BATTERIES. INSERT THE BOLT DOWN THROUGH THE HOLE IN THE BOTTOM ON THE BATTERY BOX AND FASTEN IS SECURELY WITH THE LOCKNUT. 7) NOW MAKE THE PROPER BATTERY CONNECTIONS AS SHOWN ON PAGE 10. 28
NITE SYSTEM CHECK LIST 1. NITE unit basics 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: Control position Capacity setting Blower speed Compressor 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. 2. Checking of the different NITE unit components 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. Component Function How to check it is working Blows cold air inside the sleeper area, through the ducting The system is a 100% Blower (evaporator) recirculation system; the air intakes (2) are located on top and side of the NITE unit Switch the NITE control to position 1; you must feel air coming out of the duct louvers Then switch the NITE control to position 2; you must feel an increase of the airflow coming out of the duct louvers Note: make sure nothing blocks the air intake opening (recirculation) on the NITE unit 29
Component Function How to check it is working Fan (condenser) Takes ambient air Goes under the sleeper and check under the sleeper floor that air is going out the condenser and rejects it from the air outlet when the NITE unit is floor too running (inlet and outlet are located The air goes through next to each other) the condenser coil to On the inlet you must feel the air cool it down going into the NITE unit On the outlet you must feel the air Compressor Compresses and runs the refrigerant through the NITE unit refrigerant loop going out of the NITE unit. The best way to check that the compressor is running is to feel the compressor speed changes when the control is switched from position 2 to position 3 (the compressor speed goes from low to high). Set the control to position MEDIUM and lift up the bed, so that you can hear the NITE unit vibration & sound change. Wait 1 minute. Then set the control to position HIGH: you must notice a change in the vibration & sound of the NITE unit when the compressor speed changes. A better verification is to touch the unit (or have someone touching it) in order to feel the vibration changes. 3. NITE unit electrical and temperature checking The following instructions list how to check that the NITE unit is working properly. 3.1. NITE unit electrical power 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. 3.2. Louvers temperature 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. 30
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 31
ELECTRICAL CHECK LIST NITE SYSTEM WITH SEPARATOR 1. Make sure you don t have any loose electrical connections 2. Check that the installation is done according to the electrical diagram 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. Voltage checking engine OFF 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) 32
4. Voltage checking engine ON The separator charges the batteries as follow: - when the engine is ON the alternator is going to start to charge the truck batteries first, until the truck batteries voltage reaches 13.2 V. During this period, the separator is open and the NITE batteries are not charged - when the truck batteries reaches 13.2 V, the separator closes and the NITE batteries are being charged 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 clampon type inductive ammeter, on the 4 ga cable that connects the separator to the NITE batteries positive terminal. It should be > 0 Amp. 33