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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 TOOLS LIST..9 INSTALLATION INSTRUCTIONS 10-21 ELECTRICAL SYSTEM.. 22-24 BATTERY BOX MOUNTING...25 NITE SYSTEM CHECK LIST.26-28 SEPARATOR CHECKLIST 29-30 2
INTRODUCTION BERGSTROM S NITE AIR CONDITIONING SYSTEM The NITE system is a compact electrical 3,000 3,600 BTU air conditioning system depending on standard 2 battery system or upgraded 4 battery 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 (or 4 for upgraded) 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(es). The battery box(es) are 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(es): 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(es) 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 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
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 9
INSTALLATION INSTRUCTIONS 1) Disconnect ground wire from truck batteries. 2) Remove mattress from the sleeper. 3) Cut out the (2) rectangular openings, (2) on the floor and (1) on the front wall. 10
4) Remove the template and use an airsaw to cut out the three rectangle openings. Use a 1 3/8 hole saw for drilling the wiring hole. Finally use a ½ drill bit to drill out the two holes for unit mounting. 11
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5) Remove the 4 torx screws shown in red to allow clearance for the a/c unit to drop freely into the mounting plate 6) After removing the 4 torx screws the unit can then be placed on top of the mounting plate. 7) The screws are then added to each corner connecting the mounting plate to the night system to securely hold the unit in place. 14
8) The 90* elbow is then attached to the mounting bracket using Phillips screws. 10) Use the mounting plate as a template to mark the opening to be cut in the OEM duct as close to the elbow in the OEM duct as possible. 15
11) The hole is then cut out using the air saw. 16
12) A second hole must be cut about 2 to the right of the first hole. This hole should be about an 1/8 wide and the height of the duct. This hole will be used to locate the air blockage plate included in the kit. 13) The mounting plate is then attached to the duct using black Phillips screws. Note the baffle inside the duct. 17
14) The 90* duct is then attached to mounting plate using Phillips screws. 15) Remove the OEM air louver. 18
16) Attach the included template around the louver opening. Cut the inside interior to allow the two larger louvers to be set into place. 19
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17) Find a location on the OEM control panel to mount the NITE controls. Remove the control panel to insure factory wires are not damaged.during drilling. Now a 2 1/2 hole is to be drilled into the panel to allow the control to be mounted. 18) Attach the control switch to the OEM control using the black Phillips scews included in the kit.then attach the wires the the control. 21
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. 22
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. 25
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% recirculation system; the air intakes (2) are located on top and side of the NITE unit Blower (evaporator) 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 26
Component Function How to check it is working Fan (condenser) Takes ambient air under the sleeper floor and rejects it from the floor too The air goes through the condenser coil to cool it down Goes under the sleeper and check that air is going out the condenser air outlet when the NITE unit is running (inlet and outlet are located next to each other) On the inlet you must feel the air 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. 27
3.3. 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 28
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) 29
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). 4.3. 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. 30