Bergstrom NITE Plus 9000i User manual

Model 9000i Post June 2002
Installation Manual
2390 Blackhawk Road ●P.O. Box 6007 ●Rockford, IL 61125 ●www.nitesystem.com ●1-866-204-8570

NITE Plus Installation Procedures
1-2
International 9000i (post-June 2002) rev 10/7/2013
Table of Contents
Introduction
Before You Start
Parts List
Tools Req quired
Installation
Procedures
Electrical Installation
Espar Heater
1-3
1-4
1-5
1-7
1-8
2-1
3-1
4-1
5-1
Checklists
Webasto Heater

NITE Plus Installation Procedures
1-3
International 9000i (post-June 2002) rev 10/7/2013
Congratulations. You have chosen the
premier no-idle climate control system
on the market today—the NITE® Plus
from Bergstrom.
The NITE Plus is a powerful 12V
rechargeable DC system that keeps sleeper
compartment cool in hot weather and warm
in cold weather (with optional heater)
without having to idle the truck’s engine—
and without a genset. It not only
dramatically reduces fuel consumption; it’s
also very environmentally friendly.
Your NITE Plus is a self contained,
hermetically sealed, compact A/C system
that produces approximately 4,600 Btuh
and has been quality engineered for years
of reliable service. The system operates
independently from your truck’s engine
using its own deep cycle batteries that are
completely separated from the truck’s
starting batteries.
The deep cycle AGM batteries used are
the most advanced ever—and will
efficiently power the system for 8 to 10
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 Plus from Bergstrom.
Introduction
NOTE:
The NITE Plus A/C system is designed to
maintain a comfortable temperature inside
the sleeper without running the engine.
For optimal comfort, the curtain between
the cab and the sleeper must be closed
when using the unit. To enhance cooling
efficiency during the day, solar reflectors
or curtains should be placed over
windshield and all windows to block
sunlight from entering the cab and sleeper.
The NITE Plus A/C unit will not pull
down a hot sleeper that has been sitting in
the sun without the factory A/C running.
To assist the NITE Plus unit in cooling
down the sleeper, start the engine and run
the factory A/C until desired temperature
is reached. The NITE Plus unit will then
maintain a comfortable temperature
depending on solar load & ambient
temperature.

NITE Plus Installation Procedures
1-4
International 9000i (post-June 2002) rev 10/7/2013
Before You Start
A typical installation of the NITE Plus generally takes
between 8 to 10 hours, although your particular
situation may vary. This manual contains step-by- step
installation instructions. It is divided into four
categories:
● General installation
● Electrical installation
● Heater installation (optional)
● Power inverter/battery charger installation (optional)
There is also a section on how to check your NITE Plus
to make sure the installation was successful, and a
section on how to operate your NITE Plus.
If relocation or reinstallation of any pre-installed
equipment is necessary for installation of the NITE Plus
equipment - please refer to the components manufacturer's
instructions or safety guidelines for proper installation.
Before you start, we highly 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
Plus unit in an upright position at all times. If unit
is tipped, place back in upright position for a
minimum of 6 hours prior to running.
3. Check the list of tools needed for installation and
make sure you have all of them. Keep all tools
within easy reach.
4. Look through the whole installation manual to get
an understanding of the order in which
components are installed.
5. Make sure you have good lighting and enough
space to work in.
6. You may want to get an assistant to help you to
reduce the number of times you have to climb in
and out of the cab.
7. Make sure you wear all appropriate safety
equipment.
Photo above is representative of kit
1000113987 only.

NITE Plus Installation Procedures
1-5
International 9000i (post-June 2002) rev 10/7/2013
Bergstrom
Part #
Part Description
Quantity
1000113877 NITE STANDARD KIT A/C ONLY
1000078163
ASSEMBLY, NITE UPGRADE UNIT
1
1000014440
KIT, NITE POWER
1
1000007552
POLICY, NITE WARRANTY
1
585421
MANUAL, NITE OPERATION
1
585511
CARD, NITE, WARRANTY SURVEY
1
1000119244 NITE STANDARD KIT A/C & HEAT
1000078163
ASSEMBLY, NITE UPGRADE UNIT
1
530713
KIT, ESPAR HEATER
1000014440
KIT, NITE POWER
1
1000007552
POLICY, NITE WARRANTY
1
585421
MANUAL, NITE OPERATION
1
585511
CARD, NITE, WARRANTY SURVEY
1
1000113987 INSTALL KIT
454512
ANGLE –FOOT
4
454587
BRACKET –MIDDLE BUNK
1
454641
CHANNEL, RECIRC DUCT
1
454642
PLATE, RECIRC GRILL
1
500105
LOUVER
2
869999
ASSEMBLY, BASE INTERNATIONAL
1
870059
ASSEMBLY, DUCT OUT
1
1000007614
DUCT, UPPER
1
1000011467
CONTROL DUCT ASSY
1
1000113415
WIRE HARNESS NO-IDLE CONTROL
1
1000014373
WELDMENT, MIDDLE BUNK
1
1000113995
KIT, NITE STANDARD HARDWARE
1
1000115617
CD ROM, INSTALL MANUALS
1
B360692
GROMMET, NO6 AND NO10 HOSE ADPTR
1
Parts List
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

NITE Plus Installation Procedures
1-6
International 9000i (post-June 2002) rev 10/7/2013
Bergstrom
Part #
Part Description
Quantity
1000014440 NITE Plus POWER KIT
660706
ASSY, WIRE BATTERY CABLE 5300MM BLACK
2
660707
ASSY, WIRE BATTERY CABLE 5000MM RED
3
660694
ASSY, WIRE BATTERY CABLE 225MM
2
660678
HARNESS, WIRE NO-IDLE POWER
1
660827
WIRE, 16 GAUGE BLACK
1
651383
SEPARATOR 200 AMPS
1
651225
FUSE, MAXI 50 AMP
1
B230083
RING TERMINAL, 5/16
2
B300642
WIRE LOOM, .413 I.D. X BULK –BLACK SPLIT
PLASTIC
70 ft.
B300652
WIRE LOOM, .625 I.D. X BULK –BLACK SPLIT
PLASTIC
15 ft.
B360113
STRAP, CABLE TIE
50
709860
BLADE TERMINAL
1
708000
RING TERMINAL, 5/16 16 GAUGE
1
651462
HEAT SHRINK TUBING
10
670136
5/16 RING TERMINAL, 4 GAUGE
8
670137
3/8 RING TERMINAL, 4 GAUGE
2
Parts List
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

NITE Plus Installation Procedures
1-7
International 9000i (post-June 2002) rev 10/7/2013
Tools Required
1) Drill Bit Set
2) Hole saws (1″, 1-5/8″, 2″, 2-1/2″and 4-3/4″ )
3) Electric/Air Drill
4) Screwdrivers/Assorted Bits (Flat Head & Phillips Head)
5) Impact Gun
6) Air saw/Jigsaw (Cutting Sheet metal)
7) Torx Head (T30) Bit
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 Rivet Gun

NITE Plus Installation Procedures
1-8
International 9000i (post-June 2002) rev 10/7/2013
Prepare the Work Area
Set up your work light, clear the
sleeper compartment of loose items,
and remove the divider curtain if there
is one. Then remove the mattress and
set outside the cab.
Raise Bunk Lid and Remove Tray
Remove and discard the tray. Tray
cannot be reinstalled in original
location because it will block the
recirculation air grill.
Remove Insulation and
Drill-Out Pop Rivets
Remove the insulation from
the center section under the
bunk. Drill out pop rivets.
Three on each side and several
across the bottom of the center
support wall.
1
2
3

NITE Plus Installation Procedures
1-9
International 9000i (post-June 2002) rev 10/7/2013
Remove Wires
Open wire supports and remove wires.
Remove Bunk Cylinders
Remove cylinders from lower support
bracket and drill out rivets.
Remove Center Bunk Support
Now remove center bunk support.
4
5
6

NITE Plus Installation Procedures
1-10
International 9000i (post-June 2002) rev 10/7/2013
Remove Aluminum Floor Plate
Carefully remove the screws holding
the aluminum floor plate in place, then
lift up and remove the floor plate. Set it
outside the cab.
Install the Mounting Plate
Take the NITE Plus mounting plate
with the pre-cut recirculation grills,
and set it in the space where the
previous floor plate was. The openings
should be on the passenger side. Attach
the floor plate to the back of the frame
through the 13 pre-drilled holes with
self-tapping screws.
Remove Wire Clamp
Remove nut and clamp supporting the
wires on the back wall. These have to
be unplugged and put in front of the
duct on top of the NITE Plus unit as it
is installed
7
8
9

NITE Plus Installation Procedures
1-11
International 9000i (post-June 2002) rev 10/7/2013
Remove Original Bunk Support
Remove the bunk original support (A).
Save the allen head nuts (B) to use with
the NITE Plus bunk supports.
10
A
B
C
Mark Area to be Cut for NITE Plus Duct
Before cutting –Relocate wiring under the bunk next to the hinge !!!
Locate the bottom support bracket (A) provided in your NITE Plus kit.
Rotate the bottom support bracket 180° from position shown in picture (A)
below and position bracket against back wall aligning the 4 holes in the
bracket with the 4 existing screws (C). Now mark the area to be cut out for
the NITE Plus duct then remove the bottom support bracket (D).
11
A
B
D

NITE Plus Installation Procedures
1-12
International 9000i (post-June 2002) rev 10/7/2013
Cut Notch in Bunk for NITE Plus Duct
Before cutting –Relocate wiring under the bunk next to the hinge !!!
Raise bunk and locate the wires (A) under the area marked to be cut out in
the previous step. Cut the wire ties. Remove the 4 Phillips head screws
from the center hinge (B). Move the wires away from area to be cut (C).
Cut marked notch with air-saw or jigsaw. When finished cutting (D), place
wires back to original location to prevent damage to wires.
12
B
D
A
C

NITE Plus Installation Procedures
1-13
International 9000i (post-June 2002) rev 10/7/2013
Ream Holes in NITE Plus Support
Before installing the new support
brackets, slightly ream the holes
indicated by the circle in the picture.
13
14
D
E
A
B
C
Install Top and Bottom Brackets
First install the bottom bracket. Reinstall hinge and bottom bracket using
the screws (A) removed in an earlier step. Make sure not to pinch wires
under hinge. Install top bracket. Be sure to lap them correctly so that the 2
screws in the duct opening (B) will fasten them together. The top bracket
slides in front of the lower bracket. Reinstall the 4 Allen nuts on the right
side of the support (C) and 2 –10mm hex bolts in the center. Drill the 4
holes on the left through the existing holes in the bracket (D). Insert four
¼″ carriage bolts and secure with washers and nuts (E).

NITE Plus Installation Procedures
1-14
International 9000i (post-June 2002) rev 10/7/2013
Install T-duct Mounting Bracket
on NITE Plus Unit
Attach the T-duct mounting bracket
to the back of the NITE Plus unit.
You will need to remove 3 screws
(A) and loosen the 4th one (B), then
re-tighten the 4th screw to attach the
bracket. The three top screws will be
tightened on page 18 step #22 after
recirculation duct is installed.
Prepare NITE Plus Unit for Install
Remove the three screws and the
one screw from the right-side
bottom corner as shown in the
illustration from the front bottom of
the unit. The unit is now ready to be
placed in the truck.
Place NITE Plus Unit into Position
Carefully lift the NITE Plus unit by
the two strap handles and set it on
top of the aluminum mounting plate.
Be Careful to keep NITE Plus unit
level at all times. The “STOP” label
should be on the left side, as
pictured. Be careful not to catch or
pull on the wiring harness.
15
16
17
A
B

NITE Plus Installation Procedures
1-15
International 9000i (post-June 2002) rev 10/7/2013
Attach Mounting Brackets
Attach each corner of the NITE Plus
unit to the aluminum mounting plate
using the four mounting
foot brackets. Fasten
the brackets with
the supplied screws
and washers.
Tighten securely.
18
Reinstall Bunk Support Cylinders
It is necessary to rotate the passenger’s side top support bracket 180 degrees to
gain clearance when closing the bunk.
19
Cut Opening for Recirculation Duct
Cut an opening with a metal-cutting
air saw or jigsaw for the recirculation
grill in the center bunk support panel.
The opening should be 11 ½” wide by
3 ¼” tall and should be placed 5” from
the left side and 1 ½” from the top as
in the illustration.
1 - 1/2″
5″
11 –1/2″
3 - 1/4″
20
Before
After

NITE Plus Installation Procedures
1-16
International 9000i (post-June 2002) rev 10/7/2013
22
A
C
B
Reinstall Center Support Wall
Attach Recirculation Duct to Unit
Slide duct through duct opening from
the front (A). Rear flange of duct (B)
should slide under the same screws as
the NITE Plus duct mounting bracket.
Now tighten the 3 screws at the back
of the duct. Now install the grill (C) -
install the recirculation grill over the
opening of the duct (aligning the holes
in the grill with the holes in the duct)
using the supplied ¾” black Phillips
head screws.
21

NITE Plus Installation Procedures
1-17
International 9000i (post-June 2002) rev 10/7/2013
Attach Gasket to Top of NITE Plus
Duct Bracket
Take the supplied gasket and remove the
center section. Pull off backing to expose
sticky side. Place gasket, sticky side
down, onto the T-duct mounting bracket
as pictured. Make sure you have a good
seal.
Feed Control Wiring Through Duct
Take the NITE Plus duct and thread the
end of the wiring harness with the 5
prong black plug through the opening
from the backside to front. Attach the
control panel to the wiring harness using
the wires with a 5-prong plug—make
sure the connection is tight and secure.
(The other three wires are not used in this
particular installation.)
23
24
NOTE: If you will be installing the optional ESPAR heater please
review step 17 of the heater control panel installation instructions
before proceeding.

NITE Plus Installation Procedures
1-18
International 9000i (post-June 2002) rev 10/7/2013
Attach Control Panel to Duct
Push wiring behind duct, and mount the
control panel to the duct using ¾” black
Phillips head screws through the pre-
drilled holes. Tighten carefully. When
finished make sure switch is in the off
position!
Run Wiring behind Duct
Place the wiring harness along the
channel on the back of the duct. The duct
is now ready to be attached.
Attach Duct to Back Wall
Place the bottom of the duct into the
mounting bracket on the back of the
NITE Plus unit, be careful not to damage
the foam gasket, and 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” 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.
Take care not to over tighten.
25
26
27

NITE Plus Installation Procedures
1-19
International 9000i (post-June 2002) rev 10/7/2013
Attach Bottom of Duct to Unit
Use one 1” 5/16 self-tapping screw.
Drive screw through the small lip toward
the bottom of duct for the most secure
connection.
Attach Vents to NITE Plus Duct
Snap the louvered vents into each of the
duct openings—no screws are necessary.
Attach Control Cable to Unit
Snap control cable harness into plug on
top of NITE Plus unit—it only fits one
way.
Install Drip Tube Under Truck
All drip tubes are the same but photo may
not represent actual application
28
29
30
31

NITE Plus Installation Procedures
1-20
International 9000i (post-June 2002) rev 10/7/2013
B
C
A
D
Install the NITE Plus Unit Power Harness
Take the power harness and place the protective split plastic loom around
it. Choose a convenient location to drill a 2″ hole for wiring. Attach
provided grommet to hole to protect cables (A). Run the cables from the
NITE Plus unit, down through the frame rails to the NITE Batteries.
Secure with zip ties. Insert a 50 amp MAX fuse in the fuse holder at the
other end of the power harness (B). Plug the positive end into the positive
plug on the NITE Plus unit (C). Remove a screw from the NITE Plus
unit surface, place it through BOTH of the negative ring terminals and re-
attach to the NITE Plus unit (D).
32
NOTE: DO NOT USE THE SCREW HOLDING CARRYING STRAP FOR GROUNDING!