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Lippert Vela Pop Up Installation Manual

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Vela Pop Up
Roof System
Class B (EU)
OEM INSTALLATION MANUAL

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Summary of Contents for Lippert Vela Pop Up

  • Page 1 Vela Pop Up Roof System Class B (EU) OEM INSTALLATION MANUAL...

  • Page 2: Table Of Contents

    Operation Post Installation Check Introduction The Lippert Pop Up Camper Van is a manually operated, roof-mounted sleeper extension. The Pop Up Camper Van has a hard roof with a canvas body that includes screened windows for added ventilation and comfort.

  • Page 3: Resources Required

    The “CAUTION” symbol above is a sign that a safety risk is involved and may cause personal injury and/or product or property damage if not safely adhered to and within the parameters set forth in this manual. Always wear eye protection when performing service, maintenance or installation procedures. Other safety equipment to consider would be hearing protection, gloves and possibly a full face shield, depending on the nature of the task.
  • Page 4 From inside the van, using the van ceiling frame as a reference, drill a 10 mm diameter hole through the roof to aid in the positioning of the cutting mask (Fig. 2). Using the drilled reference hole, position the cutting mask onto the van chassis roof. Use a permanent marking method to outline the cutting mask.
  • Page 5 Fig. 4 Fig. 5 Page 5 Rev: 05.10.2021 CCD-0004279...
  • Page 6 Fig. 6 Use the lower pop up component (the base) as a locating template. Position the template +/- 3 mm on each side. Refer to dimensions in figures 3-7. Use adhesive tape to mark the outline of the template. Leave at least a 6 mm gap between the template and the tape all around.

  • Page 7: Pop Up Van Assembly Preparation

    Pop Up Van Assembly Preparation Place the pre-assembled pop up component upside down on a clean work table. Note: Make sure the work surface is clean of dirt and debris to protect the top component from acquiring blemishes and scratches. Before applying cleaner to the lower pop up component, refer to figure 9 for a 1100 mm wide cutout opening and figure 10 for a 1000 mm wide cutout opening.
  • Page 8 Fig. 9 Fig. 10 Page 8 Rev: 05.10.2021 CCD-0004279...
  • Page 9 Fig. 11 Fig. 12 Page 9 Rev: 05.10.2021 CCD-0004279...

  • Page 10: Installation

    Installation Pop Up Assembly In addition to using the prepared cut out for the positioning, also use the references—adhesive tape or permanent markers—performed in step 7 of the Pop Up Van Roof Preparation procedure in the Preparation section. Lift the pop up assembly over the van chassis roof (Fig. 13), positioning it over the prepped cut out. Lay the pop up assembly onto the van roof.
  • Page 11 Fig. 15 Fig. 16 Page 11 Rev: 05.10.2021 CCD-0004279...

  • Page 12: Front Brow

    Front Brow With brow properly positioned, use adhesive tape to outline the area to be cleaned and primed. Leave a minimum of 5 mm gap around the brow for additional sealant if needed. Place the front brow upside down on a clean work table. Note: Make sure the work surface is clean of dirt and debris to protect the front brow from acquiring blemishes and scratches.
  • Page 13 Fig. 18 Apply pressure to the front brow. Make sure enough adhesive spreads out around the pop-up assembly to act as a sealant. Use BETACLEAN 3350 cleaner and lint-free wipes to prepare the mating surfaces along the perimeter of the lower component. Apply BETAPRIME 5404 primer to the previously cleaned mating areas and then apply a bead of BETAMATE 1100N-1F or Merbenit SF50 adhesive along the same perimeter (Figs. 19 and 20).
  • Page 14 Fig. 20 Use BETACLEAN 3350 cleaner and lint-free wipes to prepare the mating surfaces along the perimeter of the brow. Apply BETAPRIME 5404 primer to the previously cleaned mating areas and then apply a bead of BETAMATE 1100N-1F or Merbenit SF50 adhesive along the perimeter of the brow (Fig. 21). Fig.
  • Page 15 Use BETACLEAN 3350 cleaner and lint-free wipes to prepare the mating surfaces between the lower component and the front brow. Apply BETAPRIME 5404 primer to the previously cleaned mating areas and then apply a bead of BETAMATE 1100N-1F or Merbenit SF50 adhesive between the same areas (Fig. 22).

  • Page 16: Electrical Connections

    Wiring Diagram Electrical Connections Note: Pay attention to electric cables entering into the passenger compartment. Locate the connectors and cables extending from the pop up assembly (Fig. 23). Mate the pop up's connectors with the camper van's corresponding connectors. Refer to the Wiring Diagram section for additional information to complete the necessary electrical connections.
  • Page 17 Legend for Main Harness (Fig. 24) Callout Length Description 2650 Black, 1.5 mm², H05V-K 2650 Brown, 1.5 mm², H05V-K 2700 Red, 2.5 mm^2, H05V-K 2700 Black, 2.5 mm², H05V-K 1300 Red/Black, 0.75 mm², H05V-K Red/Black, 0.75 mm², H05V-K Red/Black, 1.5 mm², H05V-K Blue-Y/G-Brown, 1.5 mm², H05 VV-F Red/Black, 0.75 mm², H05V-K Callout...
  • Page 18 Legend for Main Harness (Fig. 24) - cont'd Callout Description 2-way Female MiniFit Connector, 4.2, Nylon, Natural 2-way Male MiniFit Connector, 4.2, Nylon, Natural Mammouth, terminal board ON-OFF Switch for Roof LED Lamps 2-way Faston Female Connector, 6.3, Nylon 66, Natural 2-way Faston Male Connector, 6.3, Nylon 66, Natural 3-way MiniFit Connector, 6.3, Nylon 66, Natural 1-way Faston Male Connector, 6.3, Nylon 66, Natural...
  • Page 19 Bottom Harness - Version 1 (full optional) Fig. 24 Page 19 Rev: 05.10.2021 CCD-0004279...
  • Page 20 Legend for USB Harness (Fig. 25) Callout Length Description Red/Black, 1.5 mm² H05V-K 1300 Red/Black, 0.75 mm²05V-K Red/Black, 0.75 mm² H05V-K Red/Black, 0.75 mm², H05V-K Red/Black, 0.75 mm², H05V-K Callout Description Male terminal lug, 6.35 x 0.81 Female Mini-Fit terminal lug Male Mini-Fit terminal lug 2-way Faston Female Connector, 6.3, Nylon 66, Natural Insulated Head Joint...
  • Page 21 Fig. 25 Bottom Harness - Version 2 Page 21 Rev: 05.10.2021 CCD-0004279...
  • Page 22 Legend for TOP Interconnect Harness (Fig. 26) Callout Length Description 2000 Red/Black, 0.75 mm², H05V-K Red/Black, 0.75 mm², H05V-K Callout Description Male Mini-Fit terminal lug Female Mini-Fit terminal lug Male terminal lug, 6.35 x 0.81 2-way Female MiniFit Connector, 4.2, Nylon, Natural 2-way Male MiniFit Connector, 4.2, Nylon, Natural 2-way Faston Female Connector, 6.3, Nylon 66, Natural Page 22...
  • Page 23 Fig. 26 TOP Interconnect Harness Page 23 Rev: 05.10.2021 CCD-0004279...
  • Page 24 Legend for Coiled Cable Harness (Fig. 27) Callout Length Description Black, 2.5mm² Black-Y/G, 2.5mm² Black, 2.5mm² Black, 2.5mm² Black, 2.5mm² Y/G, 2.5mm² Callout Description Female terminal lug, 6.35 x 0.81 Male terminal lug, 6.35 x 0.81 1-way Faston Female Connector, 6.3, Nylon 66, Natural 1-way Faston Male Connector, 6.3, Nylon 66, Natural 2-way Faston Female Connector, 6.3, Nylon 66, Natural 2-way Faston Male Connector, 6.3, Nylon 66, Natural...
  • Page 25 Coiled Cable Harness Fig. 27 Page 25 Rev: 05.10.2021 CCD-0004279...
  • Page 26 Fig. 28 Bar-light Interconnect Page 26 Rev: 05.10.2021 CCD-0004279...

  • Page 27: Operation

    Operation Post Installation Check After adhesive has fully cured, inspect the outer mating edges of the pop-up and cover for any gaps or excessive adhesive. First, remove any excessive adhesive so there remains an even, consistent bead around the pop-up and cover to act as a sealant. If necessary, clean any adhesive residue from the camper van roof.
  • Page 28 Fig. 31 Fig. 32 After unlocking the roof, grab both handles and push the roof upwards. Air springs will maintain the roof in its open position (Fig. 33A). Fig. 33 Inspect the outer sealant bead (Fig. 34A) around the pop up to make sure no gaps were created or loosening of the adhesive occurred.
  • Page 29 Fig. 34 Moving parts can pinch, crush or cut. Keep clear and use caution. After making sure all windows are closed, grip both roof handles and pull down as evenly as possible. Do NOT completely close the pop up roof at this point. D.
  • Page 30 The contents of this manual are proprietary and copyright protected by Lippert Components, Inc. (LCI). LCI prohibits the copying or dissemination of portions of this manual unless prior written consent from an authorized LCI representative has been provided.  Any unauthorized use shall void any applicable warranty. ...

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