Lippert Vela Pop Up User manual

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

Rev: 05.10.2021 Page 2 CCD-0004279
TABLE OF CONTENTS
Introduction 2
Safety 2
Resources Required 3
Preparation 3
Pop Up Van Roof Preparation 3
Pop Up Van Assembly Preparation 7
Installation 10
Pop Up Assembly 10
Front Brow 12
Electrical Connections 16
Wiring Diagram 16
Operation 27
Post Installation Check 27
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.
For information on the assembly or individual components of this product, please visit:
lippertcomponents.eu
Note: Images used in this document are for reference only when assembling, installing and/or operating
this product. Actual appearance of provided and/or purchased parts and assemblies may differ.
Safety
Read and understand all instructions before installing or operating this product. Adhere to all safety labels.
This manual provides general instructions. Many variables can change the circumstances of the instructions,
i.e., the degree of difficulty, operation and ability of the individual performing the instructions. This
manual cannot begin to plot out instructions for every possibility, but provides the general instructions,
as necessary, for effectively interfacing with the device, product or system. Failure to correctly follow the
provided instructions may result in death, serious personal injury, severe product and/or property damage,
including voiding of the Lippert limited warranty.
Failure to follow instructions provided in this manual may result in death, serious personal injury
and/or severe product and property damage, including voiding of the component warranty.
The “WARNING” symbol above is a sign that a procedure has a safety risk involved and may cause
death or serious personal injury and/or severe product or property damage if not performed safely
and within the parameters set forth in this manual.
Make sure unit is fully supported and secured per manufacturer's recommendations before working
on or underneath the unit or death, serious personal injury and/or severe product and property
damage, including voiding of the component warranty, may occur.

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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.
Resources Required
Preparation
Note: All dimensions are in millimeters unless otherwise specified.
Pop Up Van Roof Preparation
1. Make sure van chassis is level.
2. Make sure van chassis is properly supported and secured.
A. Engage brakes.
B. Chock all tires.
C. Open van side doors to provide access to roof from inside.
3. Construct and position scaffolding (Fig. 1) to safely access and work on van chassis roof.
• 2-3 persons, depending on task
• Cordless or electric drill
• Assorted drill bits
• Caulking gun
• BETACLEANTM 3350 (cleaner)
• BETAPRIMETM 5404 (primer)
• BETAMATETM 1100N-1F (adhesive)
• Merbenit®SF50 adhesive
• Lint-free wipes
• Kiwi®Camp Dry water repellent
• Scaffolding
• Cutting pattern/jig
• Cutting tool for sheet metal
• Permanent marking method
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.
Fig. 1

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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).
A. Using the drilled reference hole, position the cutting mask onto the van chassis roof.
B. Use a permanent marking method to outline the cutting mask.
Fig. 2
5. There are two different size roof cutouts; 1150 mm or 1050 mm. Use an appropriate cutting tool and
follow the cutting mask outline to create a 1150 mm or 1050 mm (+/- 4 mm) x 630 mm (+/- 4 mm)
opening.
Note: The 1050 mm cutout is offset to the right side of the camper van by 100 mm off the centerline.
A. For long and mid-length vans, refer to dimensions in figure 3 (1150 mm cutout) and figure 4 (1050
mm cutout).
B. For short length vans, refer to dimensions in figure 5 (1150 mm cutout) and figure 6 (1050 mm
cutout).
C. De-burr and clean the cut edges.
D. Coat the cut, de-burred and cleaned edges with an anti-corrosive material.
Fig. 3

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Fig. 4
Fig. 5

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Fig. 6
Chassis
Detail C Section A-A
Pay attention to electric cables entering
the passenger compartment.
943
AA
B
B
Section B-B
C
Fig. 7
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.
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. This creates a bonding area for future sealant. Refer to the
dimensions in figures 3-7.

Rev: 05.10.2021 Page 7 CCD-0004279
Pop Up Van Assembly Preparation
1. 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.
A. 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. Use BETACLEAN 3350 cleaner
and lint-free wipes to prepare the mating surfaces of the lower pop up component.
B. Before applying cleaner to the camper van roof, refer to figure 11 for a 1100 mm wide cutout
opening and figure 12 for a 1000 mm wide cutout opening. Use BETACLEAN 3350 cleaner and
lint-free wipes to prepare the mating surfaces of the camper van roof.
C. Before applying primer to the lower pop up component, refer to figure 11 for a 1100 mm wide
cutout opening and figure 12 for a 1000 mm wide cutout opening. Apply BETAPRIME 5404 primer
to the previously cleaned mating areas of the lower pop-up component as follows:
I. Before using, shake the primer can at least one full minute until the rattling of the internal
mixing spheres can be heard.
II. Apply the primer only one time in the same direction. Avoid primer overlapping.
2. With the lower pop up component still in its upside down position, refer to figure 8 for a 1100mm
wide cutout opening and figure 8 for a 1000 mm wide cutout opening for the appropriate
adhesivepattern.
A. Use BETAMATE 1100N-1F to create two continuous beads of adhesive, as defined in figure 8.
B. Apply enough BETAMATE 1100N-1F adhesive so that when the lower pop up component is
Fig. 8
installed onto the van roof the adhesive will spread out far enough to also act as asealant.
C. Additionally, create an adhesive loop across the back (rear) corners of the lower pop up
component as follows:
I. Start applying adhesive along a side 300 mm away from a rear corner, then run the bead of
adhesive down to the corner.
II. Continue applying the adhesive across the backside of the component and around the
opposite corner.
III. Then, continue applying the adhesive up 300 mm along the side.
IV. Finally, continue applying the adhesive back across to the beginning of the bead.
V. Connect the adhesive beads to complete the loop.

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Fig. 9
Fig. 10

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Fig. 11
Fig. 12

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Fig. 13 Fig. 14
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.
1. Lift the pop up assembly over the van chassis roof (Fig. 13), positioning it over the prepped cut out.
2. Lay the pop up assembly onto the van roof. For additional positioning information, refer to figure 15
for long and mid-length vans and figure 16 for short vans.
3. Adjust the pop up assembly into position. Make sure the pop up is firmly seated (pushed down)
(Fig.14). Remove the vacuum lift and open the top.
4. While wearing nylon gloves, use your finger to spread all of adhesive that has oozed out around the
perimeter of the top. Make sure to add more adhesive to close all gaps.
5. Remove the adhesive tape from the pop up that was used to mark the layout.
6. Use straps across the front and back of the pop up to hold the top in place while adhesive is curing.
7. Lower the top back down and position the vacuum lift back on top for added weight.
8. Apply pressure to the assembly (Fig. 14). Make sure enough adhesive spreads out around the pop up
assembly to act as asealant.

Rev: 05.10.2021 Page 11 CCD-0004279
Fig. 15
Fig. 16

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Fig. 17
Front Brow
1. 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.
2. 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.
A. Use BETACLEAN 3350 cleaner and lint-free wipes to prepare the mating surfaces of the front brow
(Fig. 17) and the camper van roof.
B. Apply BETAPRIME 5404 primer to the previously cleaned mating areas of the front brow (Fig. 17).
3. Apply BETAMATE 1100N-1F adhesive to the front brow where indicated in figure 17.
Note: Make sure enough adhesive is applied so that when the front brow is installed onto the van chassis
roof the adhesive will spread out enough to also act as a sealant.
4. Lift the front brow over the front of the van roof (Fig. 18).
5. Position the front brow in front of the installed pop up assembly. For additional positioning
information, refer to figure 15 for long and mid-length vans and figure 16 for short vans.

Rev: 05.10.2021 Page 13 CCD-0004279
assembly to act as asealant.
7. 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).
Fig. 19
6. Apply pressure to the front brow. Make sure enough adhesive spreads out around the pop-up
Fig. 18

Rev: 05.10.2021 Page 14 CCD-0004279
Fig. 21
8. 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. 20

Rev: 05.10.2021 Page 15 CCD-0004279
9. 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).
Note: Allow 5-6 hours for the adhesive to cure before performing any operational checks of the Pop Up
CamperVan.
Fig. 22

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Fig. 23
Solar Panel
Connector
12V Connector 220V Socket Connector
Detail A
A
Wiring Diagram
The presence of connectors depends on the type of
Electric Wiring.
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.

Rev: 05.10.2021 Page 17 CCD-0004279
Legend for Main Harness (Fig. 24)
Callout Length Description
12650 Black, 1.5 mm², H05V-K
22650 Brown, 1.5 mm², H05V-K
32700 Red, 2.5 mm^2, H05V-K
42700 Black, 2.5 mm², H05V-K
51300 Red/Black, 0.75 mm², H05V-K
6540 Red/Black, 0.75 mm², H05V-K
7500 Red/Black, 1.5 mm², H05V-K
8500 Blue-Y/G-Brown, 1.5 mm², H05 VV-F
930 Red/Black, 0.75 mm², H05V-K
Callout Description
1Female terminal lug, 6.35 x 0.81
2Male terminal lug, 6.35 x 0.81
3Female Mini-Fit terminal lug
4Male Mini-Fit terminal lug

Rev: 05.10.2021 Page 18 CCD-0004279
Legend for Main Harness (Fig. 24) - cont'd
Callout Description
A2-way Female MiniFit Connector, 4.2, Nylon, Natural
B2-way Male MiniFit Connector, 4.2, Nylon, Natural
CMammouth, terminal board
DON-OFF Switch for Roof LED Lamps
E2-way Faston Female Connector, 6.3, Nylon 66, Natural
F2-way Faston Male Connector, 6.3, Nylon 66, Natural
G3-way MiniFit Connector, 6.3, Nylon 66, Natural
H1-way Faston Male Connector, 6.3, Nylon 66, Natural
I1-way Faston Female Connector, 6.3, Nylon 66, Natural
LSocket, 220V

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Fig. 24
Bottom Harness - Version 1 (full optional)
A
4
5
3 3
C
3
1
A
1
B
2
D
2
H
I
L
F
E
G
8
9
7
2
2
4
4
1
9
9

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Legend for USB Harness (Fig. 25)
Callout Length Description
1500 Red/Black, 1.5 mm² H05V-K
21300 Red/Black, 0.75 mm²05V-K
3540 Red/Black, 0.75 mm² H05V-K
420 Red/Black, 0.75 mm², H05V-K
530 Red/Black, 0.75 mm², H05V-K
Callout Description
1Male terminal lug, 6.35 x 0.81
2Female Mini-Fit terminal lug
3Male Mini-Fit terminal lug
A2-way Faston Female Connector, 6.3, Nylon 66, Natural
BInsulated Head Joint
C2-way Male MiniFit Connector, 4.2, Nylon, Natural
D2-way Female MiniFit Connector, 4.2, Nylon, Natural