GMC EL-53200 User manual

EL-53200
BATTERY ENCLOSURE SEAL PRESSURE TESTER
USER GUIDE

Overview
BESPT PC Application V1.36, Tester Firmware V1.03, 10/21/2021 21
© 2021 Hickok Waekon LLC All rights reserved.
All rights reserved.
No part of this manual may be reproduced or transmitted in any form or by any means, electronic or mechanical, without written
permission from Hickok Waekon LLC.
Hickok Waekon LLC assumes no responsibility for use of this equipment by untrained or unauthorized persons.
Printed in the United States of America.

Table of Contents
BESPT PC Application V1.36, Tester Firmware V1.03, 10/21/2021 31
Overview ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 4
Warnings and Precautions•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 4
Kit Components •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 5
Kit Components and Descriptions •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 6
PC Requirements and Application Installation •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 7
Leak Testing Hookup ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 7
Vent Cover Adapters Installation Procedure (EL-53200 Hookup and EL-53200 Blocking)•••••••••••••••••••••••••••••••••••••••••••••••• 8
Connecting BESPT for Testing ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 9
PC Application Controls and Information Dsiplay•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 9
Connecting BESPT for Testing ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 10
Test Results (Leak rate display)•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 11
Smoke Diagnostics (Failed leak test) •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 12
Smoke Diagnostic Procedure •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 12
Smoke Diagnostics (Failed leak test) •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 13

Overview
BESPT PC Application V1.36, Tester Firmware V1.03, 10/21/2021 41
The EL-53200 Battery Enclosure Seal Pressure Tester (BESPT) is used for low pressure leak testing on
battery electric vehicle (BEV) battery packs for leaks as small as 10 SCCM. It is designed to perform leak
tests at low pressure (-0.5 psi) to prevent damage to the battery compartment and the associated
seams/seals.
The tool utilizes an internal pump that supplies low pressure or vacuum without external sources.
The BESPT is powered by an external 12VDC 4A power supply that connects via a 2.1mm plug. Pressure
and Vacuum ports on the side of the BESPT mate to a 6-Ft. hookup hose through quick connects that
also mate to battery pack specic adapters. The BESPT is operated through a dedicated
PC application using the USB cable.
Warnings and Precautions
• Leak testing of battery packs is only to be performed when indicated by diagnostic procedures.
Consult GM vehicle service procedures for specic applications.
• The battery pack must be fully disconnected from the vehicle prior to leak testing.
• Battery pack safety interlock systems must not be modied or disabled.
• Only approved adapters are allowed for sealing o electrical connector housings and vent covers.
Consult GM vehicle service procedures for specic applications.

Kit Components
BESPT PC Application V1.36, Tester Firmware V1.03, 10/21/2021 51
1
4
7
2
5
8
3
6EL-53200-HOOKUP
Vent cover hookup adapter
EL-53200-SMOKE HOSE
Smoke hose adapter
EL-53200-SMOKE SUPPLY
Smoke air supply adapter
EL-53200-POWER
Power supply (12v 4A)
EL-53200-USB 10 ft. USB cable
EL-53200-BLOCKING
Vent cover blocking
adapter
EL-53200-HOSE 6 ft. Hookup hose
EL-53200-TESTER BESPT Main unit

Kit Components and Descriptions
BESPT PC Application V1.36, Tester Firmware V1.03, 10/21/2021 61
1
4
7
2
5
8
3
6
Battery Enclosure Seal Pressure Tester (BESPT) (EL-53200-TESTER)
The main test unit contains all pressure/vacuum control hardware and rmware for testing. The tester has
interfaces for connecting the Hoses, Power Supply, and USB cable to vehicle components and computer
(not provided). Setup and use of these will be fully described in subsequent sections.
6-FT. Hookup Hose (EL-53200-HOSE)
The 6-Ft. Hookup Hose allows BESPT to evacuate the battery pack or to provide pressure for smoke
generator diagnostics. The hose has female quick connects at both ends.
Smoke Air Supply Adapter (EL-53200-SMOKE SUPPLY)
Allows the tester to act as the low pressure air supply for a smoke generator. It adapts a standard shop-air
female quick connect to the main quick connect tting. The pair of adapters (3 and 4) are used for low
pressure smoke injection and pinpointing of conrmed battery leaks.
Smoke Hose Adapter (EL-53200-SMOKE HOSE)
Allows a smoke generator machine to interface with the Vent Cover Hookup Adapter for injecting smoke
into the battery compartment under controlled low pressure for leak pinpointing.
Vent Cover Hookup Adapter (EL-53200-HOOKUP)
Replaces a pressure relief vent on the battery pack and provides an access port for leak testing. It has a
male quick connect for attaching the Hookup Hose that also mates to the tester vacuum test port. It is
installed via self-contained cap nuts. Used in conjunction with special adapter kits (see service procedures)
to block o and seal all electrical connectors on the battery pack prior to leak testing.
Vent Cover Blocking Adapter (EL-53200-BLOCKING)
Replaces a second pressure relief vent used on some battery packs prior to leak testing. Installed via
self-contained cap nuts. Used in conjunction with special adapter kits (see service procedures) to block all
electrical connectors on the battery pack prior to leak testing.
10-FT. USB Cable (EL-53200-USB)
The 10-Ft USB cable connects the main unit to the computer with the interface PC app installed. It has a
male USB micro plug on one end and USB male type A plug on the other end.
12V Power Supply (EL-53200-POWER)
Provides regulated 12 VDC 4A power to the BESPT via the power cord and 2.1mm plug. The power
supply plugs into a standard 110 VAC wall outlet.
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PC Requirements and Application Installation
BESPT PC Application V1.36, Tester Firmware V1.03, 10/21/2021 71
• Windows 10 64-bit PC • 2 Gb or more ram
• i3 Processor or above • 1 free USB Port (2.0 or higher)
• 1 Gb free hard drive space • Screen resolution 720p or higher
The BESPT PC application is found at gmtoolsandequipment.com as a self-extracting executable.
The application can be saved and installed from any download folder. The target PC requires
administrative rights to install or update this application (Contact your IT Administrator if installation
issues occur). Double click the le and follow the on screen program installation instructions. It is
recommended that you check the box to create a desktop icon.
After the PC application is installed, setup may request permission to update the tester assembly
rmware. To perform a rmware update the tester must be connected to the host PC using the 10ft.
USB cable (EL-53200-USB). (Note: The 12V power supply is not required to perform rmware updates.)
After the unit is connected, click the Begin Update button to proceed. After the rmware update has
been installed the window will close automatically and setup will nish.
For future updates to the PC application, it is not necessary to uninstall the current version.
The setup installer handles this and the desktop icon will continue to launch the latest version
of BESPT software.
Leak Testing Hookup
BESPT end plate interface
Vacuum Test Port
used for leak testing
Pressure Test Port
used for smoke diagnostics Micro USB Port to
communicate
with the PC host
Main Power
12 VDC 4A
Power LED Indicates
CPU power is active

PC Requirements and Application Installation
BESPT PC Application V1.36, Tester Firmware V1.03, 10/21/2021 81
Vent Cover Adapters Installation Procedure (EL-53200-HOOKUP & EL-53200-BLOCKING)
The battery pack must be located in a secure horizontal orientation and stabilized at room temperature
for at least one hour prior to test preparation.
Seal o all connector housings and vents per the approved service procedures.
Remove battery vent covers from the locations where the Vent Cover Adapters are to be installed
(see example in Fig. 1).
Make sure the surfaces around and under the vent mounting location are clean of debris (see Fig. 3).
Push down the Vent Cover Hookup Adapter (EL-53200-HOOKUP), with the rubber gasket down,
over the studs and continue pushing down evenly until it fully seats (see Fig. 2).
By hand, start all four hex cap nuts. Fully hand tighten evenly in sequence.
Once complete, use a wrench and tighten each cap nut one full turn (360 Degrees)
Note: No more than 1.5Nm (13.3 lb in) should be applied or damage to the Vent Cover Adapter(s) may occur.
Duplicate this procedure when both vent covers are required.
Install vent cover adapters here
2 Vent valves on pack front
Fig. 1
Fig. 2 Fig. 3
Vent assembly
removed

Connecting BESPT for Testing
BESPT PC Application V1.36, Tester Firmware V1.03, 10/21/2021 91
Connect the Hookup Hose (EL-53200-HOSE) quick connects to the Vent Cover Hookup Adapter and the
Vacuum Port on BESPT.
Connect the Power Supply (EL-53200-POWER) to the BESPT.
Connect the USB (EL-53200-USB) cable to the BESPT USB port and then to an open USB port on the host PC.
Verify that the green PWR LED on the BESPT is on.
PC application controls and Information display
Build date
and version
Connect/Disconnect
the current port
Starts ½PSI air pressure
supply for Smoke Diagnostics
Red: Port Detected
Yellow: Port not found
Green: Port Connected
Manually select
COM port
Redetects
recognized devices
Detailed history
of performed tests
Clears battery
information
Text window displays instuctions,
real time status, and test results
Resets all data
for a new test
Leak Rate
Vehicle and
Battery pack
data entry
Elapsed time
of current test
Starts vacuum leak test
(Fully automated)
Stop or Abort any test

Connecting BESPT for Testing
BESPT PC Application V1.36, Tester Firmware V1.03, 10/21/2021 101
Application should be blank
when opened. Com8 will be
"RED"until connected.
Press the connect button to
connect to BESPT to USB port.
COM8 is now connected as
referenced in "Current Port"
eld (green).
Enter VIN, Repair Order, Pack
Serial Number and Pack Part
Number.
Select "Start Leak Test". BESPT
will Pull Vacuum, stabilize the
pressure and monitor decay.
Ensure the battery pack is not
worked on or moved during
the test.
Note: Placing objects on the
pack cover will change the
internal air volume and
provide a false test result.

Test Results (Leak Rate Display)
BESPT PC Application V1.36, Tester Firmware V1.03, 10/21/2021 11
After Leak Test is completed. See Test Result: (Leak Rate).

Smoke Diagnostics (For Failed leak test)
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Smoke Diagnostic Procedure:
Start the BESPT Smoke Diagnostics by clicking on the "Smoke Diagnostics"button on the PC application.
Enable the smoke generator ow.
Temporarily disconnect the Smoke Hose Adapter from the Vent CoverAdapter.
Wait until thick smoke is coming out of the hose then re-connect the Smoke Hose Adapter to the Vent
Cover Hookup Adapter.
Remove the tape over one of the pressure relief vent ports on the HV Battery Pack Enclosure.
Allow smoke to ll battery and exit from the pack enclosure. Reseal the pressure relief vent port
with the tape.
The BESPT will pressurize the battery pack with smoke to no more than ½ PSI and hold pressure.
Allow 1-2 minutes for the smoke to saturate the battery compartment.
Using a bright light, Examine the battery pack cover seam and around all electrical connectors.
Note: air movement in the repair area may disperse leaking smoke and complicate locating a leak.
The BESPT smoke air supply function will automatically shut o after 8 minutes.
If a leak has been identied and repaired, retest with BESPT to verify the repair.

Smoke Diagnostics (For Failed leak test)
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For pinpointing the location of leaks identied
by BESPT use the Smoke Hose & Smoke Supply
Adapters with the appropriate smoke machine
as referenced in the service procedures.
Connect the Hookup Hose Adapter
(EL-53200-HOSE) to the Pressure Test
Port on the BESPT unit.
Connect the other end of the Hookup Hose
Adapter to the Smoke Supply adapter
(EL-53200-SMOKE SUPPLY).
Attach the female Smoke Supply Adapter to the smoke
machine shop air male quick connect (see Fig. 4).
The Vent Cover Hookup Adapter should already be
installed on the battery pack.
Connect the Smoke Hose Adapter (EL-53200-SMOKE HOSE)
to the end of the smoke generator hose using the rubber
cone adapter (See Fig. 5).
Plug the quick connect side of the Smoke Hose Adapter
to the Hookup Vent Cover Adapter.
Fig. 4 Smoke Machine supply hookup to BESPT
Fig. 5 Smoke Machine output hose
hookup the Vent Cover Adapter
Smoke Machine
Shop Air Input
Vent Cover
Adapter Smoke Hose
Adapter
Smoke Machine Output Hose
Smoke Air Supply
Adapter Hookup Hose

Smoke Diagnostics (For Failed leak test)
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Battery Enclosure Seal Pressure Tester
02491-123