Unit of competency details
AURETH009 - Diagnose and repair DC to DC converters in battery electric vehicles (Release 1)
Summary
Usage recommendation:
Superseded
Releases:
1 1 (this release) |
14/Apr/2016 |
Companion volumes:
Unit of competency
Assessment requirements
Training packages that include this unit
Qualifications that include this unit
Skill sets that include this unit
Classifications
Classification history
ASCED Module/Unit of Competency Field of Education Identifier | 030505 | Automotive Electrics And Electronics | 09/Aug/2016 | |
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Unit of competency
Modification History
Release
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Comment
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Release 1
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New unit of competency.
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Application
This unit describes the performance outcomes required to diagnose and repair faults in high voltage (HV) direct current (DC) to low voltage (LV) DC converters in battery electric vehicles (BEVs). It involves preparing for the task, selecting the correct diagnostic procedure, carrying out the diagnosis and the repair, performing post-repair testing, and completing workplace processes and documentation. Importance is placed in the unit on applying electrical safety procedures when working on HV rechargeable energy storage systems (RESS).
It applies to those working in the automotive service and repair industry. HV DC to LV DC converters include circuits in BEVs.
No licensing, legislative, regulatory or certification requirements apply to this unit at the time of publication.
Pre-requisite Unit
AURETH001 Depower and reinitialise battery electric vehicles
AURETR025 Test, charge and replace batteries and jump start vehicles
Competency Field
Electrical
Unit Sector
Technical - Hybrid Vehicle and Battery Electric Vehicle
Elements and Performance Criteria
Elements
Elements describe the essential outcomes.
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Performance Criteria
Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold and italicised text is used, further information is detailed in the range of conditions section.
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1. Prepare to diagnose and repair DC to DC converter
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1.2 Job requirements are determined from workplace instructions
1.3 Diagnostic information is sourced and interpreted
1.4 Diagnostic options are analysed and those most appropriate to the circumstances are selected
1.5 Hazards associated with the work are identified and risks are managed according to safety requirements and AS 5732 Electric vehicle operations: Maintenance and repair
1.6 Diagnostic tools and equipment are selected and checked for serviceability
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2. Diagnose DC to DC converter
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2.1 Diagnostic tests are carried out according to manufacturer specifications, workplace procedures and safety requirements
2.2 Faults are identified from diagnostic test results and causes of faults are determined
2.3 Diagnosis findings and recommendations for necessary repairs or adjustments are reported according to workplace procedures
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3. Repair DC to DC converter
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3.1 Repair information is sourced and interpreted
3.2 Repair options are analysed and those most appropriate to the circumstances are selected
3.3 Repair tools, equipment and materials are selected and checked
3.4 RESS service plug or manual service disconnect is located and isolated to depower vehicle HV RESS according to manufacturer specifications
3.5 DC to DC converters are replaced, repaired or adjusted as required according to manufacturer specifications, workplace procedures, safety and environmental requirements , and without causing damage to components or systems
3.6 RESS service plug or manual service disconnect is reconnected and vehicle is reactivated
3.7 Post-repair testing is carried out according to workplace procedures to confirm fault rectification, and any further problems detected as having been introduced during the repair process are rectified
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4. Complete work processes
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4.1 Final inspection is made to ensure work is to workplace expectations and vehicle is presented ready for use
4.2 Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected
4.3 Tools and equipment are checked and stored and faulty electric equipment is identified, tagged and isolated according to workplace procedures
4.4 Workplace documentation is processed according to workplace procedures
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Foundation Skills
This section describes those language, literacy, numeracy and employment skills that are essential to performance and are not explicit in the performance criteria.
Skills
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Description
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Learning skills to:
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- identify and locate various sources of information efficiently.
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Reading skills to:
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- interpret text, symbols and wiring diagrams in diagnostic and repair information in manufacturer specifications and workplace instructions and procedures.
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Writing skills to:
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- legibly and accurately fill out workplace documentation when reporting diagnostic findings, making repair recommendations, and recording parts and material used.
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Oral communication skills to:
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- clarify instructions
- report diagnostic findings and make repair recommendations.
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Numeracy skills to:
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- match electrical components and part identification numbers to workplace instructions, vehicle and component part lists, and manufacturer specifications
- interpret vehicle electrical measurements and readings
- measure voltage, current and resistance and use basic mathematical operations, including addition and subtraction, to calculate deviations from manufacturer specifications.
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Planning and organising skills to:
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- plan own work requirements and prioritise actions to achieve required outcomes and ensure tasks are completed within workplace timeframes.
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Technology skills to:
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- use specialised equipment, including multimeters and scan tools.
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Range of Conditions
This section specifies work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included. Bold italicised wording, if used in the performance criteria, is detailed below.
Safety requirements must include:
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- work health and safety (WHS) and occupational health and safety (OHS) requirements, including procedures for:
- identifying hazards and controlling risks associated with:
- working with high voltages in BEV electrical systems
- wearing jewellery while working around high electrical currents
- determining appropriate procedures for minimising risk associated with hazards, including applying electrical safety precautions:
- using personal protective equipment (PPE), including electrical safety gloves with 1000 volt rating and HV insulating mat with Australian standards rating
- identifying and using fire safety equipment as appropriate
- using the ‘one hand rule’
- following live system warning tags and signs
- depowering the vehicle
- isolating the HV RESS electrical supply
- stabilising the vehicle electrical system.
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Tools and equipment must include:
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- those specified in the specific vehicle service maintenance procedures, including:
- digital multimeter with Cat III 1000 volt rating
- insulation tester
- scan tool
- oscilloscope
- residual voltage tester, if specified in original equipment manufacturer (OEM) test requirements.
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Environmental requirements must include:
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- procedures for trapping, storing and disposing of waste produced during repair work.
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Unit Mapping Information
Equivalent to AURETH4009 Diagnose and repair DC to DC converters in battery electric vehicles
Links
Companion Volume implementation guides are found in VETNet - https://vetnet.gov.au/Pages/TrainingDocs.aspx?q=b4278d82-d487-4070-a8c4-78045ec695b1
Assessment requirements
Modification History
Release
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Comment
|
Release 1
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New unit of competency.
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Performance Evidence
Before competency can be determined, individuals must demonstrate they can perform the following according to the standard defined in the unit’s elements and performance criteria, range of conditions and foundation skills:
- diagnose and repair the DC to DC converter and its system components on two different battery electric vehicles (BEVs) to correct performance deficiencies.
Knowledge Evidence
Individuals must be able to demonstrate knowledge of:
- work health and safety (WHS) and occupational health and safety (OHS) requirements relating to diagnosing and repairing DC to DC converters in BEVs, including procedures for:
- identifying hazards and controlling risks associated with:
- working with high voltages in BEV electrical systems
- wearing jewellery while working around high electrical currents
- determining appropriate procedures for minimising risk associated with hazards, including applying electrical safety precautions:
- using personal protective equipment (PPE), including electrical safety gloves with 1000 volt rating and high voltage (HV) insulating mat with Australian standards rating
- identifying and using fire safety equipment as appropriate
- using the ‘one hand rule’
- following live system warning tags and signs
- depowering the vehicle
- isolating the HV rechargeable energy storage system (RESS) electrical supply
- stabilising the vehicle electrical system
- environmental requirements, including procedures for trapping, storing and disposing of waste produced during repair work
- key requirements of AS 5732 Electric vehicle operations: Maintenance and repair
- operating principles of DC to DC converters and associated components, including:
- step-down converters
- step-up converters
- continuous current mode
- discontinuous current mode
- signal noise, including radio frequency (RF) noise, input noise and output noise
- application, purpose and operation of DC to DC converters and components, including:
- linear converters
- switched mode conversion
- magnetic converters
- capacitive converters
- diagnostic testing procedures for DC to DC converters, including:
- accessing and interpreting scan tool system data, including:
- diagnostic trouble codes (DTCs)
- live data
- freeze frame data
- waveforms
- using diagnostic flow charts
- testing electrical systems, including procedures for:
- accessing electrical terminals and using test probes without damaging connectors, fuse holders or wiring
- checking voltage input and output of DC to DC converters
- checking routing and damage to cabling
- repair procedures for traction motor speed control systems, including:
- tightening connections
- replacing faulty or damaged cable connections
- removing and replacing faulty or damaged components
- post-repair testing procedures for BEVs, including:
- DTC clearing procedures
- checking for electrical connector mating.
Assessment Conditions
Assessors must satisfy NVR/AQTF assessor requirements.
Competency is to be assessed in the workplace or a simulated environment that accurately reflects performance in a real workplace setting.
Assessment must include direct observation of tasks.
Where assessment of competency includes third-party evidence, individuals must provide evidence that links them to the BEV DC to DC converters that they have worked on, e.g. repair orders.
Assessors must verify performance evidence through questioning on skills and knowledge to ensure correct interpretation and application.
The following resources must be made available:
- automotive repair workplace or simulated workplace
- PPE and safety equipment, including electrical safety gloves with 1000 volt rating and HV insulating mat with Australian standards rating
- manufacturer specifications for BEV DC to DC converters
- AS 5732 Electric vehicle operations: Maintenance and repair
- two different BEVs with DC to DC converters accessible for diagnostic and repair or replacement activities
- electrical diagnostic equipment appropriate to the BEV being diagnosed and repaired, including:
- digital multimeter with Cat III 1000 volt rating
- insulation tester
- scan tool
- oscilloscope
- residual voltage tester, if specified in original equipment manufacturer (OEM) test requirements
- tools, equipment and materials appropriate for repairing DC to DC converters in BEVs.
Links
Companion Volume implementation guides are found in VETNet - https://vetnet.gov.au/Pages/TrainingDocs.aspx?q=b4278d82-d487-4070-a8c4-78045ec695b1
Companion Volume implementation guides are found in VETNet - https://vetnet.gov.au/Pages/TrainingDocs.aspx?q=b4278d82-d487-4070-a8c4-78045ec695b1