Unit of competency details

AURETH010 - Diagnose and repair high voltage rechargeable energy storage systems in hybrid electric vehicles (Release 1)

Summary

Releases:
ReleaseStatusRelease date
1 1 (this release)Current 14/Apr/2016

Usage recommendation:
Current
Mapping:
MappingNotesDate
Supersedes and is equivalent to AURETH4010 - Test high voltage batteries in hybrid electric vehicles 13/Apr/2016


Training packages that include this unit

Classifications

SchemeCodeClassification value
ASCED Module/Unit of Competency Field of Education Identifier 030505 Automotive Electrics And Electronics  

Classification history

SchemeCodeClassification valueStart dateEnd date
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 

Comment 

Release 1 

New unit of competency.

Application

This unit describes the performance outcomes required to diagnose and repair faults in the high voltage (HV) rechargeable energy storage system (RESS) of hybrid electric vehicles (HEVs) and plug-in hybrid electric vehicles (PHEVs). It involves preparing for the task, selecting the correct diagnostic procedure, carrying out the diagnosis and 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 RESS.

It applies to those working in the automotive service and repair industry.

No licensing, legislative, regulatory or certification requirements apply to this unit at the time of publication.

Pre-requisite Unit

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.

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.

1. Prepare to diagnose and repair HV RESS

1.1 Job requirements are determined from workplace instructions

1.2 Diagnostic information is accessed and interpreted

1.3 Diagnostic options are analysed and those most appropriate to the circumstances are selected

1.4 Hazards associated with the work are identified and risks are managed according to safety requirements  and AS 5732 Electric vehicle operations - Maintenance and repair

1.5 Diagnostic tools and equipment  are selected and checked for serviceability

2. Diagnose RESS

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 required repairs or adjustments are reported according to workplace procedures

3. Repair RESS

3.1 Repair information is accessed 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 RESS and components 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 are 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

4. Complete work processes

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 any faulty electrical equipment is identified, tagged and isolated according to workplace procedures

4.4 Workplace documentation is processed according to workplace procedures

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 

Description 

Learning skills to:

  • locate appropriate sources of information efficiently.

Reading skills to:

  • interpret text, symbols and wiring diagrams in diagnostic and repair information in manufacturer specifications, and workplace instructions and procedures.

Writing skills to:

  • legibly and accurately fill out workplace documentation when reporting diagnostic findings, making repair recommendations, and recording parts and material used.

Oral communication skills to:

  • clarify instructions
  • report diagnostic findings and make repair recommendations.

Numeracy skills to:

  • match electrical components and part identification numbers to workplace instructions, vehicle and component part lists, and manufacturer specifications
  • interpret vehicle electrical measurements and readings on digital and analogue gauges
  • measure voltage, current and resistance and use basic mathematical operations, including addition and subtraction, to calculate deviations from manufacturer specifications.

Planning and organising skills to:

  • plan own work requirements and prioritise actions to achieve required outcomes and ensure tasks are completed within workplace timeframes.

Technology skills to:

  • use specialised tools.

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:

  • 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 HEV and PHEV electrical systems
  • wearing jewellery while working around high electrical currents
  • determining appropriate procedures for minimising risk associated with hazards, including applying electrical safety precautions when:
  • using personal protective equipment (PPE), including electrical safety gloves with 1000 volt rating and Australian standards rated HV insulating mat
  • identifying and using firefighting equipment as appropriate
  • using the ‘one hand’ rule
  • following live system warning tags and signs
  • depowering vehicle
  • isolating HV RESS electrical supply
  • stabilising vehicle electrical system.

Tools and equipment  must include:

  • those specified in the specific vehicle service maintenance procedures, including:
  • digital multimeter with Cat III 1000 volt rating
  • insulation tester
  • residual voltage tester, if specified in original equipment manufacturer (OEM) test requirements
  • scan tool
  • oscilloscope.

Environmental requirements  must include:

  • procedures for trapping, storing and disposing of waste produced during repair procedures.

Unit Mapping Information

Equivalent to AURETH4010 Test high voltage batteries in hybrid electric vehicles

Links

Companion Volume implementation guides are found in VETNet - https://vetnet.education.gov.au/Pages/TrainingDocs.aspx?q=b4278d82-d487-4070-a8c4-78045ec695b1

 

Assessment requirements

Modification History

Release 

Comment 

Release 1 

New unit of competency.

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, performance criteria, range of conditions and foundation skills:

  • diagnose and repair high voltage (HV) rechargeable energy storage systems (RESS) in two different hybrid electric vehicles (HEVs) or plug-in hybrid electric vehicles (PHEVs) 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 RESS in HEVs and PHEVs, including procedures for:
  • identifying hazards and controlling risks associated with:
  • working with high voltages on HEV and PHEV electrical systems
  • wearing jewellery while working around high electrical currents
  • determining appropriate procedures for minimising risk associated with hazards, including applying electrical safety precautions when:
  • using personal protective equipment (PPE), including electrical safety gloves with 1000 volt rating and Australian standards rated HV insulating mat
  • identifying and using firefighting equipment as appropriate
  • using the ‘one hand’ rule
  • following live system warning tags and signs
  • depowering vehicle
  • isolating HV RESS electrical supply
  • stabilising vehicle electrical system
  • environmental requirements, including procedures for trapping, storing and disposing of waste released during repair procedures
  • requirements of AS 5732 Electric vehicle operations - Maintenance and repair
  • operating principles of HV RESS in HEVs and PHEVs, including:
  • battery pack construction, including:
  • battery types
  • battery internal resistance
  • battery pack system, including:
  • charging characteristics
  • open circuit cells
  • reverse polarisation
  • series cell configuration
  • strapping and layout
  • application, purpose and operation of RESS, including:
  • HV battery charger and direct current (DC) to DC converter
  • battery management system (BMS)
  • power distribution unit (PDU)
  • diagnostic testing procedures for HV RESS in HEVs and PHEVs, including:
  • accessing and interpreting scan tool system data, including:
  • diagnostic trouble codes (DTCs)
  • live data
  • freeze frame data
  • waveforms
  • using diagnostic flow charts
  • electrical system testing, including procedures for:
  • accessing electrical terminals and using test probes without damaging connectors, fuse holders or wiring
  • testing controller input and output signals and waveforms
  • vehicle dynamic and static testing procedures
  • analysing abnormal noise
  • analysing component failure
  • RESS cooling system testing
  • repair procedures for RESS, including:
  • tightening connections
  • replacing faulty or damaged cable connections
  • removing and replacing faulty or damaged components
  • removing and replacing motor controller
  • post-repair testing procedures for BEV, including:
  • DTC clearing procedures
  • checking for electrical connector mating
  • performance testing RESS.

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 RESS in HEVs and PHEVs that they have repaired, 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, including electrical safety gloves with 1000 volt rating and Australian standards rated HV insulating mat
  • manufacturer specifications for HEV or PHEV RESS
  • AS 5732 Electric vehicle operations - Maintenance and repair
  • two different HEVs or PHEVs RESS and associated components accessible for diagnosis and repair or replacement activities
  • electrical diagnostic equipment appropriate to the HEVs or PHEVs being diagnosed and repaired, including:
  • digital multimeter with Cat III 1000 volt rating
  • insulation tester
  • residual voltage tester, if specified in original equipment manufacturer (OEM) specifications
  • scan tool
  • oscilloscope
  • tools, equipment and materials appropriate for repairing HEV or PHEV RESS and their components.

Links

Companion Volume implementation guides are found in VETNet - https://vetnet.education.gov.au/Pages/TrainingDocs.aspx?q=b4278d82-d487-4070-a8c4-78045ec695b1

Companion Volume implementation guides are found in VETNet - https://vetnet.education.gov.au/Pages/TrainingDocs.aspx?q=b4278d82-d487-4070-a8c4-78045ec695b1

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