Unit of competency details
AURETH003 - Diagnose and repair high voltage rechargeable energy storage systems in battery electric vehicle (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Superseded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
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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 the high voltage (HV) rechargeable energy storage systems (RESS) of battery electric vehicles (BEVs). 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
AURETH001 Depower and reinitialise battery electric vehicles
Competency Field
Electrical
Unit Sector
Technical - Hybrid Vehicle and Battery Electric Vehicle
Elements and Performance Criteria
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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 HV RESS
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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
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2. Diagnose RESS
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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 required repairs or adjustments are reported according to workplace procedures
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3. Repair RESS
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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
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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 any faulty electrical 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.
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Skills
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Description
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Learning skills to:
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- locate appropriate 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 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.
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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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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.
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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 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
- using the ‘one hand rule’
- following live system warning tags and signs
- depowering vehicle
- isolating HV RESS electrical supply
- stabilising 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
- residual voltage tester, if specified in original equipment manufacturer (OEM) test requirements
- scan tool
- oscilloscope.
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Environmental requirements must include:
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- procedures for trapping, storing and disposing of waste produced during repair procedures.
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Unit Mapping Information
Equivalent to AURETH4003 Test and repair high voltage battery systems 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
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Release
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Comment
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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, performance criteria, range of conditions and foundation skills:
- diagnose and repair high voltage (HV) rechargeable energy storage systems (RESS) in 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 RESS in BEVs, including procedures for:
- identifying hazards and controlling risks associated with:
- working with high voltages on 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 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 BEVs, 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 BEVs, 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 BEVs 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 BEV and RESS
- AS 5732 Electric vehicle operations - Maintenance and repair
- two different BEVs with RESS and associated components accessible for diagnosis 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
- residual voltage tester, if specified in original equipment manufacturer (OEM) specifications
- scan tool
- oscilloscope
- tools, equipment and materials appropriate for repairing BEV RESS and their components.
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
