AURETH4008 Diagnose and repair high voltage cabin heating and cooling systems in battery electric vehicles

Release 2

AURETH4008 Diagnose and repair high voltage cabin heating and cooling systems in battery electric vehicles

Modification History

Release	Comment
Release 2	Replaces AURETH4008 Diagnose and repair high voltage cabin heating and cooling systems in battery electric vehicles (Release 1) Reference to OHS legislation replaced with new WHS legislation

Unit Descriptor

Unit descriptor	This unit describes the performance outcomes required to diagnose and repair high voltage (HV) systems used to heat, ventilate and cool the cabin in battery electric vehicles (BEVs). It involves testing systems for correct operation and replacing some components. It may include removal of refrigerant and replacement of refrigerant as well as performance testing of the system. Importance is placed on the application of HV safety procedures. Licensing, legislative, regulatory or certification requirements may apply to this unit in some jurisdictions, in particular if the work involves removal and replacement of refrigerant. Users are advised to check with the relevant regulatory authority.

Application of the Unit

Application of the unit	Work applies to the diagnosis and repair of HV cabin heating, ventilation and air conditioning (HVAC) systems in BEVs in the automotive industry.

Licensing/Regulatory Information

Refer to Unit Descriptor.

Pre-Requisites

Prerequisite units	AURETH3001 Depower battery electric vehicles

Employability Skills Information

Employability skills	This unit contains employability skills.

Elements and Performance Criteria Pre-Content

Elements describe the essential outcomes of a unit of competency.	Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold italicised text is used, further information is detailed in the required skills and knowledge section and the range statement. Assessment of performance is to be consistent with the evidence guide.

Elements and Performance Criteria

ELEMENT	PERFORMANCE CRITERIA
1. Prepare for repair operations	1.1. Procedures and information relevant to the task are sourced and work requirements confirmed 1.2. Workplace health and safety (WHS) requirements and appropriate precautions are identified and applied 1.3. Repair methods for the specific work requirement are selected and prepared for 1.4. Tools and testing equipment necessary to conduct the work are assembled 1.5. Technical and/or calibration requirements for diagnosis and repair of HV HVAC systems are established
2. Perform diagnosis	2.1. Tests and checks on HVAC adjustment and activation controls are carried out using manufacturer specifications and test procedures 2.2. Air conditioning and electric heater systems are tested for correct operation 2.3. HVAC contactors are tested for correct operation 2.4. Results of diagnosis are recorded
3. Repair HVAC system	3.1. Results are compared with manufacturer specifications to decide on appropriate corrective action 3.2. Components are removed and replaced as required 3.3. Replaced components are re-tested for correct operation 3.4. Replacement, repair or adjustment procedures carried out are recorded
4. Complete repair operations	4.1. Work area is tidied, and tools and equipment replaced according to workplace requirements 4.2. Job card or repair order is completed according to workplace requirements 4.3. Client report is prepared on the outcomes of the repair according to workplace requirements 4.4. Vehicle is prepared for return to the client

Required Skills and Knowledge

This section describes the skills and knowledge required for this unit.
Required skills
technical skills to: use workplace technology relating to the diagnosis and repair of HV HVAC systems in BEVs use specialist tools and equipment use computerised measuring equipment report and record actions communication skills to: confirm work requirements and specifications communicate effectively regarding work requirements with supervisor, other workers and customers report work outcomes and problems literacy skills to interpret technical information and specifications numeracy skills to complete tests and measurements to determine correct operation problem-solving skills to: interpret test results identify repair options self-management skills to: manage risks and hazards associated with BEV electrical and HVAC systems and components optimise workflow and productivity
Required knowledge
components of HV BEVs and their functions WHS requirements relating to: electrical safety safe work practices principles of electricity, including: alternating current (AC) direct current (DC) principles of operation of HV HVAC systems risks associated when working with refrigerants and non-conductive lubricants and prevention of cross-contamination applicable commonwealth, state or territory legislation, regulations, standards and codes of practice and environmental regulations relating to the diagnosis and repair of BEV HVAC systems vehicle-specific electrical requirements workplace policies and procedures, including quality, recording and reporting procedures relating to the diagnosis and repair of BEV HVAC systems

Evidence Guide

Evidence Guide
The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.
Overview of assessment
Critical aspects for assessment and evidence required to demonstrate competency in this unit	The evidence required to demonstrate competency in this unit must be relevant to workplace operations and satisfy all of the requirements of the performance criteria and required skills and knowledge. A person who demonstrates competency in this unit must be able to: comply with WHS requirements and safe work practices ensure electrical and mechanical integrity of the HVAC components is maintained when performing tests check the operation of the HV HVAC systems against manufacturer specifications diagnose and replace, repair or adjust system components as required to correct deficiencies complete relevant documentation.
Context of, and specific resources for assessment	Competency is to be assessed in the workplace or a simulated workplace environment that accurately reflects performance in a real workplace setting. Assessment is to occur: using standard workplace practices and procedures following safety requirements applying environmental constraints. Assessment is to comply with relevant: regulatory requirements Australian standards industry codes of practice. Competency is to be assessed using a BEV that uses HV and LV AC/DC electrical systems. Where simulation is used, an operational BEV must be included in the simulation. The following resources should be made available: appropriate PPE a BEV manufacturer specifications for the BEV testing equipment full range of essential tools and equipment workplace documentation.
Method of assessment	Assessment must satisfy the endorsed Assessment Guidelines of this Training Package. Assessment methods must confirm consistency and accuracy of performance (over time and in a range of workplace relevant contexts) together with the application of required skills and knowledge. Assessment methods must be by direct observation of tasks and include questioning on required skills and knowledge to ensure correct interpretation and application. Competence in this unit may be assessed in conjunction with other units which together form part of a holistic work role. Where applicable, reasonable adjustment must be made to work environments and training situations to accommodate the needs of diverse clients. Assessment processes and techniques must be culturally sensitive and appropriate to the language, literacy and numeracy capacity of the candidate and the work being performed.

Range Statement

Range Statement
The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.
Procedures and information may include:	Australian standards diagrams and sketches engineer or manufacturer design specifications and instructions industry codes of practice material safety data sheets (MSDS) parts catalogues verbal, written and graphical instructions issued by authorised internal and external persons workplace specifications and requirements.
WHS requirements may include:	elimination of hazardous materials and substances first aid equipment following emergency procedures hazard and risk control personal protective equipment (PPE) and clothing safety equipment techniques for manual handling, including shifting, lifting and carrying.
Appropriate precautions may include:	analysing task to define risk applying electrical safety precautions, such as: “one hand rule” live system warning tags or signs checking system for residual voltage depowering the vehicle isolating the HV battery electrical supply using PPE, such as: electrical safety gloves 1000V HV insulating mats (Australian standards rated).
Testing equipment may include:	AC/DC current clamp air conditioning system service equipment battery management system (BMS) diagnostic equipment insulation or mega ohm tester multimeter CAT 3 1000V oscilloscope refrigerant leak detecting equipment thermal imaging equipment or non-contact thermometer.
Tests and checks may include:	operational tests of heating, ventilation and air conditioning refrigerant leak detecting testing of contactors.
Corrective action may include:	removing and replacing control units removing and replacing heater coolant removing and replacing heating elements removing and replacing HVAC components, such as condenser, evaporator, compressor and heater core.
Workplace requirements may include:	industry codes of practice manufacturer specifications quality policies and procedures safe work procedures sustainability, environment, equal opportunity and anti-discrimination policies and procedures workplace recording and reporting procedures.

Unit Sector(s)

Competency field	Electrical
Sector	Technical – Hybrid and Battery Electric Vehicle

Custom Content Section

Not applicable.