Assessor Resource

AURETH008
Diagnose and repair HVAC and rechargeable energy storage cooling systems in battery electric vehicle

Assessment tool

Version 1.0
Issue Date: April 2024


This unit describes the performance outcomes required to diagnose and repair faults in the heating, ventilation and air conditioning (HVAC) system and cooling system of the rechargeable energy storage system (RESS) of battery electric vehicles (BEVs). The unit involves removing and replacing refrigerant, as well as performance testing the HVAC and RESS cooling system. 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 high voltage (HV) RESS.

It applies to those working in the automotive service and repair industry. HVAC and RESS cooling systems include circuits in BEVs.

Licensing requirements apply to this unit. Users are advised to check with the relevant regulatory authority.

You may want to include more information here about the target group and the purpose of the assessments (eg formative, summative, recognition)


Evidence Required

List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.

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 HVAC and RESS cooling system

1.1 Job requirements are determined from workplace instructions

1.2 Diagnostic information is sourced 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 HVAC and RESS cooling system

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

3. Repair HVAC and RESS cooling system

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 HVAC and RESS cooling system 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 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

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

4.4 Australian Refrigeration Council accredited service decal sticker (ARCtick) and other required workplace documentation are completed and processed according to workplace procedures

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 heating, ventilation and air conditioning (HVAC) system and rechargeable energy storage system (RESS) cooling system components on two different battery electric vehicles (BEVs), in which the work must involve:

repairing or replacing one HVAC system component to correct performance deficiencies

repairing or replacing one RESS cooling system component to correct performance deficiencies.

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 HVAC and RESS cooling systems, 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

working with refrigerants at boiling point given risk of frostbite

working with system lubricants, including carcinogenic oils

handling flammable refrigerants

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 RESS electrical supply

stabilising the vehicle electrical system

environmental requirements, including procedures for:

trapping, storing and disposing of waste released from HVAC and RESS cooling systems

preventing the escape of refrigerant to the atmosphere

key requirements of AS 5732 Electric vehicle operations: Maintenance and repair

operating principles of HVAC systems and RESS cooling systems and associated components, including:

types of HVAC systems, including engine operated and electric motor operated systems

types of RESS and RESS charging

reasons for cooling the RESS

application, purpose and operation of HVAC systems and RESS cooling systems and components, including:

alternating current (AC) electric motor compressors

HVAC control units

HVAC control unit inputs and outputs

HVAC ejector cycle systems

RESS cooling systems, including air cooling, liquid cooling and HVAC cooled systems

diagnostic testing procedures for HVAC and RESS cooling systems, 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

determining damage to compressor motor windings

checking insulation resistance of compressor motor windings

checking routing and damage to HV cabling

HVAC dynamic and static testing

analysing abnormal noise

analysing component failure

repair procedures for HVAC systems and RESS cooling systems, including:

tightening connections

replacing faulty or damaged cable connections

removing and replacing faulty or damaged components

post-repair testing procedures for HVAC and RESS cooling systems, including:

DTC clearing procedures

checking for electrical connector mating

static and dynamic performance tests of HVAC systems and RESS cooling systems.

Assessors must satisfy NVR/AQTF assessor requirements and hold an Australian Refrigerant Council (ARC) Refrigerant Handling licence.

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 HVAC and RESS cooling systems 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

ARC accredited service decal sticker (ARCtick)

PPE and safety equipment, including electrical safety gloves with 1000 volt rating and HV insulating mat with Australian standards rating

manufacturer specifications for BEV HVAC and RESS cooling systems

AS 5732 Electric vehicle operations: Maintenance and repair

two different BEVs with HVAC and RESS cooling system components accessible for diagnosis and repair or replacement activities

electrical diagnostic equipment appropriate to the BEV HVAC and RESS cooling being diagnosed and repaired as specified under tools and equipment in the range of conditions

tools, equipment and materials appropriate for repairing HVAC and RESS cooling systems in BEVs.

Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assingnment, checklist) and due date here

Assessment task 1: [title]      Due date:

(add new lines for each of the assessment tasks)

Assessment Tasks

Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.

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 HVAC and RESS cooling system

1.1 Job requirements are determined from workplace instructions

1.2 Diagnostic information is sourced 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 HVAC and RESS cooling system

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

3. Repair HVAC and RESS cooling system

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 HVAC and RESS cooling system 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 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

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

4.4 Australian Refrigeration Council accredited service decal sticker (ARCtick) and other required workplace documentation are completed and processed according to workplace procedures

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 BEV electrical systems

wearing jewellery whilst working around high electrical currents

working with refrigerants at boiling point given risk of frostbite

working with system lubricants, including carcinogenic oils

handling flammable refrigerants

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.

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

scan tool

residual voltage tester, if specified in original equipment manufacturer (OEM) test requirements

temperature and pressure measuring equipment, including:

manifold and gauge set

contact thermometer

infrared thermometer (pyrometer)

electronic temperature probe

psychrometer (humidity detector)

digital vacuum gauge (vacrometer)

refrigerant leak detecting equipment, including electronic leak detector

refrigerant recovery equipment, including:

recovery unit

vacuum pump

electronic scales

miscellaneous equipment, including:

valve core removing or replacement tool

oil injector.

Environmental requirements must include:

procedures for:

trapping, storing and disposing of waste released from HVAC and RESS cooling systems

preventing the escape of refrigerant to the atmosphere.

Australian Refrigeration Council accredited service decal sticker (ARCtick) information must include:

name of the service organisation

name of technician

Refrigerant Handling Licence Number

vehicle registration number

service date

refrigerant type

lubricant type.

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 heating, ventilation and air conditioning (HVAC) system and rechargeable energy storage system (RESS) cooling system components on two different battery electric vehicles (BEVs), in which the work must involve:

repairing or replacing one HVAC system component to correct performance deficiencies

repairing or replacing one RESS cooling system component to correct performance deficiencies.

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 HVAC and RESS cooling systems, 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

working with refrigerants at boiling point given risk of frostbite

working with system lubricants, including carcinogenic oils

handling flammable refrigerants

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 RESS electrical supply

stabilising the vehicle electrical system

environmental requirements, including procedures for:

trapping, storing and disposing of waste released from HVAC and RESS cooling systems

preventing the escape of refrigerant to the atmosphere

key requirements of AS 5732 Electric vehicle operations: Maintenance and repair

operating principles of HVAC systems and RESS cooling systems and associated components, including:

types of HVAC systems, including engine operated and electric motor operated systems

types of RESS and RESS charging

reasons for cooling the RESS

application, purpose and operation of HVAC systems and RESS cooling systems and components, including:

alternating current (AC) electric motor compressors

HVAC control units

HVAC control unit inputs and outputs

HVAC ejector cycle systems

RESS cooling systems, including air cooling, liquid cooling and HVAC cooled systems

diagnostic testing procedures for HVAC and RESS cooling systems, 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

determining damage to compressor motor windings

checking insulation resistance of compressor motor windings

checking routing and damage to HV cabling

HVAC dynamic and static testing

analysing abnormal noise

analysing component failure

repair procedures for HVAC systems and RESS cooling systems, including:

tightening connections

replacing faulty or damaged cable connections

removing and replacing faulty or damaged components

post-repair testing procedures for HVAC and RESS cooling systems, including:

DTC clearing procedures

checking for electrical connector mating

static and dynamic performance tests of HVAC systems and RESS cooling systems.

Assessors must satisfy NVR/AQTF assessor requirements and hold an Australian Refrigerant Council (ARC) Refrigerant Handling licence.

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 HVAC and RESS cooling systems 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

ARC accredited service decal sticker (ARCtick)

PPE and safety equipment, including electrical safety gloves with 1000 volt rating and HV insulating mat with Australian standards rating

manufacturer specifications for BEV HVAC and RESS cooling systems

AS 5732 Electric vehicle operations: Maintenance and repair

two different BEVs with HVAC and RESS cooling system components accessible for diagnosis and repair or replacement activities

electrical diagnostic equipment appropriate to the BEV HVAC and RESS cooling being diagnosed and repaired as specified under tools and equipment in the range of conditions

tools, equipment and materials appropriate for repairing HVAC and RESS cooling systems in BEVs.
Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.

Observation Checklist

Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice Yes No Comments/feedback
Job requirements are determined from workplace instructions 
Diagnostic information is sourced and interpreted 
Diagnostic options are analysed and those most appropriate to the circumstances are selected 
Hazards associated with the work are identified and risks are managed according to safety requirements and AS 5732 Electric vehicle operations: Maintenance and repair 
Diagnostic tools and equipment are selected and checked for serviceability 
Diagnostic tests are carried out according to manufacturer specifications, workplace procedures and safety requirements 
Faults are identified from diagnostic test results and causes of faults are determined 
Diagnosis findings and recommendations for necessary repairs or adjustments are reported according to workplace procedures 
Repair information is sourced and interpreted 
Repair options are analysed and those most appropriate to the circumstances are selected 
Repair tools, equipment and materials are selected and checked 
RESS service plug or manual service disconnect is located and isolated to depower vehicle HV RESS according to manufacturer specifications 
HVAC and RESS cooling system 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 
RESS service plug or manual service disconnect is reconnected and vehicle is reactivated 
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 
Final inspection is made to ensure work is to workplace expectations and vehicle is presented ready for use 
Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected 
Tools and equipment are checked and stored and faulty electrical equipment is identified, tagged and isolated according to workplace procedures 
Australian Refrigeration Council accredited service decal sticker (ARCtick) and other required workplace documentation are completed and processed according to workplace procedures 
Job requirements are determined from workplace instructions 
Diagnostic information is sourced and interpreted 
Diagnostic options are analysed and those most appropriate to the circumstances are selected 
Hazards associated with the work are identified and risks are managed according to safety requirements and AS 5732 Electric vehicle operations: Maintenance and repair 
Diagnostic tools and equipment are selected and checked for serviceability 
Diagnostic tests are carried out according to manufacturer specifications, workplace procedures and safety requirements 
Faults are identified from diagnostic test results and causes of faults are determined 
Diagnosis findings and recommendations for necessary repairs or adjustments are reported according to workplace procedures 
Repair information is sourced and interpreted 
Repair options are analysed and those most appropriate to the circumstances are selected 
Repair tools, equipment and materials are selected and checked 
RESS service plug or manual service disconnect is located and isolated to depower vehicle HV RESS according to manufacturer specifications 
HVAC and RESS cooling system 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 
RESS service plug or manual service disconnect is reconnected and vehicle is reactivated 
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 
Final inspection is made to ensure work is to workplace expectations and vehicle is presented ready for use 
Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected 
Tools and equipment are checked and stored and faulty electrical equipment is identified, tagged and isolated according to workplace procedures 
Australian Refrigeration Council accredited service decal sticker (ARCtick) and other required workplace documentation are completed and processed according to workplace procedures 

Forms

Assessment Cover Sheet

AURETH008 - Diagnose and repair HVAC and rechargeable energy storage cooling systems in battery electric vehicle
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Assessment Record Sheet

AURETH008 - Diagnose and repair HVAC and rechargeable energy storage cooling systems in battery electric vehicle

Student name:

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Assessment task 1: [title] Result: Competent Not yet competent

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