AURETH009 - Diagnose and repair DC to DC converters in battery electric vehicles
Assessor Resource
AURETH009 Diagnose and repair DC to DC converters in battery electric vehicles
Assessment tool
Version 1.0 Issue Date: April 2024
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.
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 DC to DC converter
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
2. Diagnose DC to DC converter
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 DC to DC converter
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
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 electric equipment is identified, tagged and isolated according to workplace procedures
4.4 Workplace documentation is 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 the DC to DC converter and its system components on two different battery electric vehicles (BEVs) 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 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.
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.
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 DC to DC converter
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
2. Diagnose DC to DC converter
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 DC to DC converter
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
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 electric equipment is identified, tagged and isolated according to workplace procedures
4.4 Workplace documentation is 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 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.
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
oscilloscope
residual voltage tester, if specified in original equipment manufacturer (OEM) test requirements.
Environmental requirements must include:
procedures for trapping, storing and disposing of waste produced during repair work.
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.
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.
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.
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
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
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 electric equipment is identified, tagged and isolated according to workplace procedures
Workplace documentation is 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
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
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 electric equipment is identified, tagged and isolated according to workplace procedures
Workplace documentation is processed according to workplace procedures
Forms
Assessment Cover Sheet
AURETH009 - Diagnose and repair DC to DC converters in battery electric vehicles
Assessment task 1: [title]
Student name:
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I declare that the assessment tasks submitted for this unit are my own work.
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Result: Competent Not yet competent
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Assessment Record Sheet
AURETH009 - Diagnose and repair DC to DC converters in battery electric vehicles
Student name:
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Assessment task 1: [title] Result: Competent Not yet competent
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Feedback to student:
Overall assessment result: Competent Not yet competent