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Elements and Performance Criteria

  1. Prepare to diagnose and repair HVAC and RESS cooling system
  2. Diagnose HVAC and RESS cooling system
  3. Repair HVAC and RESS cooling system
  4. Complete work processes
  5. Prepare to diagnose and repair HVAC and RESS cooling system
  6. Diagnose HVAC and RESS cooling system
  7. Repair HVAC and RESS cooling system
  8. Complete work processes

Range Statement

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.


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 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.


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 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.