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Elements and Performance Criteria

1. Prepare to diagnose and repair DC to DC converter
   • 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
2. Diagnose DC to DC converter
   • 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
3. Repair DC to DC converter
   • 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
4. Complete work processes
   • 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
5. Prepare to diagnose and repair DC to DC converter
   • 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
6. Diagnose DC to DC converter
   • 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
7. Repair DC to DC converter
   • 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
8. Complete work processes
   • 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

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 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.

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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 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.

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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 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.

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