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Elements and Performance Criteria

1. Identify and confirm the work requirement
   • Objective of the analysis and evaluation is determined from workplace instructions
   • Specifications for HEV, PHEV or BEV management system are sourced and interpreted
   • System faults, deficiencies or discrepancies are identified and confirmed
   • Hazards associated with the work are identified, appropriate precautions are taken, and risks are managed according to workplace procedures, safety requirements, and requirements of Australian Design Rules (ADRs) and AS 5732 Electric vehicle operations: Maintenance and repair
2. Prepare for analysis and evaluation
   • Evaluation criteria are developed or adopted to meet the objective of the analysis and evaluation
   • Analytical and evaluative methodology is developed or identified from technical information
   • Testing equipment is prepared according to manufacturer specifications and workplace procedures
   • Tools and materials required to support the diagnostic procedure are identified, selected, checked and prepared for use
   • HEV, PHEV or BEV management system and components are prepared for the diagnostic process
3. Carry out failure analysis
   • Selected analytical and evaluative methodology is followed according to manufacturer specifications and workplace procedures
   • Tests are carried out according to manufacturer specifications, workplace procedures, and safety and environmental requirements
   • Analytical and other diagnostic findings are verified, as required, by using reliable alternative or optional processes
   • Analytical findings and results are assessed against evaluation criteria
   • Valid conclusions are drawn from available evidence and documented according to workplace requirements
4. Make recommendations
   • Options for responding to the objective are determined from further research of technical support information
   • Rectification method is selected from an analysis of the options, operating conditions, requirements of ADRs and AS 5732
   • Report is prepared specifying analysis and evaluation process, and detailing and justifying rectification method or variation to the rectification method
5. Complete work processes
   • Final inspection is made to ensure work is to workplace expectations
   • 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 any faulty electrical equipment is identified, tagged and isolated according to workplace procedures
   • Workplace documentation is processed according to workplace procedures
6. Identify and confirm the work requirement
   • Objective of the analysis and evaluation is determined from workplace instructions
   • Specifications for HEV, PHEV or BEV management system are sourced and interpreted
   • System faults, deficiencies or discrepancies are identified and confirmed
   • Hazards associated with the work are identified, appropriate precautions are taken, and risks are managed according to workplace procedures, safety requirements, and requirements of Australian Design Rules (ADRs) and AS 5732 Electric vehicle operations: Maintenance and repair
7. Prepare for analysis and evaluation
   • Evaluation criteria are developed or adopted to meet the objective of the analysis and evaluation
   • Analytical and evaluative methodology is developed or identified from technical information
   • Testing equipment is prepared according to manufacturer specifications and workplace procedures
   • Tools and materials required to support the diagnostic procedure are identified, selected, checked and prepared for use
   • HEV, PHEV or BEV management system and components are prepared for the diagnostic process
8. Carry out failure analysis
   • Selected analytical and evaluative methodology is followed according to manufacturer specifications and workplace procedures
   • Tests are carried out according to manufacturer specifications, workplace procedures, and safety and environmental requirements
   • Analytical and other diagnostic findings are verified, as required, by using reliable alternative or optional processes
   • Analytical findings and results are assessed against evaluation criteria
   • Valid conclusions are drawn from available evidence and documented according to workplace requirements
9. Make recommendations
   • Options for responding to the objective are determined from further research of technical support information
   • Rectification method is selected from an analysis of the options, operating conditions, requirements of ADRs and AS 5732
   • Report is prepared specifying analysis and evaluation process, and detailing and justifying rectification method or variation to the rectification method
10. Complete work processes
    • Final inspection is made to ensure work is to workplace expectations
    • 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 any faulty electrical 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 on vehicle electrical systems working with hazardous materials and toxic substances wearing jewellery while working around high electrical currents minimising risk, including: analysing task to define risk applying electrical safety precautions, including ‘one hand’ rule, live system warning tags and signs, depowering the vehicle, isolating the HV RESS electrical supply, and stabilising the vehicle HV electrical systems using personal protective equipment, including electrical safety gloves with 1000 volt rating and Australian standards rated HV insulating mat identifying fire safety equipment.

Analytical and evaluative methodology must include:

diagnostic process, sequence, tests and testing equipment.

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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 this unit’s elements, performance criteria, range of conditions and foundation skills:

analyse and evaluate an electrical or electronic fault in the network management systems of one hybrid electric vehicle (HEV) and one battery electric vehicle (BEV)

the above faults must involve two of the following:

battery management system (BMS)

rechargeable energy storage system (RESS)

power distribution unit (PDU)

high voltage traction motor drive assembly

direct current (DC) to DC converter assembly

RESS cooling system.

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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 analysing and evaluating electrical and electronic faults in HEV and BEV management systems, including procedures for:

identifying hazards and controlling risks associated with:

working with high voltages on vehicle electrical systems

working with hazardous materials and toxic substances

wearing jewellery while working around high electrical currents

minimising risk, including:

analysing task to define risk

applying electrical safety precautions, including ‘one hand’ rule, live system warning tags and signs, depowering the vehicle, isolating the HV RESS electrical supply, and stabilising the vehicle HV electrical systems

using personal protective equipment (PPE), including electrical safety gloves with 1000 volt rating and Australian standards rated HV insulating mat

identifying and using fire safety equipment

methods for locating and content of manufacturer specifications, workplace procedures, Australian standards and Australian Design Rules (ADRs) relating to embedded network management systems of HEV, plug-in hybrid electric vehicle (PHEV) and BEV

principles and processes involved in planning and implementing analysis and evaluation of electrical and electronic faults in HEV, PHEV and BEV embedded network management systems

design and planning of diagnostic procedures for electrical and electronic faults in HEV and BEV management systems, including procedures for diagnosing:

mechanical faults

electrical faults

electronics faults

types, function and operation of hybrid and battery electric vehicle systems, including:

DC electric motor types, including:

separately excited motors

permanent magnet motors

alternating current (AC) electric motor types, including:

induction motors

brushless motors

HV traction motor drive assembly and motor controllers, including:

variable pulse width DC types

variable frequency and variable amplitude AC motor types

on-board RESS system and batteries, including:

lead acid

nickel metal hydride

lithium ion

ultra capacitors and super capacitors

key features of associated components and systems, including:

BMS

PDU

DC to DC converter assembly

RESS cooling system, including the vehicle HVAC system

parallel HEVs and PHEVs

series HEVs and PHEVs

power split HEVs and PHEVs

testing procedures for HEV and BEV management systems, including:

vehicle dynamic and static testing procedures

abnormal noise analysis

component failure analysis

types, functions, operation and limitations of diagnostic testing equipment required to analyse and evaluate electrical and electronic faults in HEV, PHEV and BEV management systems

procedures for accessing and interpreting scan tool system data, including:

diagnostic trouble codes (DTCs), including:

conditions that set the DTCs

conditions for running DTCs

live data

freeze frame data

waveforms

procedures for documenting and reporting the analysis and evaluation process

requirements of AS 5732 Electric vehicle operations: Maintenance and repair relating to HEV, PHEV and BEV management systems.

requirements of Australian Design Rules (ADRs) relating to HEV, PHEV and BEV management systems.

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