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Elements and Performance Criteria

  1. Prepare for repair operations
  2. Test battery system
  3. Repair battery system
  4. Complete repair operations

Required Skills

Required skills

technical skills to

use workplace technology relating to testing and repairing BEV HV battery systems and components

use specialist tools and equipment

use computerised measuring equipment

report and record actions

communication skills to

confirm work requirements and specifications

communicate effectively regarding work requirements with supervisor other workers and customers

report work outcomes and problems

literacy skills to interpret technical information and specifications

numeracy skills to complete tests and measurements to determine correct operation

problemsolving skills to

interpret test results

identify repair options

selfmanagement skills to

manage risks and hazards associated with HV BEV battery systems and components

optimise workflow and productivity

Required knowledge

components of HV battery systems and their functions

battery management system BMS theory

battery theory including

battery internal resistance

battery types

terminal corrosion

terminal resistance

battery pack theory including

cell failure theory

charging characteristics

open circuit cells

reverse polarisation

series cell configuration

strapping and layout

HV battery charger and DC to DC converter characteristics

WHS requirements relating to

safe work practices

electrical safety

power distribution unit PDU theory

principles of electricity including AC and DC

principles of operation of HV battery systems

applicable commonwealth state or territory legislation regulations standards codes of practice and environmental regulations relating to the repair of HV battery systems

vehiclespecific electrical requirements

workplace policies and procedures including quality recording and reporting procedures relating to the repair of HV BEV battery systems

Evidence Required

The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria required skills and knowledge range statement and the Assessment Guidelines for the Training Package

Overview of assessment

Critical aspects for assessment and evidence required to demonstrate competency in this unit

The evidence required to demonstrate competency in this unit must be relevant to workplace operations and satisfy all of the requirements of the performance criteria and required skills and knowledge

A person who demonstrates competency in this unit must be able to

comply with WHS requirements and safe work practices

ensure electrical and mechanical integrity of any component or system is maintained when performing tests

check HV battery system performance against manufacturers specifications

replace repair and adjust HV battery system components as required to correct deficiencies

complete relevant documentation for the repair of the HV battery system

Context of and specific resources for assessment

Competency is to be assessed in the workplace or a simulated workplace environment that accurately reflects performance in a real workplace setting

Assessment is to occur

using standard workplace practices and procedures

following safety requirements

applying environmental constraints

Assessment is to comply with relevant

regulatory requirements

Australian standards

industry codes of practice

Competency is to be assessed using a BEV that uses HV and LV ACDC electrical systems Where simulation is used an operational BEV must be included in the simulation

The following resources must be made available for the assessment of this unit

appropriate PPE

a BEV

manufacturer specifications for the BEV

testing equipment

full range of essential tools and equipment

workplace documentation

Method of assessment

Assessment must satisfy the endorsed Assessment Guidelines of this Training Package

Assessment methods must confirm consistency and accuracy of performance over time and in a range of workplace relevant contexts together with the application of required skills and knowledge

Assessment methods must be by direct observation of tasks and include questioning on required skills and knowledge to ensure correct interpretation and application

Competence in this unit may be assessed in conjunction with other units which together form part of an holistic work role

Where applicable reasonable adjustment must be made to work environments and training situations to accommodate the needs of diverse clients

Assessment processes and techniques must be culturally sensitive and appropriate to the language literacy and numeracy capacity of the candidate and the work being performed


Range Statement

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Repair information may include:

Australian standards

diagrams and sketches

engineer or manufacturer design specifications and instructions

industry codes of practice

parts catalogues

verbal, written and graphical instructions issued by authorised internal and external persons

workplace specifications and requirements.

WHS requirements may include:

elimination of hazardous materials and substances

first aid equipment

following emergency procedures

hazard and risk control

material safety data sheets (MSDS)

personal protective equipment (PPE) and clothing

safety equipment

techniques for manual handling, including shifting, lifting and carrying.

Appropriate precautions may include:

analysing task to define risk

applying electrical safety precautions, such as:

“one hand rule”

live system warning tags and signs

isolating the HV battery supply

depowering the vehicle

using PPE, such as:

electrical safety gloves 1000V

HV insulating mats (Australian standards rated).

Testing equipment may include:

AC/DC current clamp

BMS diagnostic equipment

diagnostic scanner

insulation or mega ohm tester

multimeter CAT 3 1000V

oscilloscope

thermal imaging equipment or non-contact thermometer.

Electrical efficiency relates to:

charging

discharge rate

holding capacity

temperature

voltage.

Test procedures may include:

battery charging interlock

battery cooling system

BMS

HV contactors

HV current leakage to vehicle chassis

HV fuse

inertia safety cut-out switch

isolation/cut-off emergency device

leakage of electrolyte

loose cable connections

mounting of batteries

on-board battery charging system

PDU.

Appropriate corrective action may include:

balancing state of charge

replacing cable connection

replacing system component

replacing the battery

tightening connection.

Workplace requirements may include:

industry codes of practice

manufacturer specifications

quality policies and procedures

safe work procedures

sustainability, environment, equal opportunity and anti-discrimination policies and procedures

workplace recording and reporting procedures.