Unit of Competency Mapping – Information for Teachers/Assessors – Information for Learners

AURETH009 Mapping and Delivery Guide
Diagnose and repair DC to DC converters in battery electric vehicles

Version 1.0
Issue Date: March 2024


Qualification -
Unit of Competency AURETH009 - Diagnose and repair DC to DC converters in battery electric vehicles
Description
Employability Skills
Learning Outcomes and Application 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.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.

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.

Prerequisites/co-requisites
Competency Field Electrical
Development and validation strategy and guide for assessors and learners Student Learning Resources Handouts
Activities
Slides
PPT
Assessment 1 Assessment 2 Assessment 3 Assessment 4
Elements of Competency Performance Criteria              
Element: 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
       
Element: 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
       
Element: 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
       
Element: 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
       
Element: 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
       
Element: 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
       
Element: 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
       
Element: 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
       


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.


Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assignment, 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.

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:

Student ID:

I declare that the assessment tasks submitted for this unit are my own work.

Student signature:

Result: Competent Not yet competent

Feedback to student

 

 

 

 

 

 

 

 

Assessor name:

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Assessment Record Sheet

AURETH009 - Diagnose and repair DC to DC converters in battery electric vehicles

Student name:

Student ID:

Assessment task 1: [title] Result: Competent Not yet competent

(add lines for each task)

Feedback to student:

 

 

 

 

 

 

 

 

Overall assessment result: Competent Not yet competent

Assessor name:

Signature:

Date:

Student signature:

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