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

AURETH4009 Mapping and Delivery Guide
Diagnose and repair DC to DC converters in battery electric vehicles

Version 1.0
Issue Date: April 2024


Qualification -
Unit of Competency AURETH4009 - Diagnose and repair DC to DC converters in battery electric vehicles
Description This unit describes the performance outcomes required to diagnose and repair high voltage (HV) direct current (DC) to low voltage (LV) DC converters in battery electric vehicles (BEVs). It involves working with LV automotive electrical components as well as HV alternating current (AC) and DC automotive electrical components and battery systems. Work includes testing the converter and relevant accessories and applications for correct operation. Importance is placed on the application of HV safety procedures.Licensing, legislative, regulatory or certification requirements may apply to this unit in some jurisdictions. Users are advised to check with the relevant regulatory authority.
Employability Skills This unit contains employability skills.
Learning Outcomes and Application Work applies to the diagnosis, repair and replacement of the DC to DC converter in BEVs in the automotive industry.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.
Prerequisites/co-requisites AURETH3001 Depower battery electric vehiclesAURETR3025 Test, charge and replace batteries
Competency Field
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 for repair operations
  • Procedures and information relevant to the task are sourced and work requirements confirmed
  • Workplace health and safety (WHS) requirements and appropriate precautions are identified and applied
  • Repair methods for the specific work requirement are selected and prepared for
  • Tools and testing equipment necessary to conduct the work are assembled
  • Technical and/or calibration requirements for diagnosis and repair of the DC to DC converter are established
       
Element: Perform diagnosis
  • Tests and checks on DC to DC converter input and output voltage and current are carried out using manufacturer specifications and test procedures
  • Relevant applications and accessories are tested and checked for correct operation
  • Test results are recorded
       
Element: Repair DC to DC converter
  • Test results are compared with manufacturer specifications to decide on corrective action
  • Components are removed and repaired or replaced as required
  • Replaced or repaired components are re-tested for correct operation
  • Replacement, repair or adjustment procedures are recorded on job card or repair order
       
Element: Complete repair operations
  • Work area is tidied, and tools and equipment replaced according to workplace requirements
  • Job card or repair order is completed according to workplace requirements
  • Client report is prepared on the outcomes of the diagnosis and repair according to workplace requirements
  • Vehicle is prepared for return to the client
       


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.

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 the DC to DC converter is maintained when performing tests

diagnose the operation of the DC to DC converter against manufacturer specifications

remove and replace or repair the DC to DC converter

complete relevant documentation for the diagnosis and repair of the DC to DC converter.

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 AC/DC 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 a 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.

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.

Required skills

technical skills to:

use workplace technology relating to the diagnosis and repair of BEV DC to DC converters

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 accurately complete tests and measurements to determine correct operation

problem-solving skills to:

interpret test results

identify repair options

self-management skills to:

manage risks and hazards associated with the diagnosis and repair of BEV DC to DC converters

optimise workflow and productivity

Required knowledge

components of HV BEVs and their functions

WHS requirements relating to:

safe work practices

electrical safety

principles of electricity, including AC and DC

principles of operation of a DC to DC converter

applicable commonwealth, state or territory legislation, regulations, standards and codes of practice and environmental regulations relating to the diagnosis and repair of a BEV DC to DC converter

vehicle-specific electrical requirements

workplace policies and procedures, including quality, recording and reporting procedures relating to the diagnosis and repair of a BEV DC to DC converter

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, 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.

Procedures and information may include:

Australian standards

diagrams and sketches

engineer or manufacturer design specifications and instructions

industry codes of practice

material safety data sheets (MSDS)

parts catalogues

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

workplace specifications and requirements.

WHS requirements may include:

eliminating hazardous materials and substances

first aid equipment

following emergency procedures

hazard and risk control

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 or signs

checking for residual voltage

depowering the vehicle

isolating the HV battery electrical supply

using PPE, such as:

electrical safety gloves 1000V

HV insulating mats (Australian standards rated).

Testing equipment may include:

AC/DC current clamp

battery management system (BMS) diagnostic equipment

multimeter CAT 3 1000V

oscilloscope

thermal imaging equipment or non-contact thermometer.

Tests and checks may include:

testing accessories and applications operating on LV DC

testing input and output voltage and current.

Applications and accessories may include:

electric power steering (EPS)

electric vacuum pump

electric coolant pumps in:

heating, ventilation and air conditioning (HVAC) system

powertrain cooling system

battery pack cooling system

horn

wipers

radio

lights

indicators.

Corrective action may include:

removing and replacing converter

replacing fuses.

Workplace requirements may include:

manufacturer specifications and industry codes of practice

quality policies and procedures

safe work procedures

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

workplace recording and reporting procedures.

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
Procedures and information relevant to the task are sourced and work requirements confirmed 
Workplace health and safety (WHS) requirements and appropriate precautions are identified and applied 
Repair methods for the specific work requirement are selected and prepared for 
Tools and testing equipment necessary to conduct the work are assembled 
Technical and/or calibration requirements for diagnosis and repair of the DC to DC converter are established 
Tests and checks on DC to DC converter input and output voltage and current are carried out using manufacturer specifications and test procedures 
Relevant applications and accessories are tested and checked for correct operation 
Test results are recorded 
Test results are compared with manufacturer specifications to decide on corrective action 
Components are removed and repaired or replaced as required 
Replaced or repaired components are re-tested for correct operation 
Replacement, repair or adjustment procedures are recorded on job card or repair order 
Work area is tidied, and tools and equipment replaced according to workplace requirements 
Job card or repair order is completed according to workplace requirements 
Client report is prepared on the outcomes of the diagnosis and repair according to workplace requirements 
Vehicle is prepared for return to the client 

Forms

Assessment Cover Sheet

AURETH4009 - 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:

Signature:

Date:

Assessment Record Sheet

AURETH4009 - 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:

Date: