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

AURETU005 Mapping and Delivery Guide
Retrofit and modify air conditioning and HVAC systems

Version 1.0
Issue Date: March 2024


Qualification -
Unit of Competency AURETU005 - Retrofit and modify air conditioning and HVAC systems
Description
Employability Skills
Learning Outcomes and Application This unit describes the performance outcomes required to retrofit and modify air conditioning systems, including heating, ventilation and air conditioning (HVAC) systems, fitted to a range of vehicles and machinery. It involves preparing for the task, selecting the correct de-gas procedure, carrying out the retrofit and modification procedures, performing post-modification testing, and completing workplace processes and documentation.Air conditioning systems may contain a mixture of both natural and flammable synthetic refrigerants that are difficult to accurately identify and safely recover. To minimise the possibility of ignition, the procedures and equipment used when recovering refrigerants must be those required for flammable refrigerants.It applies to those working in the automotive service and repair industry. Automotive air conditioners, including HVAC systems, include those in agricultural machinery, heavy commercial vehicles, light vehicles or mobile plant machinery.Licensing requirements apply to this unit. Users are advised to check with relevant regulatory authority. An Australian Refrigeration Council accredited (ARCtick) Refrigerant Handling licence is required for those carrying out this work.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.

Assessors must satisfy NVR/AQTF assessor requirements and hold an Australian Refrigerant Council (ARC) Refrigerant Handling licence.

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 air conditioning and HVAC systems that they have retrofitted and modified, 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

workplace instructions

vehicle or machinery air conditioning and HVAC system manufacturer specifications

Australian automotive code of practice: Control of refrigerant gases during manufacture, installation, servicing or de-commissioning of motor vehicle air conditioners

two different vehicles or machinery with air conditioning and HVAC systems requiring retrofitting and modification

retrofit, modification and testing equipment for air conditioning and HVAC systems, including:

manifold and gauge set

recovery unit

vacuum pump

leak detector

refrigerant analyser.

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 retrofit system
  • Job requirements are determined from workplace instructions
  • Retrofit information, manufacturer specifications, and relevant code of practice are accessed and interpreted
  • Type of refrigerant is determined according to workplace procedures and safety and environmental requirements
  • Retrofit options are analysed and those most appropriate to the circumstances are selected
  • Hazards associated with the work are identified and risks are managed
  • Retrofit tools and equipment are selected and checked for serviceability
       
Element: De-gas system
  • System de-gas procedures are carried out according to manufacturer specifications, workplace procedures, and safety and environmental requirements, and without causing damage to components or system
  • Refrigerant is recovered into appropriate refrigerant recovery cylinder for the refrigerant type
  • Oil recovered is measured to determine replacement volume
  • System is evacuated according to manufacturer specifications, workplace procedures, and safety and environmental requirements
       
Element: Retrofit system
  • Technical information relating to vehicle or machinery being retrofitted is accessed and interpreted
  • Air conditioning retrofit modification procedures are carried out according to manufacturer specifications, workplace procedures, and safety and environmental requirements
  • System is pressure tested for leaks before being re-gassed according to manufacturer specifications, workplace procedures, and safety and environmental requirements
  • System is re-gassed with appropriate refrigerant gas and lubricating oil according to manufacturer specifications and workplace procedures
  • Post-modification testing is carried out according to workplace procedures and test results are checked to confirm system performance is operating to manufacturer specifications, reported pre-modification issue has been resolved, and no other faults are present
       
Element: Complete work processes
  • Final inspection is made to ensure work is to workplace expectations and the vehicle or machinery 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 any faulty electrical equipment is identified, tagged and isolated according to workplace procedures
  • Australian Refrigeration Council accredited (ARCtick)service decal sticker and other required workplace documentation are completed and processed according to workplace procedures
       
Element: Prepare to retrofit system
  • Job requirements are determined from workplace instructions
  • Retrofit information, manufacturer specifications, and relevant code of practice are accessed and interpreted
  • Type of refrigerant is determined according to workplace procedures and safety and environmental requirements
  • Retrofit options are analysed and those most appropriate to the circumstances are selected
  • Hazards associated with the work are identified and risks are managed
  • Retrofit tools and equipment are selected and checked for serviceability
       
Element: De-gas system
  • System de-gas procedures are carried out according to manufacturer specifications, workplace procedures, and safety and environmental requirements, and without causing damage to components or system
  • Refrigerant is recovered into appropriate refrigerant recovery cylinder for the refrigerant type
  • Oil recovered is measured to determine replacement volume
  • System is evacuated according to manufacturer specifications, workplace procedures, and safety and environmental requirements
       
Element: Retrofit system
  • Technical information relating to vehicle or machinery being retrofitted is accessed and interpreted
  • Air conditioning retrofit modification procedures are carried out according to manufacturer specifications, workplace procedures, and safety and environmental requirements
  • System is pressure tested for leaks before being re-gassed according to manufacturer specifications, workplace procedures, and safety and environmental requirements
  • System is re-gassed with appropriate refrigerant gas and lubricating oil according to manufacturer specifications and workplace procedures
  • Post-modification testing is carried out according to workplace procedures and test results are checked to confirm system performance is operating to manufacturer specifications, reported pre-modification issue has been resolved, and no other faults are present
       
Element: Complete work processes
  • Final inspection is made to ensure work is to workplace expectations and the vehicle or machinery 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 any faulty electrical equipment is identified, tagged and isolated according to workplace procedures
  • Australian Refrigeration Council accredited (ARCtick)service decal sticker and other required workplace documentation are completed and 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 retrofit system

1.1 Job requirements are determined from workplace instructions

1.2 Retrofit information, manufacturer specifications, and relevant code of practice are accessed and interpreted

1.3 Type of refrigerant is determined according to workplace procedures and safety and environmental requirements

1.4 Retrofit 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

1.6 Retrofit tools and equipment are selected and checked for serviceability

2. De-gas system

2.1 System de-gas procedures are carried out according to manufacturer specifications, workplace procedures, and safety and environmental requirements, and without causing damage to components or system

2.2 Refrigerant is recovered into appropriate refrigerant recovery cylinder for the refrigerant type

2.3 Oil recovered is measured to determine replacement volume

2.4 System is evacuated according to manufacturer specifications, workplace procedures, and safety and environmental requirements

3. Retrofit system

3.1 Technical information relating to vehicle or machinery being retrofitted is accessed and interpreted

3.2 Air conditioning retrofit modification procedures are carried out according to manufacturer specifications, workplace procedures, and safety and environmental requirements

3.3 System is pressure tested for leaks before being re-gassed according to manufacturer specifications, workplace procedures, and safety and environmental requirements

3.4 System is re-gassed with appropriate refrigerant gas and lubricating oil according to manufacturer specifications and workplace procedures

3.5 Post-modification testing is carried out according to workplace procedures and test results are checked to confirm system performance is operating to manufacturer specifications, reported pre-modification issue has been resolved, and no other faults are present

4. Complete work processes

4.1 Final inspection is made to ensure work is to workplace expectations and the vehicle or machinery 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 any faulty electrical equipment is identified, tagged and isolated according to workplace procedures

4.4 Australian Refrigeration Council accredited (ARCtick)service decal sticker and other required workplace documentation are completed and 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, performance criteria, range of conditions and foundation skills:

retrofit and modify the air conditioning and HVAC systems of two different vehicles or machinery, in which the work must include changing the type of refrigerant.

Individuals must be able to demonstrate knowledge of:

work health and safety (WHS) and occupational health and safety (OHS) requirements relating to retrofitting and modifying air conditioning and HVAC systems, including procedures for:

working with refrigerants at boiling point given risk of frostbite

working with system lubricants, including carcinogenic oils

identifying and handling flammable refrigerants, including hydrocarbon (HC) refrigerants

selecting and using personal protective equipment (PPE)

identifying firefighting equipment

environmental requirements, including procedures for:

preventing loss of refrigerant to the atmosphere

handling materials and refrigerant recovery equipment

key requirements of Australian automotive code of practice: Control of refrigerant gases during manufacture, installation, servicing or de-commissioning of motor vehicle air conditioners

application, purpose and operation of air conditioning and HVAC systems and components, including:

high pressure and low pressure sides of air conditioning systems

compressors, including:

piston, scroll and rotary vane compressors

electric compressors

variable displacement compressors

clutchless compressors electromagnetic clutches

condensers

receiver-dryers, including filters and desiccants

expansion valves, including capillary tubes

evaporators

thermostats

refrigerants, including R12, R134a, R1234yf, R290 and R600a blends

compressor oils

air conditioner and heating controls, including levers and ducting

air conditioner and heating electrical circuits and sensors, including:

high and low pressure switches

pressure relief valves

temperature sensors

climate control systems

procedures for retrofitting and modifying air conditioning and HVAC systems, including:

determining original system fitted to vehicle, including refrigerant and oil type and types of components

determining appropriate retrofit and modification options, including:

determining required system performance output

component replacement, including O rings and seals

refrigerant and oil selection

procedures for removing and replacing system components

procedures for changing system refrigerant, including:

changing refrigerant gas from R12 to R134a:

receiver dryer filter replacement

change system fittings for manifold gauge attachment

change oil type

changing refrigerant gas from R134a to R1234yf:

change refrigerant recharging ports

change system fittings for manifold gauge attachment

changing refrigerant gas from R134a to blends of R290 and R600a:

change refrigerant re-charging ports

change system fittings for manifold gauge attachment

procedures for recovering automotive refrigerant, including:

testing refrigerant to determine its type

connecting manifold and gauge set and recovery unit, including types and location of service ports

identifying recovery cylinder appropriate to the refrigerant

operating recovery unit, including weighing recovery cylinder before after recovery

disconnecting and storing recovery unit and cylinder

procedures for re-gassing air conditioning and HVAC systems, including:

testing system for leaks using vacuum and pressure testing

using manifold gauges to charge system

post-retrofit testing procedures for air conditioning and HVAC systems, including procedures for checking for:

refrigerant leaks

heater core and system water coolant leaks

static and dynamic performance tests of air conditioning and HVAC systems, including checking:

ambient temperature

vent temperature

condenser and suction line temperature

procedures for completing workplace documentation, including ARCtick service decal sticker.


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 retrofit system

1.1 Job requirements are determined from workplace instructions

1.2 Retrofit information, manufacturer specifications, and relevant code of practice are accessed and interpreted

1.3 Type of refrigerant is determined according to workplace procedures and safety and environmental requirements

1.4 Retrofit 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

1.6 Retrofit tools and equipment are selected and checked for serviceability

2. De-gas system

2.1 System de-gas procedures are carried out according to manufacturer specifications, workplace procedures, and safety and environmental requirements, and without causing damage to components or system

2.2 Refrigerant is recovered into appropriate refrigerant recovery cylinder for the refrigerant type

2.3 Oil recovered is measured to determine replacement volume

2.4 System is evacuated according to manufacturer specifications, workplace procedures, and safety and environmental requirements

3. Retrofit system

3.1 Technical information relating to vehicle or machinery being retrofitted is accessed and interpreted

3.2 Air conditioning retrofit modification procedures are carried out according to manufacturer specifications, workplace procedures, and safety and environmental requirements

3.3 System is pressure tested for leaks before being re-gassed according to manufacturer specifications, workplace procedures, and safety and environmental requirements

3.4 System is re-gassed with appropriate refrigerant gas and lubricating oil according to manufacturer specifications and workplace procedures

3.5 Post-modification testing is carried out according to workplace procedures and test results are checked to confirm system performance is operating to manufacturer specifications, reported pre-modification issue has been resolved, and no other faults are present

4. Complete work processes

4.1 Final inspection is made to ensure work is to workplace expectations and the vehicle or machinery 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 any faulty electrical equipment is identified, tagged and isolated according to workplace procedures

4.4 Australian Refrigeration Council accredited (ARCtick)service decal sticker and other required workplace documentation are completed and 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.

Code of practice must include:

Australian automotive code of practice: Control of refrigerant gases during manufacture, installation, servicing or de-commissioning of motor vehicle air conditioners.

Safety and environmental requirements must include:

work health and safety (WHS) and occupational health and safety (OHS) requirements, including procedures for:

working with refrigerants at boiling point given risk of frostbite

working with system lubricants, including carcinogenic oils

identifying flammable refrigerants, including hydrocarbon (HC) refrigerants

selecting and using personal protective equipment (PPE)

identifying firefighting equipment

environmental requirements, including procedures for:

preventing loss of refrigerant to the atmosphere

handling materials and refrigerant recovery equipment.

Australian Refrigeration Council accredited (ARCtick) service decal sticker information must include:

name of the service organisation

ARCtick business authority number

quantity of refrigerant added

refrigerant and oil type

service date

technician name and licence number.

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 
Retrofit information, manufacturer specifications, and relevant code of practice are accessed and interpreted 
Type of refrigerant is determined according to workplace procedures and safety and environmental requirements 
Retrofit options are analysed and those most appropriate to the circumstances are selected 
Hazards associated with the work are identified and risks are managed 
Retrofit tools and equipment are selected and checked for serviceability 
System de-gas procedures are carried out according to manufacturer specifications, workplace procedures, and safety and environmental requirements, and without causing damage to components or system 
Refrigerant is recovered into appropriate refrigerant recovery cylinder for the refrigerant type 
Oil recovered is measured to determine replacement volume 
System is evacuated according to manufacturer specifications, workplace procedures, and safety and environmental requirements 
Technical information relating to vehicle or machinery being retrofitted is accessed and interpreted 
Air conditioning retrofit modification procedures are carried out according to manufacturer specifications, workplace procedures, and safety and environmental requirements 
System is pressure tested for leaks before being re-gassed according to manufacturer specifications, workplace procedures, and safety and environmental requirements 
System is re-gassed with appropriate refrigerant gas and lubricating oil according to manufacturer specifications and workplace procedures 
Post-modification testing is carried out according to workplace procedures and test results are checked to confirm system performance is operating to manufacturer specifications, reported pre-modification issue has been resolved, and no other faults are present 
Final inspection is made to ensure work is to workplace expectations and the vehicle or machinery 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 any faulty electrical equipment is identified, tagged and isolated according to workplace procedures 
Australian Refrigeration Council accredited (ARCtick)service decal sticker and other required workplace documentation are completed and processed according to workplace procedures 
Job requirements are determined from workplace instructions 
Retrofit information, manufacturer specifications, and relevant code of practice are accessed and interpreted 
Type of refrigerant is determined according to workplace procedures and safety and environmental requirements 
Retrofit options are analysed and those most appropriate to the circumstances are selected 
Hazards associated with the work are identified and risks are managed 
Retrofit tools and equipment are selected and checked for serviceability 
System de-gas procedures are carried out according to manufacturer specifications, workplace procedures, and safety and environmental requirements, and without causing damage to components or system 
Refrigerant is recovered into appropriate refrigerant recovery cylinder for the refrigerant type 
Oil recovered is measured to determine replacement volume 
System is evacuated according to manufacturer specifications, workplace procedures, and safety and environmental requirements 
Technical information relating to vehicle or machinery being retrofitted is accessed and interpreted 
Air conditioning retrofit modification procedures are carried out according to manufacturer specifications, workplace procedures, and safety and environmental requirements 
System is pressure tested for leaks before being re-gassed according to manufacturer specifications, workplace procedures, and safety and environmental requirements 
System is re-gassed with appropriate refrigerant gas and lubricating oil according to manufacturer specifications and workplace procedures 
Post-modification testing is carried out according to workplace procedures and test results are checked to confirm system performance is operating to manufacturer specifications, reported pre-modification issue has been resolved, and no other faults are present 
Final inspection is made to ensure work is to workplace expectations and the vehicle or machinery 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 any faulty electrical equipment is identified, tagged and isolated according to workplace procedures 
Australian Refrigeration Council accredited (ARCtick)service decal sticker and other required workplace documentation are completed and processed according to workplace procedures 

Forms

Assessment Cover Sheet

AURETU005 - Retrofit and modify air conditioning and HVAC systems
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

AURETU005 - Retrofit and modify air conditioning and HVAC systems

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: