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

AURETU007 Mapping and Delivery Guide
Overhaul air conditioning and HVAC system compressors

Version 1.0
Issue Date: April 2024


Qualification -
Unit of Competency AURETU007 - Overhaul air conditioning and HVAC system compressors
Description
Employability Skills
Learning Outcomes and Application This unit describes the performance outcomes required to overhaul and return air conditioning and heating, ventilation and air conditioning (HVAC) system compressors to original manufacturer tolerances and clearances. It involves preparing for the task, dismantling and evaluating the compressor, carrying out the overhaul process, reassembling and testing the compressor, and completing workplace processes and documentation.It applies to those working in an automotive service and repair industry. The air conditioning and HVAC system compressors include those fitted to 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.
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 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

workplace instructions

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

manufacturer specifications for air conditioning and HVAC system components

two different vehicles or machinery requiring overhaul, with operational air conditioning and HVAC systems and with components specified in the performance evidence

tools, equipment and materials appropriate for overhauling and adjusting a range of air conditioning and HVAC compressors.
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 dismantle air conditioning compressor
  • Job requirements are determined from workplace instructions
  • Australian automotive code of practice: Control of refrigerant gases during manufacture, installation, servicing or de-commissioning of motor vehicle air conditioners is sourced and interpreted
  • Dismantling information is sourced and interpreted
  • Dismantling options are analysed and those most appropriate to the circumstances are selected
  • Hazards associated with the work are identified and risks are managed
  • Dismantling tools and equipment are selected and checked for serviceability
       
Element: Dismantle and evaluate compressor and components
  • Compressor is dismantled in a logical sequence according to manufacturer and workplace procedures, and safety and environmental requirements,and without causing unnecessary damage to components or systems
  • Components are cleaned for evaluation according to workplace procedures and safety and environmental requirements
  • Components are measured and compared with manufacturer specifications and serviceability is determined
  • Component repair method is determined
  • Unserviceable parts are identified and replacement parts sourced
       
Element: Carry out overhaul
  • Overhaul information is sourced and interpreted
  • Overhaul options are analysed and those most appropriate to the circumstances are selected
  • Overhaul tools and equipment are selected and checked for serviceability
  • Components are machined, repaired and replaced as required, and adjustments are carried out according to manufacturer specifications, workplace procedures, safety and environmental requirements, and Australian automotive code of practice
       
Element: Assemble compressor and components
  • Compressor is assembled according to manufacturer specifications, workplace procedures, and safety and environmental requirements
  • Tolerances and clearances are measured against manufacturer specifications and necessary adjustments are made
  • Assembly of compressor is completed within workplace timeframes and without causing damage to other components or systems
  • Post-assembly testing is carried out according to workplace procedures and safety and environmental requirements, and any problems detected as having been introduced during the assembly process are rectified
       
Element: Complete work processes
  • Final inspection is made to ensure work is to workplace expectations and compressor is presented ready for use or storage
  • 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
       
Element: Prepare to dismantle air conditioning compressor
  • Job requirements are determined from workplace instructions
  • Australian automotive code of practice: Control of refrigerant gases during manufacture, installation, servicing or de-commissioning of motor vehicle air conditioners is sourced and interpreted
  • Dismantling information is sourced and interpreted
  • Dismantling options are analysed and those most appropriate to the circumstances are selected
  • Hazards associated with the work are identified and risks are managed
  • Dismantling tools and equipment are selected and checked for serviceability
       
Element: Dismantle and evaluate compressor and components
  • Compressor is dismantled in a logical sequence according to manufacturer and workplace procedures, and safety and environmental requirements,and without causing unnecessary damage to components or systems
  • Components are cleaned for evaluation according to workplace procedures and safety and environmental requirements
  • Components are measured and compared with manufacturer specifications and serviceability is determined
  • Component repair method is determined
  • Unserviceable parts are identified and replacement parts sourced
       
Element: Carry out overhaul
  • Overhaul information is sourced and interpreted
  • Overhaul options are analysed and those most appropriate to the circumstances are selected
  • Overhaul tools and equipment are selected and checked for serviceability
  • Components are machined, repaired and replaced as required, and adjustments are carried out according to manufacturer specifications, workplace procedures, safety and environmental requirements, and Australian automotive code of practice
       
Element: Assemble compressor and components
  • Compressor is assembled according to manufacturer specifications, workplace procedures, and safety and environmental requirements
  • Tolerances and clearances are measured against manufacturer specifications and necessary adjustments are made
  • Assembly of compressor is completed within workplace timeframes and without causing damage to other components or systems
  • Post-assembly testing is carried out according to workplace procedures and safety and environmental requirements, and any problems detected as having been introduced during the assembly process are rectified
       
Element: Complete work processes
  • Final inspection is made to ensure work is to workplace expectations and compressor is presented ready for use or storage
  • 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
       


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 dismantle air conditioning compressor

1.1 Job requirements are determined from workplace instructions

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

1.3 Dismantling information is sourced and interpreted

1.4 Dismantling 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 Dismantling tools and equipment are selected and checked for serviceability

2. Dismantle and evaluate compressor and components

2.1 Compressor is dismantled in a logical sequence according to manufacturer and workplace procedures, and safety and environmental requirements,and without causing unnecessary damage to components or systems

2.2 Components are cleaned for evaluation according to workplace procedures and safety and environmental requirements

2.3 Components are measured and compared with manufacturer specifications and serviceability is determined

2.4 Component repair method is determined

2.5 Unserviceable parts are identified and replacement parts sourced

3. Carry out overhaul

3.1 Overhaul information is sourced and interpreted

3.2 Overhaul options are analysed and those most appropriate to the circumstances are selected

3.3 Overhaul tools and equipment are selected and checked for serviceability

3.4 Components are machined, repaired and replaced as required, and adjustments are carried out according to manufacturer specifications, workplace procedures, safety and environmental requirements, and Australian automotive code of practice

4. Assemble compressor and components

4.1 Compressor is assembled according to manufacturer specifications, workplace procedures, and safety and environmental requirements

4.2 Tolerances and clearances are measured against manufacturer specifications and necessary adjustments are made

4.3 Assembly of compressor is completed within workplace timeframes and without causing damage to other components or systems

4.4 Post-assembly testing is carried out according to workplace procedures and safety and environmental requirements, and any problems detected as having been introduced during the assembly process are rectified

5. Complete work processes

5.1 Final inspection is made to ensure work is to workplace expectations and compressor is presented ready for use or storage

5.2 Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected

5.3 Tools and equipment are checked and stored, and any faulty electrical equipment is identified, tagged and isolated according to workplace procedures

5.4 Workplace documentation is processed according to workplace procedures

Before competency can be determined, individuals must demonstrate they can perform the following according to the standards defined in this unit’s elements, performance criteria, range of conditions and foundation skills:

overhaul the air conditioning compressors of two different vehicles or machinery, including:

piston, scroll and rotary vane compressors

electric compressors

variable displacement compressors

clutchless compressors

recover and evacuate refrigerants according to required code of practice and regulations, and recharge the system with the appropriate manufacturer refrigerant and oil type.

Individuals must be able to demonstrate knowledge of:

work health and safety (WHS) and occupational health and safety (OHS) requirements relating to overhauling air conditioning and heating, ventilation and air conditioning (HVAC) system components, including procedures for:

working with refrigerants at boiling point given risk of frostbite

working with system lubricants, including carcinogenic oils

handling flammable refrigerants

using personal protective equipment (PPE)

identifying and using fire safety equipment

environmental requirements, including procedures for preventing loss of refrigerant to the atmosphere

techniques for reading and interpreting technical information, including:

refrigerant saturation temperatures in relation to ambient temperatures and changing levels of humidity

graphic symbols and diagrams

principal types of vehicle air conditioning and HVAC systems, including:

piston, scroll and rotary vane compressors

electric compressors

variable displacement compressors

clutchless compressors

principal refrigerant types and their respective operating pressures and lubricating oils, including:

R12

R134a

R1234yf

air conditioning and HVAC system component overhaul procedures, including:

methods for cleaning and preparing air conditioning and HVAC system compressor for overhaul

air conditioning and HVAC system compressor dismantling procedures

air conditioning and HVAC system compressor inspection, measuring and evaluation procedures, including methods for measuring and calculating tolerances and clearances

air conditioning and HVAC compressor repair and adjustment procedures, including:

piston, scroll and rotary vane compressors

electric compressors

variable displacement compressors

clutchless compressors

procedures for tolerance measuring and calculating and adjusting components

post-overhaul bench testing procedures, including:

use of manifold gauges and surface probe thermocouples for complete system analysis

analysis of system operation while using gauges, temperature probes, electrical test equipment, scan tools, oscilloscopes and other industry-relevant test equipment

post-overhaul testing of air conditioning and HVAC systems in vehicle or machinery, including:

diagnostic procedures for air conditioning and HVAC systems, including:

accessing and interpreting diagnostic trouble codes (DTCs)

diagnostic flow charts

visual, aural and functional assessments

ambient temperature

centre vent temperature

condenser and suction line temperature

manifold gauge pressure readings

refrigerant leaks.

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 dismantle air conditioning compressor

1.1 Job requirements are determined from workplace instructions

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

1.3 Dismantling information is sourced and interpreted

1.4 Dismantling 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 Dismantling tools and equipment are selected and checked for serviceability

2. Dismantle and evaluate compressor and components

2.1 Compressor is dismantled in a logical sequence according to manufacturer and workplace procedures, and safety and environmental requirements,and without causing unnecessary damage to components or systems

2.2 Components are cleaned for evaluation according to workplace procedures and safety and environmental requirements

2.3 Components are measured and compared with manufacturer specifications and serviceability is determined

2.4 Component repair method is determined

2.5 Unserviceable parts are identified and replacement parts sourced

3. Carry out overhaul

3.1 Overhaul information is sourced and interpreted

3.2 Overhaul options are analysed and those most appropriate to the circumstances are selected

3.3 Overhaul tools and equipment are selected and checked for serviceability

3.4 Components are machined, repaired and replaced as required, and adjustments are carried out according to manufacturer specifications, workplace procedures, safety and environmental requirements, and Australian automotive code of practice

4. Assemble compressor and components

4.1 Compressor is assembled according to manufacturer specifications, workplace procedures, and safety and environmental requirements

4.2 Tolerances and clearances are measured against manufacturer specifications and necessary adjustments are made

4.3 Assembly of compressor is completed within workplace timeframes and without causing damage to other components or systems

4.4 Post-assembly testing is carried out according to workplace procedures and safety and environmental requirements, and any problems detected as having been introduced during the assembly process are rectified

5. Complete work processes

5.1 Final inspection is made to ensure work is to workplace expectations and compressor is presented ready for use or storage

5.2 Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected

5.3 Tools and equipment are checked and stored, and any faulty electrical equipment is identified, tagged and isolated according to workplace procedures

5.4 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 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

handling flammable refrigerants

using personal protective equipment (PPE)

identifying fire safety equipment

environmental requirements, including procedures for preventing loss of refrigerant to the atmosphere.

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 
Australian automotive code of practice: Control of refrigerant gases during manufacture, installation, servicing or de-commissioning of motor vehicle air conditioners is sourced and interpreted 
Dismantling information is sourced and interpreted 
Dismantling options are analysed and those most appropriate to the circumstances are selected 
Hazards associated with the work are identified and risks are managed 
Dismantling tools and equipment are selected and checked for serviceability 
Compressor is dismantled in a logical sequence according to manufacturer and workplace procedures, and safety and environmental requirements,and without causing unnecessary damage to components or systems 
Components are cleaned for evaluation according to workplace procedures and safety and environmental requirements 
Components are measured and compared with manufacturer specifications and serviceability is determined 
Component repair method is determined 
Unserviceable parts are identified and replacement parts sourced 
Overhaul information is sourced and interpreted 
Overhaul options are analysed and those most appropriate to the circumstances are selected 
Overhaul tools and equipment are selected and checked for serviceability 
Components are machined, repaired and replaced as required, and adjustments are carried out according to manufacturer specifications, workplace procedures, safety and environmental requirements, and Australian automotive code of practice 
Compressor is assembled according to manufacturer specifications, workplace procedures, and safety and environmental requirements 
Tolerances and clearances are measured against manufacturer specifications and necessary adjustments are made 
Assembly of compressor is completed within workplace timeframes and without causing damage to other components or systems 
Post-assembly testing is carried out according to workplace procedures and safety and environmental requirements, and any problems detected as having been introduced during the assembly process are rectified 
Final inspection is made to ensure work is to workplace expectations and compressor is presented ready for use or storage 
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 
Job requirements are determined from workplace instructions 
Australian automotive code of practice: Control of refrigerant gases during manufacture, installation, servicing or de-commissioning of motor vehicle air conditioners is sourced and interpreted 
Dismantling information is sourced and interpreted 
Dismantling options are analysed and those most appropriate to the circumstances are selected 
Hazards associated with the work are identified and risks are managed 
Dismantling tools and equipment are selected and checked for serviceability 
Compressor is dismantled in a logical sequence according to manufacturer and workplace procedures, and safety and environmental requirements,and without causing unnecessary damage to components or systems 
Components are cleaned for evaluation according to workplace procedures and safety and environmental requirements 
Components are measured and compared with manufacturer specifications and serviceability is determined 
Component repair method is determined 
Unserviceable parts are identified and replacement parts sourced 
Overhaul information is sourced and interpreted 
Overhaul options are analysed and those most appropriate to the circumstances are selected 
Overhaul tools and equipment are selected and checked for serviceability 
Components are machined, repaired and replaced as required, and adjustments are carried out according to manufacturer specifications, workplace procedures, safety and environmental requirements, and Australian automotive code of practice 
Compressor is assembled according to manufacturer specifications, workplace procedures, and safety and environmental requirements 
Tolerances and clearances are measured against manufacturer specifications and necessary adjustments are made 
Assembly of compressor is completed within workplace timeframes and without causing damage to other components or systems 
Post-assembly testing is carried out according to workplace procedures and safety and environmental requirements, and any problems detected as having been introduced during the assembly process are rectified 
Final inspection is made to ensure work is to workplace expectations and compressor is presented ready for use or storage 
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 

Forms

Assessment Cover Sheet

AURETU007 - Overhaul air conditioning and HVAC system compressors
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

AURETU007 - Overhaul air conditioning and HVAC system compressors

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: