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

AURETU3005 Mapping and Delivery Guide
Retrofit and modify air conditioning and HVAC systems

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency AURETU3005 - Retrofit and modify air conditioning and HVAC systems
Description This unit describes the performance outcomes required to retrofit and modify automotive air conditioning systems - including heating, ventilation, air conditioning and cooling (HVAC) systems - that are fitted to a range of vehicles and equipment for passenger convenience and comfort.The unit involves diagnosing deviations from correct operation, the retrofit and modification of vehicle air conditioning and HVAC system components and associated systems, and applying post-modification testing procedures.The unit also involves identifying and confirming work requirements, preparing for work, de-gassing and re-gassing systems, and completing work finalisation processes, including clean-up and documentation.Licensing, legislative, regulatory or certification requirements apply to this unit. Users are advised to check with the relevant regulatory authority.
Employability Skills This unit contains employability skills.
Learning Outcomes and Application Work applies to automotive air conditioners, including HVAC systems fitted in light and heavy vehicle, mining, construction, agricultural, motorcycle and outdoor power equipment environments.Work requires individuals to demonstrate discretion, judgement and problem-solving skills in managing own work activities and contributing to a productive team environment.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.
Prerequisites/co-requisites Not applicable. Not applicable.
Competency Field Technical – Air Conditioning and HVAC
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 air conditioning and HVAC system
  • Nature and scope of work requirements are identified and confirmed
  • Workplace health and safety (WHS) requirements are observed throughout the work
  • Procedures and information are sourced and interpreted
  • Australian Refrigeration Council (ARC) code of practice is sourced and complied with
  • Retrofit options are analysed and those most appropriate to the circumstances are selected and prepared
  • Technical and calibration requirements for retrofit are sourced and support equipment is identified and prepared
  • Tools and equipment are identified for effective retrofit and modification methods
  • Critical precautions in relation to working with air conditioning, refrigerant and refrigerant oils are observed
       
Element: De-gas and re-gas air conditioning and HVAC system
  • Correct information is accessed and interpreted from manufacturer and component supplier specifications
  • System is de-gassed using approved recovery unit and appropriate refrigerant recovery cylinder for individual refrigerant type
  • Oil recovered is measured for replacement purposes
  • System is evacuated according to manufacturer and component supplier specifications and industry codes of practice, including state and territory legislation with reference to ozone depleting substances
  • System is pressure tested for leaks prior to being re-gassed and performance tested using approved methods and equipment
  • Recovery and charging of air conditioning system are completed without causing damage to components or systems and in line with requirements for ozone depleting substances, industry regulations and guidelines, WHS legislation, and relevant industry codes of practice
       
Element: Retrofit air conditioning and HVAC system
  • Correct information is accessed and interpreted from manufacturer and component supplier specifications
  • Air conditioning retrofit procedures are determined after performance testing
  • Retrofit of the system and components is carried out according to manufacturer and component supplier specifications
  • Modifications are carried out without additional pressures associated with the performance of the system or any loss to system integrity
  • Retrofit to air conditioning system is completed without causing damage to components or systems and according to industry regulations and guidelines, WHS legislation, and relevant industry codes of practice
       
Element: Performance test air conditioning and HVAC system
  • System is performance tested prior to placing into service and results are documented according to workplace policies and procedures
  • Service schedule documentation is completed
  • Final inspection is made to ensure protective guards and safety features are in place
       
Element: Retest air conditioning and HVAC systems
  • Retests are carried out to ensure correct and safe system performance operation
  • Post-retrofit testing is carried out according to workplace procedures and relevant legislation
       
Element: Prepare vehicle and equipment for delivery to customer
  • Final inspection is made to ensure work is to workplace expectations
  • Vehicle is cleaned to workplace expectations and presented ready for use
  • Workplace documentation is processed according to workplace procedures
  • Appropriate decal sticker is placed in engine compartment
       
Element: Clean up work area and maintain equipment
  • Material that can be reused is collected and stored in the appropriate designated area and
  • Waste and scrap are removed following workplace procedures and disposed of according to environmental regulations
  • Equipment and work area are cleaned and inspected for serviceable condition according to workplace procedures
  • Faulty equipment is identified, tagged and isolated according to workplace procedures and WHS regulations
  • Operator maintenance is completed according to manufacturer and component supplier specifications, site procedures and ARC code of practice
  • Tools and equipment are maintained 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.

The evidence guide provides advice on assessment and must be read in conjunction with the Performance Criteria, required Skills and Knowledge, the 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:

observe safety procedures and requirements, in particular the dangers associated with handling refrigerants

select methods and techniques appropriate to the retrofit and modification of an air conditioning system

conduct performance testing to establish viability of retrofit and modification

complete preparatory activity in a systematic manner

apply full retrofit and modify sequence in line with scope of work

accurately interpret air conditioning performance test results

conduct refrigerant recovery and evacuation of refrigerant operations according to industry codes of practice and legislation, and charge the system with the appropriate refrigerant and oil type

complete a retrofit and modification of air conditioning system and associated components within workplace time frames

present vehicle and equipment in a condition that complies with workplace requirements

complete workplace and equipment documents to ARC code of practice requirements

clean up work area and maintain equipment to workplace standards.

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

ARC code of practice.

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

workplace location or simulated workplace

light and heavy vehicles with air conditioning and HVAC systems relevant to the qualification being sought

material relevant to perform a retrofit and modification of air conditioning systems

equipment appropriate for the retrofit or modification of light and heavy vehicle air conditioning and HVAC systems, including:

manifold and gauge set

recovery unit

vacuum pump

electronic leak detector

nitrogen cylinder and regulator

digital vacuum gauge (vacrometer)

digital multimeter

electronic scales

oil injector

infra-red thermometer (pyrometer)

electronic temperature probe

valve core removing/replacement tool

psychrometer (humidity detector)

various refrigerant hoses and couplers

diagnostic scan tool

specifications and work instructions

service procedures for above equipment appropriate for the retrofit and modification of vehicle air conditioning and HVAC systems.

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

communication skills to:

follow verbal and written instructions

clarify workplace instructions and determine job requirements

gain information from appropriate persons and assistance as required

initiative and enterprise skills to:

apply learning when retrofitting and modifying various air conditioning and HVAC systems

recognise a workplace problem or potential problem and take action

learning skills to identify sources of information, assistance and expert knowledge to expand skills, knowledge and understanding

literacy skills to:

read and follow information in written job instructions, specifications, standard operating procedures, charts, lists, drawings and other applicable reference documents

obtain and record measurements

document required repairs and parts

numeracy skills to:

test, measure and analyse test equipment results compared to desired system performance

assess tolerances and apply accurate measurements and adjustments

planning and organising skills to:

plan own work requirements and prioritise actions to achieve required outcomes and ensure tasks are completed on time

identify risk factors and take action to minimise them

problem-solving skills to:

refer problems outside area of responsibility to appropriate person and suggest possible causes

seek information and assistance as required to solve problems

self-management skills to:

select and use appropriate equipment, materials, processes and procedures

recognise limitations and seek timely advice

follow workplace documentation, such as codes of practice and operating procedures

teamwork skills to apply knowledge of own role to complete activities efficiently to support team activities and tasks

technical skills to use workplace technology and tools relating to the retrofit and modification of air conditioning and HVAC systems, including:

specialist tools and equipment

measuring equipment

computerised technology

technology skills to:

operate diagnostic and test equipment

use technology to collect, analyse and provide information

Required knowledge

WHS regulations, requirements, equipment, material and personal safety requirements, including:

legislation

ARC code of practice

principles of operation of automotive air conditioning and HVAC systems, including:

piston, scroll and rotary vane compressors

electric compressors

variable displacement compressors

clutchless compressors

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

climate control

multi-zone systems

technical information relating to air conditioning and HVAC systems, including:

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

graphic symbols and diagrams

diagnostic and testing procedures, including:

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

diagnostic procedures for air conditioning and HVAC systems, including:

accessing and interpreting diagnostic trouble codes

diagnostic flow charts

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

visual, aural and functional assessments, including:

component damage and wear

component corrosion

vacuum and leaks

repair procedures, including:

component removal and replacement procedures

component and associated system adjustment procedures

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.

Scope of work may include:

type of system fitted

refrigerant type

oil type

system variables, including:

refrigerant leak detecting

refrigerant recovery and charging

system evacuation

mechanical removal and replacement of components

system and component testing

performance testing.

Workplace health and safety requirements may include:

material safety data sheets (MSDS)

first aid kit

personal protective clothing and equipment

use of tools and equipment

safe handling of material

use of fire-fighting equipment

workplace safety policies and procedures

workplace first aid equipment

water shower or equivalent

hazard control, including control of hazardous materials and toxic substances

dangers associated with handling refrigerants and oils.

Procedures and information may include:

verbal, written and graphical instructions

signage

work schedules, plans and specifications

work bulletins and memos

MSDS

diagrams and sketches

safe work procedures relating to the retrofit and modification to air conditioning and HVAC systems

regulatory and legislative requirements relating to automotive industry

Australian Design Rules

engineer's design specifications and instructions

workplace work specifications and requirements

instructions issued by authorised workplace or external persons

Australian standards

ARC code of practice

vehicle service requirements and repair manuals.

Retrofit options may include:

change of refrigerant gas from R12 to R134a:

receiver dryer filter replacement

change of system fittings for gauge fitment

change of refrigerant gas from R134a to R1234yf:

change of system fittings for gauge fitment.

Tools and equipment:

are to include the following specialist tools, which are mandatory under the ARC code of practice:

manifold and gauge set

recovery unit

vacuum pump

electronic leak detector

electronic scales

may include:

normal hand tools

nitrogen cylinder and regulator

digital vacuum gauge (vacrometer)

oil injector

infra-red thermometer (pyrometer)

electronic temperature probe

valve core removing/replacement tool

psychrometer (humidity detector)

various refrigerant hoses and couplers

digital multimeter

diagnostic scan tool.

Critical precautions may include:

dangers associated when working with refrigerants and lubricants, including:

frostbite (refrigerant boiling point -36.7ºC)

carcinogenic oil

care taken with some flammable refrigerants.

Post-retrofit testing may include:

validating the effectiveness of the retrofit and modification action, including the following checks:

ambient temperature

centre vent temperature

condenser and suction line temperature

manifold gauge pressure readings

refrigerant leaks

confirming that reported faults have been rectified

confirming that no other faults are present as a result of the retrofit and modification action.

Information on decal sticker must include:

name of the service organisation

quantity of refrigerant added

refrigerant and oil type

service date

technician’s licence number

vehicle odometer reading.

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
Nature and scope of work requirements are identified and confirmed 
Workplace health and safety (WHS) requirements are observed throughout the work 
Procedures and information are sourced and interpreted 
Australian Refrigeration Council (ARC) code of practice is sourced and complied with 
Retrofit options are analysed and those most appropriate to the circumstances are selected and prepared 
Technical and calibration requirements for retrofit are sourced and support equipment is identified and prepared 
Tools and equipment are identified for effective retrofit and modification methods 
Critical precautions in relation to working with air conditioning, refrigerant and refrigerant oils are observed 
Correct information is accessed and interpreted from manufacturer and component supplier specifications 
System is de-gassed using approved recovery unit and appropriate refrigerant recovery cylinder for individual refrigerant type 
Oil recovered is measured for replacement purposes 
System is evacuated according to manufacturer and component supplier specifications and industry codes of practice, including state and territory legislation with reference to ozone depleting substances 
System is pressure tested for leaks prior to being re-gassed and performance tested using approved methods and equipment 
Recovery and charging of air conditioning system are completed without causing damage to components or systems and in line with requirements for ozone depleting substances, industry regulations and guidelines, WHS legislation, and relevant industry codes of practice 
Correct information is accessed and interpreted from manufacturer and component supplier specifications 
Air conditioning retrofit procedures are determined after performance testing 
Retrofit of the system and components is carried out according to manufacturer and component supplier specifications 
Modifications are carried out without additional pressures associated with the performance of the system or any loss to system integrity 
Retrofit to air conditioning system is completed without causing damage to components or systems and according to industry regulations and guidelines, WHS legislation, and relevant industry codes of practice 
System is performance tested prior to placing into service and results are documented according to workplace policies and procedures 
Service schedule documentation is completed 
Final inspection is made to ensure protective guards and safety features are in place 
Retests are carried out to ensure correct and safe system performance operation 
Post-retrofit testing is carried out according to workplace procedures and relevant legislation 
Final inspection is made to ensure work is to workplace expectations 
Vehicle is cleaned to workplace expectations and presented ready for use 
Workplace documentation is processed according to workplace procedures 
Appropriate decal sticker is placed in engine compartment 
Material that can be reused is collected and stored in the appropriate designated area and 
Waste and scrap are removed following workplace procedures and disposed of according to environmental regulations 
Equipment and work area are cleaned and inspected for serviceable condition according to workplace procedures 
Faulty equipment is identified, tagged and isolated according to workplace procedures and WHS regulations 
Operator maintenance is completed according to manufacturer and component supplier specifications, site procedures and ARC code of practice 
Tools and equipment are maintained according to workplace procedures 

Forms

Assessment Cover Sheet

AURETU3005 - 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

AURETU3005 - 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: