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.

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.

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.

This section describes those language, literacy, numeracy and employment skills that are essential to performance and are not explicit in the performance criteria.

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.

Technical - Air Conditioning and HVAC

Electrical