Work applies to automotive air conditioners, including HVAC systems fitted to vehicles 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.

ELEMENT

PERFORMANCE CRITERIA

1. Prepare to service an air conditioning and HVAC system

1.1. Workplace instructions are used to determine job requirements

1.2. Workplace health and safety (WHS) requirements are observed throughout the work

1.3. Procedures and information are sourced and interpreted

1.4. Australian Refrigeration Council (ARC) code of practice is sourced and complied with

1.5. Servicing options are analysed and those most appropriate to the circumstances are selected and prepared

1.6. Tools and equipment are identified for effective servicing procedures

1.7. Critical precautions in relation to working with air conditioning, refrigerant and refrigerant oils are observed

2. Functionally test air conditioning and HVAC system and components and identify faults

2.1. Correct information is accessed and interpreted from manufacturer and component supplier specifications

2.2. Air conditioning and HVAC systems are performance tested to isolate faults according to workplace procedures and without causing damage to components or systems as a result of inappropriate testing procedures

2.3. Faults are identified from test results and causes of faults are determined

2.4. Diagnosis findings are reported according to workplace procedures, including recommendations for necessary repairs or adjustments

2.5. Tests are carried out according to industry and WHS regulations and guidelines, and relevant industry codes of practice

3. Service air conditioning and HVAC system

3.1. Service of the system and components is carried out according to manufacturer and component supplier specifications, industry regulations and guidelines, WHS legislation, workplace policies and procedures, and relevant industry codes of practice

3.2. Air conditioning system service is completed without causing damage to components or systems

3.3. Regulations regarding topping up refrigerant are understood and followed

4. Retest air conditioning and HVAC system

4.1. System is retested to ensure correct and safe performance and operation

4.2. Post-service testing is carried out and results are documented according to air conditioning service procedures and relevant industry codes of practice

5. Prepare vehicle and equipment for delivery to customer

5.1. Final inspection is made to ensure vehicle protective guards and safety features are in place and work is to workplace expectations

5.2. Vehicle is cleaned to workplace expectations and presented ready for use

5.3. Workplace documentation is processed according to workplace procedures

5.4. Appropriate decal sticker is placed in engine compartment

6. Clean up work area and maintain equipment

6.1. Material that can be reused is collected and stored in the appropriate designated area and according to workplace sustainability practices

6.2. Waste and scrap are removed following workplace procedures and disposed of according to environmental regulations

6.3. Equipment and work area are cleaned and inspected for serviceable condition according to workplace procedures

6.4. Faulty equipment is identified, tagged and isolated according to workplace procedures and WHS regulations

6.5. Operator maintenance is completed according to manufacturer and component supplier specifications, site procedures and relevant industry codes of practice

6.6. Tools and equipment are maintained according to workplace procedures

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 servicing 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:

work with diverse individuals and groups

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 servicing 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 and regulatory requirements

ARC code of practice

principal types of vehicle 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

techniques for reading and interpreting technical information, graphic symbols and diagrams

diagnostic and testing procedures, including:

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 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 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 servicing an air conditioning system

complete preparatory activity in a systematic manner

identify application, purpose and operating principles of automotive air conditioning and HVAC systems

conduct inspection, servicing and operational testing according to industry codes of practice and workplace, manufacturer and component supplier specifications

ensure that the addition of refrigerant to an existing system charge to ‘top up’ the air conditioning system is not carried out

performance test air conditioning systems

accurately interpret performance test results

complete servicing of air conditioning systems 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

ARC code of practice.

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

workplace location or simulated workplace

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

material relevant to servicing air conditioning systems

equipment appropriate for the testing of vehicle air conditioning and HVAC systems relevant to the qualification being sought, 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 or 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 service and adjustment 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.

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.

Workplace instructions may include:

electronic or hard copy instructions

verbal instructions

written instructions

safe work procedures relating to refrigerant recovery and replacement.

Job requirements may include:

testing and service methods, processes and equipment

diagnosing faults that may be in addition to normal service procedures and may be detrimental to future performance of the air conditioning and HVAC system.

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

hazard control, including control of hazardous materials and toxic substances

water shower or equivalent.

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 servicing 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.

Servicing options may include:

fluid levels:

refrigerant

lubricating oils

filter serviceability:

receiver dryer

cabin filter

O-rings and seals

adjustments and operational testing

visual inspections and documentation.

Tools and equipment:

are to include the following specialist tools that 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 or replacement tool

psychrometer (humidity detector)

various refrigerant hoses and couplers

digital multimeter

diagnostic scan tool.

Critical precautions may include:

those relating to dangers associated with working with refrigerants and lubricants, including:

frostbite (refrigerant boiling point -36.7ºC)

carcinogenic oil

care taken with some flammable refrigerants.

Air conditioning and HVAC systems may include:

single zone and multi-zone, including:

climate control

electric compressors

R12 systems

R134a systems

R1234yf systems

high and low pressure switches

pressure relief valves

temperature sensors

sunlight sensors

carbon dioxide sensors

zone temperature sensors.

Inappropriate testing procedures may include:

intrusive testing (which must not be performed as it is not a recommended test and repair method), which includes:

back probing terminals and connectors and fuse holders with inappropriate test probes

probing terminal and connectors with inappropriate test probes

pushing sharp probes and objects into wiring insulation.

Faults may include:

system containing atmospheric air with moisture

electrical sensor malfunction

dislodged temperature sensor or transfer valve

faulty pressure relief valve

vacuum leak

air flow restriction or blockage

receiver drier blockage

evaporator fan not working

electrical fault

electrical system fault.

Post-service testing may include:

validating the effectiveness of the service action, including the following checks:

ambient temperature

centre vent temperature

condenser and suction line temperature

manifold gauge pressure readings

refrigerant leaks

confirming that reported fault has now been rectified

confirming that no other faults are present as a result of the service 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.

Unit sector

Electrical

Technical – Air Conditioning and HVAC

This unit contains employability skills.