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Evidence Guide: AURETH003 - Diagnose and repair high voltage rechargeable energy storage systems in battery electric vehicle

Student: __________________________________________________

Signature: _________________________________________________

Tips for gathering evidence to demonstrate your skills

The important thing to remember when gathering evidence is that the more evidence the better - that is, the more evidence you gather to demonstrate your skills, the more confident an assessor can be that you have learned the skills not just at one point in time, but are continuing to apply and develop those skills (as opposed to just learning for the test!). Furthermore, one piece of evidence that you collect will not usualy demonstrate all the required criteria for a unit of competency, whereas multiple overlapping pieces of evidence will usually do the trick!

From the Wiki University

 

AURETH003 - Diagnose and repair high voltage rechargeable energy storage systems in battery electric vehicle

What evidence can you provide to prove your understanding of each of the following citeria?

Prepare to diagnose and repair HV RESS

  1. Job requirements are determined from workplace instructions
  2. Diagnostic information is accessed and interpreted
  3. Diagnostic options are analysed and those most appropriate to the circumstances are selected
  4. Hazards associated with the work are identified and risks are managed according to safety requirements and AS 5732 Electric vehicle operations - Maintenance and repair
  5. Diagnostic tools and equipment are selected and checked for serviceability
Job requirements are determined from workplace instructions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Diagnostic information is accessed and interpreted

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Diagnostic options are analysed and those most appropriate to the circumstances are selected

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Hazards associated with the work are identified and risks are managed according to safety requirements and AS 5732 Electric vehicle operations - Maintenance and repair

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Diagnostic tools and equipment are selected and checked for serviceability

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Diagnose RESS

  1. Diagnostic tests are carried out according to manufacturer specifications, workplace procedures and safety requirements
  2. Faults are identified from diagnostic test results and causes of faults are determined
  3. Diagnosis findings and recommendations for required repairs or adjustments are reported according to workplace procedures
Diagnostic tests are carried out according to manufacturer specifications, workplace procedures and safety requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Faults are identified from diagnostic test results and causes of faults are determined

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Diagnosis findings and recommendations for required repairs or adjustments are reported according to workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Repair RESS

  1. Repair information is accessed and interpreted
  2. Repair options are analysed and those most appropriate to the circumstances are selected
  3. Repair tools, equipment and materials are selected and checked
  4. RESS service plug or manual service disconnect is located and isolated to depower vehicle HV RESS according to manufacturer specifications
  5. RESS and components are replaced, repaired or adjusted as required according to manufacturer specifications, workplace procedures, safety and environmental requirements, and without causing damage to components or systems
  6. RESS service plug or manual service disconnect are reconnected and vehicle is reactivated
  7. Post-repair testing is carried out according to workplace procedures to confirm fault rectification, and any further problems detected as having been introduced during the repair process are rectified
Repair information is accessed and interpreted

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Repair options are analysed and those most appropriate to the circumstances are selected

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Repair tools, equipment and materials are selected and checked

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

RESS service plug or manual service disconnect is located and isolated to depower vehicle HV RESS according to manufacturer specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

RESS and components are replaced, repaired or adjusted as required according to manufacturer specifications, workplace procedures, safety and environmental requirements, and without causing damage to components or systems

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

RESS service plug or manual service disconnect are reconnected and vehicle is reactivated

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Post-repair testing is carried out according to workplace procedures to confirm fault rectification, and any further problems detected as having been introduced during the repair process are rectified

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete work processes

  1. Final inspection is made to ensure work is to workplace expectations and vehicle is presented ready for use
  2. Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected
  3. Tools and equipment are checked and stored and any faulty electrical equipment is identified, tagged and isolated according to workplace procedures
  4. Workplace documentation is processed according to workplace procedures
Final inspection is made to ensure work is to workplace expectations and vehicle is presented ready for use

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Workplace documentation is processed according to workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Prepare to diagnose and repair HV RESS

  1. Job requirements are determined from workplace instructions
  2. Diagnostic information is accessed and interpreted
  3. Diagnostic options are analysed and those most appropriate to the circumstances are selected
  4. Hazards associated with the work are identified and risks are managed according to safety requirements and AS 5732 Electric vehicle operations - Maintenance and repair
  5. Diagnostic tools and equipment are selected and checked for serviceability
Job requirements are determined from workplace instructions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Diagnostic information is accessed and interpreted

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Diagnostic options are analysed and those most appropriate to the circumstances are selected

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Hazards associated with the work are identified and risks are managed according to safety requirements and AS 5732 Electric vehicle operations - Maintenance and repair

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Diagnostic tools and equipment are selected and checked for serviceability

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Diagnose RESS

  1. Diagnostic tests are carried out according to manufacturer specifications, workplace procedures and safety requirements
  2. Faults are identified from diagnostic test results and causes of faults are determined
  3. Diagnosis findings and recommendations for required repairs or adjustments are reported according to workplace procedures
Diagnostic tests are carried out according to manufacturer specifications, workplace procedures and safety requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Faults are identified from diagnostic test results and causes of faults are determined

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Diagnosis findings and recommendations for required repairs or adjustments are reported according to workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Repair RESS

  1. Repair information is accessed and interpreted
  2. Repair options are analysed and those most appropriate to the circumstances are selected
  3. Repair tools, equipment and materials are selected and checked
  4. RESS service plug or manual service disconnect is located and isolated to depower vehicle HV RESS according to manufacturer specifications
  5. RESS and components are replaced, repaired or adjusted as required according to manufacturer specifications, workplace procedures, safety and environmental requirements, and without causing damage to components or systems
  6. RESS service plug or manual service disconnect are reconnected and vehicle is reactivated
  7. Post-repair testing is carried out according to workplace procedures to confirm fault rectification, and any further problems detected as having been introduced during the repair process are rectified
Repair information is accessed and interpreted

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Repair options are analysed and those most appropriate to the circumstances are selected

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Repair tools, equipment and materials are selected and checked

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

RESS service plug or manual service disconnect is located and isolated to depower vehicle HV RESS according to manufacturer specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

RESS and components are replaced, repaired or adjusted as required according to manufacturer specifications, workplace procedures, safety and environmental requirements, and without causing damage to components or systems

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

RESS service plug or manual service disconnect are reconnected and vehicle is reactivated

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Post-repair testing is carried out according to workplace procedures to confirm fault rectification, and any further problems detected as having been introduced during the repair process are rectified

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete work processes

  1. Final inspection is made to ensure work is to workplace expectations and vehicle is presented ready for use
  2. Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected
  3. Tools and equipment are checked and stored and any faulty electrical equipment is identified, tagged and isolated according to workplace procedures
  4. Workplace documentation is processed according to workplace procedures
Final inspection is made to ensure work is to workplace expectations and vehicle is presented ready for use

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Workplace documentation is processed according to workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Evidence Guide

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 diagnose and repair HV RESS

1.1 Job requirements are determined from workplace instructions

1.2 Diagnostic information is accessed and interpreted

1.3 Diagnostic options are analysed and those most appropriate to the circumstances are selected

1.4 Hazards associated with the work are identified and risks are managed according to safety requirements and AS 5732 Electric vehicle operations - Maintenance and repair

1.5 Diagnostic tools and equipment are selected and checked for serviceability

2. Diagnose RESS

2.1 Diagnostic tests are carried out according to manufacturer specifications, workplace procedures and safety requirements

2.2 Faults are identified from diagnostic test results and causes of faults are determined

2.3 Diagnosis findings and recommendations for required repairs or adjustments are reported according to workplace procedures

3. Repair RESS

3.1 Repair information is accessed and interpreted

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

3.3 Repair tools, equipment and materials are selected and checked

3.4 RESS service plug or manual service disconnect is located and isolated to depower vehicle HV RESS according to manufacturer specifications

3.5 RESS and components are replaced, repaired or adjusted as required according to manufacturer specifications, workplace procedures, safety and environmental requirements, and without causing damage to components or systems

3.6 RESS service plug or manual service disconnect are reconnected and vehicle is reactivated

3.7 Post-repair testing is carried out according to workplace procedures to confirm fault rectification, and any further problems detected as having been introduced during the repair process are rectified

4. Complete work processes

4.1 Final inspection is made to ensure work is to workplace expectations and vehicle 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 Workplace documentation is processed according to workplace procedures

Required Skills and Knowledge

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 diagnose and repair HV RESS

1.1 Job requirements are determined from workplace instructions

1.2 Diagnostic information is accessed and interpreted

1.3 Diagnostic options are analysed and those most appropriate to the circumstances are selected

1.4 Hazards associated with the work are identified and risks are managed according to safety requirements and AS 5732 Electric vehicle operations - Maintenance and repair

1.5 Diagnostic tools and equipment are selected and checked for serviceability

2. Diagnose RESS

2.1 Diagnostic tests are carried out according to manufacturer specifications, workplace procedures and safety requirements

2.2 Faults are identified from diagnostic test results and causes of faults are determined

2.3 Diagnosis findings and recommendations for required repairs or adjustments are reported according to workplace procedures

3. Repair RESS

3.1 Repair information is accessed and interpreted

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

3.3 Repair tools, equipment and materials are selected and checked

3.4 RESS service plug or manual service disconnect is located and isolated to depower vehicle HV RESS according to manufacturer specifications

3.5 RESS and components are replaced, repaired or adjusted as required according to manufacturer specifications, workplace procedures, safety and environmental requirements, and without causing damage to components or systems

3.6 RESS service plug or manual service disconnect are reconnected and vehicle is reactivated

3.7 Post-repair testing is carried out according to workplace procedures to confirm fault rectification, and any further problems detected as having been introduced during the repair process are rectified

4. Complete work processes

4.1 Final inspection is made to ensure work is to workplace expectations and vehicle 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 Workplace documentation is 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:

diagnose and repair high voltage (HV) rechargeable energy storage systems (RESS) in two different battery electric vehicles (BEVs) to correct performance deficiencies.

Individuals must be able to demonstrate knowledge of:

work health and safety (WHS) and occupational health and safety (OHS) requirements relating to diagnosing and repairing RESS in BEVs, including procedures for:

identifying hazards and controlling risks associated with:

working with high voltages on BEV electrical systems

wearing jewellery while working around high electrical currents

determining appropriate procedures for minimising risk associated with hazards, including applying electrical safety precautions when:

using personal protective equipment (PPE), including electrical safety gloves with 1000 volt rating and Australian standards rated HV insulating mat

identifying and using firefighting equipment as appropriate

using the ‘one hand’ rule

following live system warning tags and signs

depowering vehicle

isolating HV RESS electrical supply

stabilising vehicle electrical system

environmental requirements, including procedures for trapping, storing and disposing of waste released during repair procedures

requirements of AS 5732 Electric vehicle operations - Maintenance and repair

operating principles of HV RESS in BEVs, including:

battery pack construction, including:

battery types

battery internal resistance

battery pack system, including:

charging characteristics

open circuit cells

reverse polarisation

series cell configuration

strapping and layout

application, purpose and operation of RESS, including:

HV battery charger and direct current (DC) to DC converter

battery management system (BMS)

power distribution unit (PDU)

diagnostic testing procedures for HV RESS in BEVs, including:

accessing and interpreting scan tool system data, including:

diagnostic trouble codes (DTCs)

live data

freeze frame data

waveforms

using diagnostic flow charts

electrical system testing, including procedures for:

accessing electrical terminals and using test probes without damaging connectors, fuse holders or wiring

testing controller input and output signals and waveforms

vehicle dynamic and static testing procedures

analysing abnormal noise

analysing component failure

RESS cooling system testing

repair procedures for RESS, including:

tightening connections

replacing faulty or damaged cable connections

removing and replacing faulty or damaged components

removing and replacing motor controller

post-repair testing procedures for BEV, including:

DTC clearing procedures

checking for electrical connector mating

performance testing RESS.

Range Statement

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 requirements must include:

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

identifying hazards and controlling risks associated with:

working with high voltages in BEV electrical systems

wearing jewellery while working around high electrical currents

determining appropriate procedures for minimising risk associated with hazards, including applying electrical safety precautions when:

using personal protective equipment (PPE), including electrical safety gloves with 1000 volt rating and Australian standards rated HV insulating mat

identifying and using firefighting equipment

using the ‘one hand rule’

following live system warning tags and signs

depowering vehicle

isolating HV RESS electrical supply

stabilising vehicle electrical system.

Tools and equipment must include:

those specified in the specific vehicle service maintenance procedures, including:

digital multimeter with Cat III 1000 volt rating

insulation tester

residual voltage tester, if specified in original equipment manufacturer (OEM) test requirements

scan tool

oscilloscope.

Environmental requirements must include:

procedures for trapping, storing and disposing of waste produced during repair procedures.