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Evidence Guide: AURETU3005 - Retrofit and modify air conditioning and HVAC systems

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

 

AURETU3005 - Retrofit and modify air conditioning and HVAC systems

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

Prepare to retrofit air conditioning and HVAC system

  1. Nature and scope of work requirements are identified and confirmed
  2. Workplace health and safety (WHS) requirements are observed throughout the work
  3. Procedures and information are sourced and interpreted
  4. Australian Refrigeration Council (ARC) code of practice is sourced and complied with
  5. Retrofit options are analysed and those most appropriate to the circumstances are selected and prepared
  6. Technical and calibration requirements for retrofit are sourced and support equipment is identified and prepared
  7. Tools and equipment are identified for effective retrofit and modification methods
  8. Critical precautions in relation to working with air conditioning, refrigerant and refrigerant oils are observed
Nature and scope of work requirements are identified and confirmed

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Procedures and information are sourced and interpreted

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Retrofit options are analysed and those most appropriate to the circumstances are selected and prepared

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Technical and calibration requirements for retrofit are sourced and support equipment is identified and prepared

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Tools and equipment are identified for effective retrofit and modification methods

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

De-gas and re-gas air conditioning and HVAC system

  1. Correct information is accessed and interpreted from manufacturer and component supplier specifications
  2. System is de-gassed using approved recovery unit and appropriate refrigerant recovery cylinder for individual refrigerant type
  3. Oil recovered is measured for replacement purposes
  4. 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
  5. System is pressure tested for leaks prior to being re-gassed and performance tested using approved methods and equipment
  6. 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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

System is de-gassed using approved recovery unit and appropriate refrigerant recovery cylinder for individual refrigerant type

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Oil recovered is measured for replacement purposes

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

System is pressure tested for leaks prior to being re-gassed and performance tested using approved methods and equipment

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Retrofit air conditioning and HVAC system

  1. Correct information is accessed and interpreted from manufacturer and component supplier specifications
  2. Air conditioning retrofit procedures are determined after performance testing
  3. Retrofit of the system and components is carried out according to manufacturer and component supplier specifications
  4. Modifications are carried out without additional pressures associated with the performance of the system or any loss to system integrity
  5. 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
Correct information is accessed and interpreted from manufacturer and component supplier specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Air conditioning retrofit procedures are determined after performance testing

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Retrofit of the system and components is carried out according to manufacturer and component supplier specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Modifications are carried out without additional pressures associated with the performance of the system or any loss to system integrity

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Performance test air conditioning and HVAC system

  1. System is performance tested prior to placing into service and results are documented according to workplace policies and procedures
  2. Service schedule documentation is completed
  3. Final inspection is made to ensure protective guards and safety features are in place
System is performance tested prior to placing into service and results are documented according to workplace policies and procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Service schedule documentation is completed

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Final inspection is made to ensure protective guards and safety features are in place

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Retest air conditioning and HVAC systems

  1. Retests are carried out to ensure correct and safe system performance operation
  2. Post-retrofit testing is carried out according to workplace procedures and relevant legislation
Retests are carried out to ensure correct and safe system performance operation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Post-retrofit testing is carried out according to workplace procedures and relevant legislation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Prepare vehicle and equipment for delivery to customer

  1. Final inspection is made to ensure work is to workplace expectations
  2. Vehicle is cleaned to workplace expectations and presented ready for use
  3. Workplace documentation is processed according to workplace procedures
  4. Appropriate decal sticker is placed in engine compartment
Final inspection is made to ensure work is to workplace expectations

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Vehicle is cleaned to workplace expectations and presented ready for use

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Workplace documentation is processed according to workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Appropriate decal sticker is placed in engine compartment

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Clean up work area and maintain equipment

  1. Material that can be reused is collected and stored in the appropriate designated area and
  2. Waste and scrap are removed following workplace procedures and disposed of according to environmental regulations
  3. Equipment and work area are cleaned and inspected for serviceable condition according to workplace procedures
  4. Faulty equipment is identified, tagged and isolated according to workplace procedures and WHS regulations
  5. Operator maintenance is completed according to manufacturer and component supplier specifications, site procedures and ARC code of practice
  6. Tools and equipment are maintained according to workplace procedures
Material that can be reused is collected and stored in the appropriate designated area and

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Operator maintenance is completed according to manufacturer and component supplier specifications, site procedures and ARC code of practice

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Tools and equipment are maintained according to workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Evidence Guide

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.

Required Skills and Knowledge

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

Range Statement

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.