AURETU007 - Overhaul air conditioning and HVAC system compressors
Assessor Resource
AURETU007 Overhaul air conditioning and HVAC system compressors
Assessment tool
Version 1.0 Issue Date: June 2024
This unit describes the performance outcomes required to overhaul and return air conditioning and heating, ventilation and air conditioning (HVAC) system compressors to original manufacturer tolerances and clearances. It involves preparing for the task, dismantling and evaluating the compressor, carrying out the overhaul process, reassembling and testing the compressor, and completing workplace processes and documentation.
It applies to those working in an automotive service and repair industry. The air conditioning and HVAC system compressors include those fitted to 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.
You may want to include more information here about the target group and the purpose of the assessments (eg formative, summative, recognition)
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.
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 dismantle air conditioning compressor
1.1 Job requirements are determined from workplace instructions
1.2 Australian automotive code of practice: Control of refrigerant gases during manufacture, installation, servicing or de-commissioning of motor vehicle air conditioners is sourced and interpreted
1.3 Dismantling information is sourced and interpreted
1.4 Dismantling options are analysed and those most appropriate to the circumstances are selected
1.5 Hazards associated with the work are identified and risks are managed
1.6 Dismantling tools and equipment are selected and checked for serviceability
2. Dismantle and evaluate compressor and components
2.1 Compressor is dismantled in a logical sequence according to manufacturer and workplace procedures, and safety and environmental requirements,and without causing unnecessary damage to components or systems
2.2 Components are cleaned for evaluation according to workplace procedures and safety and environmental requirements
2.3 Components are measured and compared with manufacturer specifications and serviceability is determined
2.4 Component repair method is determined
2.5 Unserviceable parts are identified and replacement parts sourced
3. Carry out overhaul
3.1 Overhaul information is sourced and interpreted
3.2 Overhaul options are analysed and those most appropriate to the circumstances are selected
3.3 Overhaul tools and equipment are selected and checked for serviceability
3.4 Components are machined, repaired and replaced as required, and adjustments are carried out according to manufacturer specifications, workplace procedures, safety and environmental requirements, and Australian automotive code of practice
4. Assemble compressor and components
4.1 Compressor is assembled according to manufacturer specifications, workplace procedures, and safety and environmental requirements
4.2 Tolerances and clearances are measured against manufacturer specifications and necessary adjustments are made
4.3 Assembly of compressor is completed within workplace timeframes and without causing damage to other components or systems
4.4 Post-assembly testing is carried out according to workplace procedures and safety and environmental requirements, and any problems detected as having been introduced during the assembly process are rectified
5. Complete work processes
5.1 Final inspection is made to ensure work is to workplace expectations and compressor is presented ready for use or storage
5.2 Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected
5.3 Tools and equipment are checked and stored, and any faulty electrical equipment is identified, tagged and isolated according to workplace procedures
5.4 Workplace documentation is processed according to workplace procedures
Before competency can be determined, individuals must demonstrate they can perform the following according to the standards defined in this unit’s elements, performance criteria, range of conditions and foundation skills:
overhaul the air conditioning compressors of two different vehicles or machinery, including:
piston, scroll and rotary vane compressors
electric compressors
variable displacement compressors
clutchless compressors
recover and evacuate refrigerants according to required code of practice and regulations, and recharge the system with the appropriate manufacturer refrigerant and oil type.
Individuals must be able to demonstrate knowledge of:
work health and safety (WHS) and occupational health and safety (OHS) requirements relating to overhauling air conditioning and heating, ventilation and air conditioning (HVAC) system components, including procedures for:
working with refrigerants at boiling point given risk of frostbite
working with system lubricants, including carcinogenic oils
handling flammable refrigerants
using personal protective equipment (PPE)
identifying and using fire safety equipment
environmental requirements, including procedures for preventing loss of refrigerant to the atmosphere
techniques for reading and interpreting technical information, including:
refrigerant saturation temperatures in relation to ambient temperatures and changing levels of humidity
graphic symbols and diagrams
principal types of vehicle air conditioning and HVAC systems, including:
piston, scroll and rotary vane compressors
electric compressors
variable displacement compressors
clutchless compressors
principal refrigerant types and their respective operating pressures and lubricating oils, including:
R12
R134a
R1234yf
air conditioning and HVAC system component overhaul procedures, including:
methods for cleaning and preparing air conditioning and HVAC system compressor for overhaul
air conditioning and HVAC system compressor dismantling procedures
air conditioning and HVAC system compressor inspection, measuring and evaluation procedures, including methods for measuring and calculating tolerances and clearances
air conditioning and HVAC compressor repair and adjustment procedures, including:
piston, scroll and rotary vane compressors
electric compressors
variable displacement compressors
clutchless compressors
procedures for tolerance measuring and calculating and adjusting components
use of manifold gauges and surface probe thermocouples for complete system analysis
analysis of system operation while using gauges, temperature probes, electrical test equipment, scan tools, oscilloscopes and other industry-relevant test equipment
post-overhaul testing of air conditioning and HVAC systems in vehicle or machinery, including:
diagnostic procedures for air conditioning and HVAC systems, including:
accessing and interpreting diagnostic trouble codes (DTCs)
diagnostic flow charts
visual, aural and functional assessments
ambient temperature
centre vent temperature
condenser and suction line temperature
manifold gauge pressure readings
refrigerant leaks.
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 worked on, 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
Australian automotive code of practice:Control of refrigerant gases during manufacture, installation, servicing or de-commissioning of motor vehicle air conditioners.
manufacturer specifications for air conditioning and HVAC system components
two different vehicles or machinery requiring overhaul, with operational air conditioning and HVAC systems and with components specified in the performance evidence
tools, equipment and materials appropriate for overhauling and adjusting a range of air conditioning and HVAC compressors.
Submission Requirements
List each assessment task's title, type (eg project, observation/demonstration, essay, assingnment, 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.
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 dismantle air conditioning compressor
1.1 Job requirements are determined from workplace instructions
1.2 Australian automotive code of practice: Control of refrigerant gases during manufacture, installation, servicing or de-commissioning of motor vehicle air conditioners is sourced and interpreted
1.3 Dismantling information is sourced and interpreted
1.4 Dismantling options are analysed and those most appropriate to the circumstances are selected
1.5 Hazards associated with the work are identified and risks are managed
1.6 Dismantling tools and equipment are selected and checked for serviceability
2. Dismantle and evaluate compressor and components
2.1 Compressor is dismantled in a logical sequence according to manufacturer and workplace procedures, and safety and environmental requirements,and without causing unnecessary damage to components or systems
2.2 Components are cleaned for evaluation according to workplace procedures and safety and environmental requirements
2.3 Components are measured and compared with manufacturer specifications and serviceability is determined
2.4 Component repair method is determined
2.5 Unserviceable parts are identified and replacement parts sourced
3. Carry out overhaul
3.1 Overhaul information is sourced and interpreted
3.2 Overhaul options are analysed and those most appropriate to the circumstances are selected
3.3 Overhaul tools and equipment are selected and checked for serviceability
3.4 Components are machined, repaired and replaced as required, and adjustments are carried out according to manufacturer specifications, workplace procedures, safety and environmental requirements, and Australian automotive code of practice
4. Assemble compressor and components
4.1 Compressor is assembled according to manufacturer specifications, workplace procedures, and safety and environmental requirements
4.2 Tolerances and clearances are measured against manufacturer specifications and necessary adjustments are made
4.3 Assembly of compressor is completed within workplace timeframes and without causing damage to other components or systems
4.4 Post-assembly testing is carried out according to workplace procedures and safety and environmental requirements, and any problems detected as having been introduced during the assembly process are rectified
5. Complete work processes
5.1 Final inspection is made to ensure work is to workplace expectations and compressor is presented ready for use or storage
5.2 Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected
5.3 Tools and equipment are checked and stored, and any faulty electrical equipment is identified, tagged and isolated according to workplace procedures
5.4 Workplace documentation is processed according to workplace procedures
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 and environmental requirements must include:
work health and safety (WHS) and occupational health and safety (OHS) requirements, including procedures for:
working with refrigerants at boiling point given risk of frostbite
working with system lubricants, including carcinogenic oils
handling flammable refrigerants
using personal protective equipment (PPE)
identifying fire safety equipment
environmental requirements, including procedures for preventing loss of refrigerant to the atmosphere.
Before competency can be determined, individuals must demonstrate they can perform the following according to the standards defined in this unit’s elements, performance criteria, range of conditions and foundation skills:
overhaul the air conditioning compressors of two different vehicles or machinery, including:
piston, scroll and rotary vane compressors
electric compressors
variable displacement compressors
clutchless compressors
recover and evacuate refrigerants according to required code of practice and regulations, and recharge the system with the appropriate manufacturer refrigerant and oil type.
Individuals must be able to demonstrate knowledge of:
work health and safety (WHS) and occupational health and safety (OHS) requirements relating to overhauling air conditioning and heating, ventilation and air conditioning (HVAC) system components, including procedures for:
working with refrigerants at boiling point given risk of frostbite
working with system lubricants, including carcinogenic oils
handling flammable refrigerants
using personal protective equipment (PPE)
identifying and using fire safety equipment
environmental requirements, including procedures for preventing loss of refrigerant to the atmosphere
techniques for reading and interpreting technical information, including:
refrigerant saturation temperatures in relation to ambient temperatures and changing levels of humidity
graphic symbols and diagrams
principal types of vehicle air conditioning and HVAC systems, including:
piston, scroll and rotary vane compressors
electric compressors
variable displacement compressors
clutchless compressors
principal refrigerant types and their respective operating pressures and lubricating oils, including:
R12
R134a
R1234yf
air conditioning and HVAC system component overhaul procedures, including:
methods for cleaning and preparing air conditioning and HVAC system compressor for overhaul
air conditioning and HVAC system compressor dismantling procedures
air conditioning and HVAC system compressor inspection, measuring and evaluation procedures, including methods for measuring and calculating tolerances and clearances
air conditioning and HVAC compressor repair and adjustment procedures, including:
piston, scroll and rotary vane compressors
electric compressors
variable displacement compressors
clutchless compressors
procedures for tolerance measuring and calculating and adjusting components
use of manifold gauges and surface probe thermocouples for complete system analysis
analysis of system operation while using gauges, temperature probes, electrical test equipment, scan tools, oscilloscopes and other industry-relevant test equipment
post-overhaul testing of air conditioning and HVAC systems in vehicle or machinery, including:
diagnostic procedures for air conditioning and HVAC systems, including:
accessing and interpreting diagnostic trouble codes (DTCs)
diagnostic flow charts
visual, aural and functional assessments
ambient temperature
centre vent temperature
condenser and suction line temperature
manifold gauge pressure readings
refrigerant leaks.
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 worked on, 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
Australian automotive code of practice:Control of refrigerant gases during manufacture, installation, servicing or de-commissioning of motor vehicle air conditioners.
manufacturer specifications for air conditioning and HVAC system components
two different vehicles or machinery requiring overhaul, with operational air conditioning and HVAC systems and with components specified in the performance evidence
tools, equipment and materials appropriate for overhauling and adjusting a range of air conditioning and HVAC compressors.
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
Job requirements are determined from workplace instructions
Australian automotive code of practice: Control of refrigerant gases during manufacture, installation, servicing or de-commissioning of motor vehicle air conditioners is sourced and interpreted
Dismantling information is sourced and interpreted
Dismantling options are analysed and those most appropriate to the circumstances are selected
Hazards associated with the work are identified and risks are managed
Dismantling tools and equipment are selected and checked for serviceability
Compressor is dismantled in a logical sequence according to manufacturer and workplace procedures, and safety and environmental requirements,and without causing unnecessary damage to components or systems
Components are cleaned for evaluation according to workplace procedures and safety and environmental requirements
Components are measured and compared with manufacturer specifications and serviceability is determined
Component repair method is determined
Unserviceable parts are identified and replacement parts sourced
Overhaul information is sourced and interpreted
Overhaul options are analysed and those most appropriate to the circumstances are selected
Overhaul tools and equipment are selected and checked for serviceability
Components are machined, repaired and replaced as required, and adjustments are carried out according to manufacturer specifications, workplace procedures, safety and environmental requirements, and Australian automotive code of practice
Compressor is assembled according to manufacturer specifications, workplace procedures, and safety and environmental requirements
Tolerances and clearances are measured against manufacturer specifications and necessary adjustments are made
Assembly of compressor is completed within workplace timeframes and without causing damage to other components or systems
Post-assembly testing is carried out according to workplace procedures and safety and environmental requirements, and any problems detected as having been introduced during the assembly process are rectified
Final inspection is made to ensure work is to workplace expectations and compressor is presented ready for use or storage
Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected
Tools and equipment are checked and stored, and any faulty electrical equipment is identified, tagged and isolated according to workplace procedures
Workplace documentation is processed according to workplace procedures
Job requirements are determined from workplace instructions
Australian automotive code of practice: Control of refrigerant gases during manufacture, installation, servicing or de-commissioning of motor vehicle air conditioners is sourced and interpreted
Dismantling information is sourced and interpreted
Dismantling options are analysed and those most appropriate to the circumstances are selected
Hazards associated with the work are identified and risks are managed
Dismantling tools and equipment are selected and checked for serviceability
Compressor is dismantled in a logical sequence according to manufacturer and workplace procedures, and safety and environmental requirements,and without causing unnecessary damage to components or systems
Components are cleaned for evaluation according to workplace procedures and safety and environmental requirements
Components are measured and compared with manufacturer specifications and serviceability is determined
Component repair method is determined
Unserviceable parts are identified and replacement parts sourced
Overhaul information is sourced and interpreted
Overhaul options are analysed and those most appropriate to the circumstances are selected
Overhaul tools and equipment are selected and checked for serviceability
Components are machined, repaired and replaced as required, and adjustments are carried out according to manufacturer specifications, workplace procedures, safety and environmental requirements, and Australian automotive code of practice
Compressor is assembled according to manufacturer specifications, workplace procedures, and safety and environmental requirements
Tolerances and clearances are measured against manufacturer specifications and necessary adjustments are made
Assembly of compressor is completed within workplace timeframes and without causing damage to other components or systems
Post-assembly testing is carried out according to workplace procedures and safety and environmental requirements, and any problems detected as having been introduced during the assembly process are rectified
Final inspection is made to ensure work is to workplace expectations and compressor is presented ready for use or storage
Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected
Tools and equipment are checked and stored, and any faulty electrical equipment is identified, tagged and isolated according to workplace procedures
Workplace documentation is processed according to workplace procedures
Forms
Assessment Cover Sheet
AURETU007 - Overhaul air conditioning and HVAC system compressors
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
AURETU007 - Overhaul air conditioning and HVAC system compressors
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