Product Overview

Summary: This Safe Operating Procedure provides a clear, step-by-step method for the safe and compliant setup of heat pump systems in Australian workplaces. It supports technicians and contractors to manage electrical, refrigerant and manual handling risks while delivering consistent, high‑quality installations that meet WHS and energy efficiency requirements.

Heat pumps are increasingly used across Australian commercial, industrial and residential sites for heating, cooling and hot water, but incorrect setup can create serious safety, compliance and performance issues. This SOP provides a structured, WHS-aligned process for planning, installing and commissioning heat pump systems, from pre‑start checks and site preparation through to electrical connection, refrigerant management and final verification testing. It helps duty holders demonstrate that reasonably practicable steps have been taken to control risks associated with pressurised refrigerants, live electrical work, working at height and confined plant rooms.

Developed for the Australian regulatory environment, the procedure emphasises safe isolation practices, leak prevention, environmental protection of refrigerants, and correct documentation of commissioning data. By standardising the way technicians approach system setup, this SOP reduces variability between installers, supports competency-based training, and minimises the likelihood of costly rework, warranty claims, system failures and regulatory scrutiny. It is suitable for organisations rolling out heat pump programs across multiple sites, as well as smaller contractors wanting a professional, defensible procedure that aligns with best practice and relevant Australian Standards.

Key Benefits

• Ensure safe, consistent setup of heat pump systems across all sites and technicians.
• Reduce the risk of electrical shock, refrigerant leaks and manual handling injuries during installation.
• Streamline commissioning and handover with clear checklists, test records and documentation requirements.
• Support compliance with WHS duties, electrical safety regulations and refrigerant handling obligations.
• Improve system performance, reliability and energy efficiency by following a structured setup methodology.

Who is this for?

• Refrigeration and Air Conditioning Technicians
• Electrical Tradespersons
• HVAC Installers
• Maintenance Supervisors
• Facilities Managers
• WHS Advisors and Coordinators
• Construction Project Managers
• Mechanical Services Contractors

Hazards Addressed

• Electrical shock and arc flash from incorrect isolation or connection of live circuits
• Exposure to refrigerant gases, including cold burns, asphyxiation and eye injuries
• Environmental release of refrigerants contributing to ozone depletion or global warming
• Manual handling injuries from lifting and positioning outdoor and indoor units
• Falls from height when installing roof-mounted or elevated units
• Trips, slips and impact injuries around congested plant areas and pipework
• Noise exposure during testing and commissioning in confined plant rooms
• Contact with hot or moving components during functional testing
• Use of power tools and cutting equipment for mounting, pipework and ductwork
• Confined space risks in plant rooms or service shafts with poor ventilation

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and References
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Pre-Start Planning and Site Risk Assessment
• 5.0 Required Tools, Equipment and Personal Protective Equipment (PPE)
• 6.0 Isolation, Lockout and Verification of Electrical Supply
• 7.0 Handling, Storage and Transfer of Refrigerants
• 8.0 Unit Positioning, Mounting and Structural Considerations
• 9.0 Pipework, Drainage and Electrical Connection Requirements
• 10.0 System Evacuation, Charging and Leak Testing
• 11.0 Commissioning, Functional Testing and Performance Verification
• 12.0 Environmental Protection and Waste Management (Refrigerants and Materials)
• 13.0 Hazard Controls, Safe Work Practices and Prohibited Actions
• 14.0 Emergency Procedures (Electrical Incidents, Refrigerant Leaks, Injuries)
• 15.0 Documentation, Commissioning Records and Handover Requirements
• 16.0 Training, Review and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and corresponding state and territory WHS Acts
• Work Health and Safety Regulations 2011 and state/territory equivalents
• Safe Work Australia – Managing Electrical Risks in the Workplace Code of Practice
• Safe Work Australia – Hazardous Chemicals (including refrigerants) Codes of Practice
• AS/NZS 3000:2018 Electrical installations (Wiring Rules)
• AS/NZS 5149 (series): Refrigerating systems and heat pumps – Safety and environmental requirements
• AS/NZS 60335.2.40: Household and similar electrical appliances – Safety – Particular requirements for electrical heat pumps, air-conditioners and dehumidifiers
• AS/NZS 3666 (series): Air-handling and water systems of buildings – Microbial control
• AS/NZS ISO 45001:2018 Occupational health and safety management systems – Requirements with guidance for use
• Ozone Protection and Synthetic Greenhouse Gas Management Act 1989 and associated regulations