Product Overview

Summary: This Safe Operating Procedure sets out a clear, WHS-aligned method for the safe installation of split system air conditioners in Australian workplaces and residential settings. It guides technicians through pre-start checks, electrical isolation, working at heights, refrigerant handling and commissioning to reduce risk, improve quality, and support regulatory compliance.

The installation of split system air conditioning units involves a combination of electrical work, working at heights, drilling and penetration of building structures, and handling of refrigerants under pressure. Each of these tasks carries inherent WHS risks if not managed under a structured, documented procedure. This SOP provides a step‑by‑step, site-ready framework that walks technicians through planning the installation, assessing the work area, isolating services, mounting indoor and outdoor units, running pipework and cabling, pressure testing, evacuation and commissioning, all with a strong focus on safety and compliance with Australian requirements.

Developed for the Australian HVAC and electrical services environment, this procedure helps businesses demonstrate due diligence under WHS legislation while lifting workmanship quality and consistency across teams. It addresses common problem areas such as unsafe ladder use, poor anchoring of outdoor units, incorrect cable sizing or protection, inadequate condensate management and uncontrolled refrigerant release. By implementing this SOP, organisations can reduce the likelihood of incidents, callbacks and warranty claims, streamline training for apprentices and new staff, and provide clear evidence of a systematic approach to risk management for clients, principal contractors and regulators.

Key Benefits

• Ensure installations are completed in line with Australian WHS duties, electrical requirements and refrigerant handling obligations.
• Reduce the risk of falls, electrical shock, manual handling injuries and refrigerant exposure during installation activities.
• Standardise installation quality across technicians, reducing callbacks, defects and customer complaints.
• Streamline onboarding and competency assessment for new and apprentice HVAC technicians.
• Demonstrate a documented, defensible process to principal contractors, auditors and regulators during safety or compliance reviews.

Who is this for?

• HVAC Technicians
• Refrigeration and Air Conditioning Mechanics
• Electrical Contractors
• Apprentice HVAC Technicians
• Site Supervisors
• Construction Project Managers
• Facilities and Maintenance Managers
• WHS Advisors and Safety Officers
• Small Business Owners in HVAC and Electrical Services
• Strata and Property Managers

Hazards Addressed

• Falls from ladders, platforms or roofs while mounting indoor or outdoor units
• Electrical shock or arc flash from live circuits and incorrect isolation
• Exposure to refrigerants under pressure, including leaks, frostbite and asphyxiation risks
• Manual handling injuries from lifting and positioning heavy indoor and outdoor units
• Struck-by injuries from falling tools, brackets or equipment during overhead work
• Noise and vibration from power tools used for drilling and cutting
• Dust and debris inhalation from drilling through masonry, brick or plasterboard
• Penetration of concealed services (electrical, gas, water) when drilling walls or slabs
• Environmental harm and regulatory breaches from uncontrolled refrigerant release
• Trips, slips and housekeeping hazards from hoses, cables, packaging and condensate
• Weather-related risks when working outdoors or at heights (heat stress, UV exposure, wet surfaces)

Included Sections

• 1.0 Purpose and Scope
• 2.0 References, Standards and Legal Requirements
• 3.0 Definitions and Abbreviations
• 4.0 Roles and Responsibilities
• 5.0 Competency, Licensing and Training Requirements
• 6.0 Tools, Equipment and Materials
• 7.0 Personal Protective Equipment (PPE) Requirements
• 8.0 Pre-Start Planning and Site Assessment
• 9.0 Hazard Identification and Risk Controls
• 10.0 Electrical Isolation and Lockout/Tagout Requirements
• 11.0 Working at Heights and Ladder Safety Procedures
• 12.0 Indoor Unit Location, Mounting and Fixing Procedure
• 13.0 Outdoor Unit Location, Mounting and Fixing Procedure
• 14.0 Pipework, Drainage and Cable Routing Requirements
• 15.0 Refrigerant Handling, Pressure Testing and Leak Detection
• 16.0 Evacuation, Charging and Commissioning Procedure
• 17.0 Housekeeping, Waste Management and Environmental Controls
• 18.0 Post-Installation Checks, Testing and Documentation
• 19.0 Emergency Procedures and Incident Response
• 20.0 Monitoring, Review and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and relevant state and territory WHS legislation
• Work Health and Safety Regulations 2011 (Cth) and state/territory equivalents
• Safe Work Australia – Model Code of Practice: Construction Work
• Safe Work Australia – Model Code of Practice: Managing the Risk of Falls at Workplaces
• Safe Work Australia – Model Code of Practice: Managing Electrical Risks in the Workplace
• 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 1668.2: The use of ventilation and air conditioning in buildings – Mechanical ventilation in buildings
• AS/NZS 1891 (series): Industrial fall-arrest systems and devices
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 1337.1: Personal eye protection
• Refrigerant Handling Licence and Refrigerant Trading Authorisation requirements – Australian Refrigeration Council (ARC)