Product Overview

Summary: This SOP provides a clear, step-by-step process for the safe installation, commissioning and configuration of multi-split air conditioning systems in Australian workplaces and residential settings. It supports WHS compliance, protects technicians from electrical and refrigerant hazards, and helps businesses deliver consistent, high‑quality installations that perform reliably over the long term.

Multi-split air conditioning systems are increasingly used across Australian commercial, industrial and residential sites due to their flexibility and energy efficiency. However, incorrect installation or configuration can create serious WHS risks, including electric shock, refrigerant exposure, manual handling injuries and property damage, as well as costly call-backs and system failures. This Safe Operating Procedure sets out a structured, repeatable method for planning, installing, wiring, pressure testing, evacuating, charging and commissioning multi-split systems in accordance with Australian standards and manufacturer requirements.

The document goes beyond a simple checklist. It embeds WHS risk controls into every stage of the job, from pre-start site assessment and isolation of services through to leak testing, electrical verification, commissioning, documentation and client handover. By implementing this SOP, HVAC businesses can standardise how their teams work, demonstrate due diligence under WHS legislation, reduce rework and warranty claims, and provide clear evidence of compliance for builders, principal contractors and auditors. It is particularly valuable for organisations scaling their service teams or working across multiple sites who need consistent, safe and compliant installation practices.

Key Benefits

• Ensure installations are completed safely in line with Australian WHS legislation and relevant electrical and refrigeration standards.
• Reduce the risk of electric shock, refrigerant leaks and manual handling injuries during installation and commissioning.
• Standardise installation and configuration practices across all technicians, improving quality and reducing call‑backs and warranty claims.
• Streamline training and onboarding of new HVAC technicians with a clear, step‑by‑step procedure and defined responsibilities.
• Demonstrate compliance and due diligence to builders, principal contractors, auditors and regulators through documented procedures and records.

Who is this for?

• HVAC Technicians
• Refrigeration Mechanics
• Electrical Contractors
• Site Supervisors
• WHS Managers
• Project Managers (Construction and Fit‑out)
• Facilities and Maintenance Managers
• Air Conditioning Company Owners and Directors

Hazards Addressed

• Electric shock and arc flash from live electrical work or incorrect isolation
• Exposure to refrigerant gases during charging, recovery or leak events
• Manual handling injuries from lifting and positioning indoor and outdoor units
• Falls from ladders, platforms or roofs when mounting units and running services
• Use of power tools and sharp hand tools for cutting, flaring and fixing pipework and cabling
• Pressure-related incidents during nitrogen pressure testing and system evacuation
• Environmental harm from uncontrolled refrigerant release and improper disposal
• Heat stress and dehydration when working in roof spaces, plant rooms or outdoor areas in hot conditions

Included Sections

• 1.0 Purpose and Scope
• 2.0 References, Standards and Legislative Requirements
• 3.0 Definitions and System Overview (Multi‑Split Systems)
• 4.0 Roles, Responsibilities and Competency Requirements
• 5.0 Required Tools, Equipment and Materials
• 6.0 Personal Protective Equipment (PPE) Requirements
• 7.0 Pre‑Start Planning and Site Risk Assessment (SWMS/JSA)
• 8.0 Isolation of Services and Permit Requirements
• 9.0 Equipment Handling, Transport and Storage
• 10.0 Indoor and Outdoor Unit Positioning and Mounting Requirements
• 11.0 Pipework Design, Routing and Installation (Refrigerant and Condensate)
• 12.0 Electrical Cabling, Controls and Communication Wiring
• 13.0 Brazing, Flaring and Joint Integrity Requirements
• 14.0 Nitrogen Pressure Testing and Leak Detection Procedure
• 15.0 System Evacuation and Dehydration Procedure
• 16.0 Refrigerant Charging, Recovery and Environmental Controls
• 17.0 Electrical Testing, Verification and Compliance Checks
• 18.0 System Configuration and Commissioning (Controller Set‑up and Balancing)
• 19.0 Functional Testing, Performance Verification and Adjustments
• 20.0 Housekeeping, Waste Management and Site Restoration
• 21.0 Documentation, Compliance Records and Labelling
• 22.0 Client Handover, Instructions and Maintenance Recommendations
• 23.0 Emergency Procedures (Electrical Incident, Refrigerant Leak, Fall or Injury)
• 24.0 Training, Review and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and corresponding state and territory WHS legislation
• 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 – Managing the Risk of Falls at Workplaces Code 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 1677: Refrigerating systems (where still referenced and applicable)
• AS/NZS 3666 (series): Air-handling and water systems of buildings – Microbial control
• AS/NZS 5141: Residential heating and cooling systems – Minimum applications and requirements (where applicable)
• Ozone Protection and Synthetic Greenhouse Gas Management Act 1989 and associated Regulations
• State and territory electrical licensing and refrigeration handling licence requirements