Comprehensive SWMS for Split System, Ducted, and Multi-Head Air Conditioning Installation

Air Conditioning Installation Safe Work Method Statement

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Air conditioning installation involves the complete setup of climate control systems including split systems, ducted units, and multi-head configurations in residential, commercial, and industrial buildings. This specialised HVAC work requires licensed refrigerant handling, electrical connections, structural mounting, and system commissioning while managing hazards including working at heights, refrigerant gas exposure, electrical risks, manual handling of heavy equipment, and heat stress. This SWMS addresses the specific safety requirements for air conditioning installation work in accordance with Australian WHS legislation and refrigerant handling regulations, providing detailed hazard controls, inspection procedures, and step-by-step installation methods to ensure worker safety and compliant system commissioning.

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Overview

What this SWMS covers

Air conditioning installation is a specialised HVAC activity involving the complete setup of cooling and heating systems in residential, commercial, and industrial environments. This work encompasses split system installations with single indoor and outdoor units, ducted systems with central air handling and distribution ductwork, multi-head systems with multiple indoor units connected to single outdoor condensers, and commercial package units serving larger spaces. Air conditioning installers must interpret system specifications, assess structural mounting requirements, run refrigerant piping and electrical circuits, pressure test refrigeration systems, vacuum purge installations, charge systems with appropriate refrigerant quantities, and commission complete operating systems. Split system installation represents the most common residential application, involving wall-mounted or floor-standing indoor units connected to ground-level or wall-mounted outdoor condensers. Indoor units typically mount on external walls at heights of 2.1 to 2.4 metres, requiring ladder or platform access for secure bracket installation and unit mounting. Outdoor condensers weighing 30 to 80 kilograms must be positioned on suitable mounting pads or wall brackets with adequate drainage, airflow clearances, and noise attenuation from neighbouring properties. Refrigerant pipes connect indoor and outdoor units through wall penetrations, run inside protective conduit or trunking, and terminate at flared or compression fittings requiring leak-tight connections. Ducted air conditioning installations involve significantly more complex work, typically occurring during construction or major renovation projects. Central air handling units install in roof spaces or plant rooms, with insulated supply and return ductwork distributed throughout the building. Installers must work in confined roof spaces with extreme temperatures, position heavy air handlers on structural supports, install extensive ductwork runs with proper sealing and insulation, mount ceiling grilles with accurate positioning, and commission zoning systems with electronic controls. The work requires coordination with electricians for power circuits and control wiring, and with builders for ceiling access points and ductwork chases. Commercial installations present additional complexities including larger equipment capacities, three-phase electrical connections, building management system integration, and stringent commissioning requirements. Multi-storey installations may require crane lifting of condensers to rooftop locations, working at heights on building exteriors, and coordination with other building services. All air conditioning installation work requires licensing under Australian refrigerant handling regulations, electrical work licenses for power connections, and working at heights certification for elevated installations. Installation timeframes vary from single-day residential split systems to multi-week commercial ducted installations.

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Why this SWMS matters

Air conditioning installation presents multiple serious safety hazards that require careful management under Australian WHS legislation. Working at heights occurs frequently when mounting indoor units on walls at 2.1 to 2.4 metre heights, installing outdoor condensers on upper floor balconies or rooftops, and accessing roof spaces for ducted system installations. Falls from ladders, scaffolds, or through fragile roof materials cause severe injuries including fractures, head trauma, and spinal injuries. The combination of working at heights while handling heavy equipment and performing precise installation tasks increases fall risk significantly. Safe Work Australia identifies falls as a leading cause of construction fatalities, making height safety controls absolutely critical for air conditioning work. Refrigerant gas exposure presents serious health risks during air conditioning installation. Modern refrigerants including R32, R410A, and R134a are generally low-toxicity but can cause asphyxiation in confined spaces by displacing oxygen. When released in roof spaces, plant rooms, or poorly ventilated areas, refrigerant gases accumulate at floor level creating suffocation hazards. Refrigerants can also cause cold burns on skin contact with liquid refrigerant during charging operations. Some older systems still containing R22 require special handling due to ozone depletion concerns. Under the Ozone Protection and Synthetic Greenhouse Gas Management Act 1989, only licensed technicians holding ARCtick refrigerant handling licences may work on refrigeration systems. Improper refrigerant handling can result in significant penalties including fines exceeding $13,000 for individuals and $65,000 for companies, alongside potential prosecution for WHS breaches causing injury. Electrical hazards exist throughout air conditioning installation including working near existing energised circuits, connecting new circuits from switchboards, installing isolators, and commissioning electrical controls. Contact with live conductors causes electrocution, severe burns, or death. Air conditioning systems typically require dedicated electrical circuits with appropriately rated circuit breakers and isolating switches. Installers must follow lock-out/tag-out procedures when working on electrical systems, verify circuits are de-energised before commencing work, and ensure all electrical work complies with AS/NZS 3000 wiring standards. Only licensed electricians may perform electrical connection work, though refrigeration mechanics may perform limited electrical work under specific exemptions. Manual handling injuries commonly occur when lifting and positioning air conditioning equipment. Outdoor condenser units weighing 30 to 80 kilograms must be carried to installation locations, lifted to wall mounting brackets, or positioned on concrete pads. Indoor units weighing 8 to 25 kilograms must be held at shoulder height or above during wall bracket installation and unit mounting. Ducted air handling units can exceed 100 kilograms requiring mechanical lifting aids or team lifting. The combination of equipment weight, awkward shapes, working at heights, and confined spaces creates significant musculoskeletal injury risk including back strains, shoulder injuries, and hernias. Heat stress affects installers working in roof spaces during Australian summer months when temperatures regularly exceed 50 degrees Celsius in unventilated roof cavities. Prolonged exposure causes heat exhaustion, heat stroke, dehydration, and impaired judgment that increases other risks. Installers wearing protective clothing and respirators face additional heat stress. Adequate hydration, scheduled rest breaks, heat monitoring, and limiting work duration in extreme conditions are essential controls. Only through comprehensive SWMS implementation addressing these multiple hazards can air conditioning installation work proceed safely while meeting regulatory requirements and protecting worker health.

Reinforce licensing, insurance, and regulator expectations for Air Conditioning Installation Safe Work Method Statement crews before they mobilise.

Hazard identification

Surface the critical risks tied to this work scope and communicate them to every worker.

Risk register

Falls from Heights During Indoor Unit Installation

High

Indoor air conditioning units mount on walls at heights typically between 2.1 and 2.4 metres, requiring installers to work from ladders or scaffolds while handling equipment weighing 8 to 25 kilograms. Workers must drill wall penetrations, install mounting brackets, run refrigerant pipes, and secure indoor units while working at height with both hands occupied. Overreaching to position units accurately, working on unstable ladder placement, or attempting single-person installation of heavy units creates significant fall risk. Falls from this height commonly cause head injuries, fractures, and spinal trauma requiring hospitalisation.

Consequence: Head trauma, skull fractures, spinal cord injuries, fractured arms and wrists, dislocated shoulders, and permanent disability. Falls from 2 to 3 metres frequently result in injuries requiring extended hospitalisation and can be fatal if head impacts occur.

Refrigerant Gas Exposure and Asphyxiation

High

Air conditioning installation involves handling pressurised refrigerant gases including R32, R410A, and R134a during system charging, pressure testing, and commissioning. If refrigerant escapes in confined spaces such as roof cavities, small plant rooms, or enclosed work areas, gases displace oxygen creating asphyxiation hazards. Refrigerant gases are heavier than air and accumulate at floor level where workers may be kneeling or sitting during installation. Liquid refrigerant contact during charging operations causes cold burns to skin and eyes. Refrigerants exposed to open flames or hot surfaces decompose producing toxic gases including hydrogen fluoride.

Consequence: Oxygen deprivation causing unconsciousness, brain damage, and death. Cold burns from liquid refrigerant causing severe tissue damage. Toxic gas inhalation causing respiratory damage and long-term health effects. Regulatory penalties for unlicensed refrigerant handling.

Electrocution from Electrical Connections

High

Air conditioning installation requires electrical connections from switchboards to isolators, from isolators to outdoor condensers, and control wiring between indoor and outdoor units. Installers may work near energised circuits in switchboards when installing dedicated air conditioning circuit breakers. Incorrect wiring connections, failure to verify de-energisation before work, or contact with existing live conductors causes electrocution. Outdoor condenser installations near overhead power lines create additional electrical hazards if equipment contacts or approaches conductors too closely.

Consequence: Electrocution causing cardiac arrest and death, severe electrical burns requiring skin grafts and amputation, neurological damage from electric shock, and permanent disability. Arc flash events causing catastrophic burns and explosive pressure injuries.

Manual Handling of Heavy Air Conditioning Equipment

High

Outdoor condenser units weigh between 30 and 80 kilograms depending on capacity, requiring manual handling from delivery location to installation position. Units must often be carried through confined spaces, up stairs, or lifted to elevated mounting brackets. Indoor units weighing 8 to 25 kilograms must be held at shoulder height during wall mounting. Ducted air handling units exceeding 100 kilograms require mechanical lifting or team lifting. The awkward shapes of air conditioning equipment with sharp fins and protruding pipes make secure grip difficult. Manual handling in combination with working at heights or in confined spaces significantly increases injury risk.

Consequence: Lower back injuries including disc herniation and chronic back pain, shoulder rotator cuff tears requiring surgical repair, inguinal hernias from lifting heavy loads, wrist and hand injuries from grip strain, and long-term musculoskeletal disorders causing permanent work capacity reduction.

Heat Stress in Roof Spaces During Ducted Installations

High

Ducted air conditioning installation requires extended periods working in roof spaces where temperatures regularly exceed 50 degrees Celsius during Australian summer months. Installers must position air handling units, install metres of ductwork, mount ceiling grilles, and run refrigerant pipes in extreme heat with limited ventilation. Protective clothing including long sleeves and pants, combined with respirator use when insulation fibres are present, increases heat stress. Dehydration occurs rapidly in these conditions, and heat exhaustion can progress to life-threatening heat stroke within 30 to 60 minutes of continuous exposure.

Consequence: Heat exhaustion causing weakness, nausea, and impaired judgment that increases other risks. Heat stroke causing organ failure, brain damage, and death. Dehydration causing reduced cognitive function, increased error rates, and higher likelihood of falls or electrical contact incidents.

Refrigerant System Pressure Hazards

Medium

Air conditioning systems operate under significant refrigerant pressures, typically 15 to 25 bar on the high-pressure side during operation. During installation, systems must be pressure tested to 40 to 45 bar using nitrogen to verify pipe integrity before refrigerant charging. If piping fails under test pressure due to incorrect flaring, damaged pipes, or inadequate support, sudden refrigerant or nitrogen release creates projectile hazards from failing components. Over-pressurisation during charging or incorrect pressure testing procedures can cause catastrophic system failure with violent refrigerant discharge.

Consequence: Impact injuries from failing system components becoming projectiles, refrigerant discharge causing cold burns and asphyxiation risk, hearing damage from explosive decompression, and eye injuries from high-pressure gas discharge. Equipment damage requiring system replacement.

Power Tool and Equipment Operation Hazards

Medium

Air conditioning installation requires extensive power tool use including core drilling for wall penetrations, hammer drilling for bracket fixings, cutting and flaring copper refrigerant pipes, brazing pipe connections with oxy-acetylene equipment, and using vacuum pumps for system evacuation. Core drilling through masonry or concrete walls creates significant vibration, dust, and potential for drill bit binding and kickback. Brazing operations involve open flames near combustible building materials and produce copper oxide fumes requiring ventilation. Flaring tools can cause crush injuries if mishandled.

Consequence: Laceration injuries from rotating drill bits, crush injuries from equipment kickback, burns from brazing equipment, respiratory damage from metal fumes and concrete dust, hearing damage from prolonged tool noise exposure, and vibration white finger from extended power tool use.

Confined Space Entry for Ductwork Installation

Medium

Ducted air conditioning installation frequently requires confined space entry into roof cavities with limited access, inadequate headroom, and restricted egress routes. These spaces may contain insulation fibres creating respiratory hazards, electrical cables presenting contact risks, and structural members limiting movement. Roof spaces have limited ventilation allowing refrigerant gases to accumulate if leaks occur. During summer, confined roof spaces become extremely hot with temperatures exceeding 60 degrees Celsius. Emergency rescue from roof spaces presents significant challenges if workers become injured or overcome by heat or gas exposure.

Consequence: Asphyxiation from refrigerant accumulation or oxygen depletion, heat-related illness in extreme temperatures, entrapment following injury with delayed rescue, respiratory damage from insulation fibre exposure, and injuries from contact with electrical cables or structural members in confined spaces.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

Engineered Height Access Systems for Indoor Unit Installation

Engineering Control

Eliminate ladder use for indoor unit installation by providing platform ladders with minimum 450mm x 450mm platform area and handrails, or mobile scaffold platforms providing continuous work height access. Platform systems allow both hands free operation while maintaining three points of contact, significantly reducing fall risk compared to conventional stepladders. For multiple unit installations, mobile scaffolds with adjustable height platforms provide safer access than repeatedly moving ladders.

Implementation

1. Assess indoor unit installation height and select appropriate access equipment - platform ladders for single units, mobile scaffold for multiple installations 2. Ensure platform ladders are rated to minimum 150kg industrial capacity and include handrails extending above platform level 3. Position platform ladder base on level, stable surface with adequate clearance from walls for bracket installation and unit mounting 4. Verify all scaffold components are in serviceable condition with current inspection tags before assembly 5. Ensure mobile scaffold includes toe boards, guardrails, and wheel locks engaged before use 6. Maintain three points of contact when ascending or descending access equipment 7. Position worker to face work without twisting or overreaching - reposition equipment rather than stretching beyond safe reach

Refrigerant Gas Monitoring and Ventilation Protocol

Engineering Control

Implement continuous atmospheric monitoring in confined spaces and poorly ventilated areas where refrigerant work occurs. Use portable gas detectors calibrated for specific refrigerants being handled to provide early warning of refrigerant release. Establish forced ventilation using portable extraction fans positioned to remove gases at floor level where heavier-than-air refrigerants accumulate. Maintain minimum 8 air changes per hour in confined work areas during refrigerant handling. Establish exclusion zones preventing entry to areas where refrigerant work occurs until atmospheric testing confirms safe oxygen levels.

Implementation

1. Calibrate portable refrigerant gas detector before each shift using manufacturer-specified calibration gas 2. Position gas detector sensor at floor level in work area where refrigerant gases would accumulate 3. Set alarm threshold at 50% of refrigerant lower flammability limit or 1000ppm oxygen depletion, whichever is lower 4. Install portable extraction fan at floor level in confined spaces, directing airflow to external atmosphere 5. Verify ventilation achieves minimum 8 air changes per hour before commencing refrigerant work 6. Establish barricades and signage preventing entry to confined spaces during refrigerant charging operations 7. If gas detector alarms activate, immediately evacuate area, ventilate for minimum 15 minutes, and re-test atmosphere before re-entry

Lock-Out/Tag-Out Electrical Isolation Procedure

Administrative Control

Require documented electrical isolation following formal lock-out/tag-out procedure before commencing any electrical connection work. Identify the specific circuit breaker or isolator controlling the air conditioning circuit, isolate at switchboard, apply personal safety lock and danger tag, test circuit with voltage tester to confirm de-energisation, and only then commence electrical work. Each worker applies their own personal lock - never rely on another person's isolation. Maintain isolation throughout electrical work until all tasks are complete and workers are clear of circuits.

Implementation

1. Identify the specific circuit breaker controlling the air conditioning circuit using circuit directory or testing methodology 2. Notify all affected persons that electrical isolation will occur and work is commencing on the circuit 3. Switch circuit breaker to OFF position and physically lock using personal safety padlock that only the worker holds keys for 4. Attach danger tag to isolation point including worker name, date, time, and nature of work being performed 5. Test circuit at work location using voltage tester rated for expected voltage level - verify zero voltage on all conductors 6. Re-test at 1-minute interval to confirm voltage tester is functioning correctly - test on known live circuit if available 7. Only after confirmed de-energisation, commence electrical connection work 8. Upon completion, remove all tools and equipment, verify area is clear, remove personal tag and lock, restore circuit to service, and test operation

Two-Person Lift and Mechanical Aid Protocol for Heavy Equipment

Engineering Control

Eliminate single-person manual handling of outdoor condenser units by mandating two-person lifts for all units exceeding 20kg or requiring movement over distances greater than 10 metres. Provide mechanical lifting aids including sack trucks, trolleys, and lifting straps for unit transport. For wall-mounted outdoor units, use purpose-built wall mounting systems that allow unit weight to rest on brackets before final securing, eliminating the need to hold weight during fixing. Schedule adequate workforce to ensure two-person lifts are always available.

Implementation

1. Weigh or check manufacturer specifications for all air conditioning units before moving - mark units requiring two-person lift 2. Assess transport route from delivery point to installation location identifying obstacles, stairs, and confined spaces requiring careful handling 3. Provide heavy-duty sack truck rated to 150kg capacity for moving outdoor condensers across level surfaces 4. Use mechanical trolley for any movement exceeding 20 metres or involving uneven surfaces 5. For wall-mounted outdoor units, install bracket system allowing unit to rest on brackets during final securing - never require worker to hold full unit weight 6. Assign specific workers to two-person lift team with clear communication protocol including agreed commands for lift initiation and lowering 7. Brief workers on correct lifting technique - bend knees, keep back straight, lift with legs, maintain load close to body, avoid twisting during carry

Heat Stress Management Plan for Roof Space Work

Administrative Control

Implement mandatory heat stress controls when working in roof spaces during hot weather. Limit continuous work periods to maximum 20 minutes when roof space temperatures exceed 40 degrees Celsius, with mandatory 10-minute rest breaks in cooled environments. Provide unlimited cold drinking water at work location. Schedule roof space work during cooler morning hours before 11am when possible. Monitor workers for heat stress symptoms including confusion, weakness, or cessation of sweating. Provide cooling vests or other personal cooling equipment for workers in extreme heat conditions.

Implementation

1. Measure roof space temperature using thermometer before commencing work - document temperature in work log 2. When temperature exceeds 40°C, implement 20 minutes work / 10 minutes rest cycle with strict enforcement 3. Position cooled drinking water in roof space access area - minimum 1 litre per worker per hour in extreme heat 4. Schedule roof space work for early morning hours when outdoor temperature is coolest, ideally before 11am 5. Provide personal cooling vests or cooling towels for workers during extreme heat conditions (roof space temperatures exceeding 50°C) 6. Assign supervisor to monitor workers for heat stress symptoms - confusion, excessive sweating followed by dry skin, weakness, or disorientation 7. If heat stress symptoms observed, immediately remove worker from roof space, move to cool area, provide water, and seek medical attention 8. Cancel roof space work if outdoor temperature exceeds 38°C and building cannot be safely accessed from cooled interior

Pressure Testing Safety Protocol

Administrative Control

Establish documented pressure testing procedure for refrigerant systems using nitrogen instead of refrigerant. Limit test pressure to maximum 150% of system working pressure or manufacturer specifications. Use pressure relief valves set at safe maximum pressure. Conduct pressure testing with all personnel clear of system components. Maintain test pressure for minimum 20 minutes while monitoring for pressure drop indicating leaks. Never use oxygen or compressed air for pressure testing due to combustion and contamination risks respectively.

Implementation

1. Calculate maximum test pressure based on system specifications - typically 40 to 45 bar for residential split systems, never exceed manufacturer limits 2. Connect nitrogen cylinder to system via pressure regulator set to correct test pressure 3. Install pressure relief valve on test equipment set to 110% of test pressure to prevent over-pressurisation 4. Pressurise system slowly monitoring pressure gauge continuously - stop immediately if unusual sounds, movements, or pressure spikes occur 5. Evacuate all personnel from immediate vicinity once test pressure reached - maintain minimum 3 metre exclusion zone 6. Monitor pressure gauge from safe distance for 20-minute hold period - any pressure drop indicates leak requiring investigation 7. If system holds pressure, slowly release nitrogen in controlled manner before disconnecting test equipment 8. Document test pressure, hold time, and results in installation records for warranty and compliance purposes

Personal Protective Equipment for HVAC Installation

Personal Protective Equipment

Provide and mandate comprehensive PPE specific to air conditioning installation hazards. Safety glasses protect against copper swarf during pipe cutting and flaring. Cut-resistant gloves prevent injuries from sharp condenser fins and copper pipe edges. Respirators protect against brazing fumes and insulation fibres in roof spaces. Arc-rated gloves required for any electrical connection work. Hearing protection mandatory during core drilling and power tool use. Heat-resistant clothing for brazing operations.

Implementation

1. Issue safety glasses with side shields rated to AS/NZS 1337 to all workers - mandatory during pipe cutting, brazing, and power tool operation 2. Provide cut-resistant gloves rated to Level 3 per AS/NZS 2161.4 for handling air conditioning units with sharp fins and cutting copper pipe 3. Supply P2 particulate respirators conforming to AS/NZS 1716 for work in roof spaces containing insulation fibres 4. Provide specific respirator type for brazing fumes if local exhaust ventilation not available - supplied air respirator for extended brazing in confined spaces 5. Issue Class 0 electrical safety gloves rated to 1000V per AS/NZS 2225 for electrical connection work - inspect before each use for tears or damage 6. Provide Class 4 hearing protection per AS/NZS 1270 when using core drills, power tools, or working near operating machinery 7. Supply leather or fire-resistant apron and heat-resistant gloves for all brazing operations 8. Ensure all PPE is maintained in serviceable condition and replaced when damaged - maintain spare PPE on site

Download complete control procedures

Personal protective equipment

Requirement: Medium impact rated per AS/NZS 1337

When: During all power tool operation, core drilling, copper pipe cutting and flaring, brazing operations, and when working beneath ceiling cavities

Requirement: Level 3 cut resistance per AS/NZS 2161.4

When: When handling air conditioning units with sharp aluminium fins, cutting copper pipes, or moving equipment with protruding sharp edges

Requirement: Class 0 rated to 1000V per AS/NZS 2225

When: During all electrical connection work including switchboard circuit installation and isolator wiring

Requirement: P2 particulate filter per AS/NZS 1716

When: When working in roof spaces containing fibreglass or rockwool insulation, or during brazing operations producing metal fumes

Requirement: Class 4 protection per AS/NZS 1270

When: When operating core drills, power tools, or any equipment producing noise levels exceeding 85dB(A) for more than 5 minutes

Requirement: Category 1 impact protection per AS/NZS 2210.3

When: Throughout all air conditioning installation work to protect against dropped equipment, outdoor units, and tools

Requirement: Full body harness per AS/NZS 1891.1

When: When installing outdoor condensers on rooftops, working on elevated platforms above 2 metres, or accessing roof spaces where fall hazards exist

Inspections & checks

Before work starts

✓Verify installation location is accessible and clear of obstacles for safe equipment delivery and positioning
✓Measure indoor unit mounting height and mark wall stud locations for bracket installation - verify structural adequacy of wall
✓Assess outdoor condenser location for adequate ventilation clearances (minimum 300mm from walls) and drainage requirements
✓Confirm electrical circuit has been installed by licensed electrician or obtain approval to install dedicated circuit
✓Check refrigerant handling licence currency for all technicians who will perform refrigerant work - verify ARCtick licence validity
✓Inspect all power tools including core drill, hammer drill, flaring tool, and brazing equipment for serviceability
✓Test portable gas detector calibration using manufacturer-specified calibration gas before commencing refrigerant work
✓Verify platform ladder or scaffold system is in serviceable condition with current inspection tags and rated capacity labels
✓Assess roof space access if ducted installation - measure access dimensions, temperature, and identify confined space hazards
✓Confirm availability of lifting aids, trolleys, and minimum two workers for heavy equipment manual handling

During work

✓Monitor platform ladder stability during indoor unit bracket installation - verify three points of contact maintained at all times
✓Check core drill operation and cooling water supply when drilling wall penetrations for refrigerant pipes and electrical conduit
✓Verify refrigerant gas detector is operating and positioned at floor level during all refrigerant handling activities
✓Inspect flared pipe connections for correct dimensions and surface finish before assembling refrigerant joints
✓Monitor nitrogen pressure gauge during pressure testing - evacuate personnel if pressure rises above safe test pressure
✓Verify ventilation fan operation in roof spaces and confined areas during refrigerant work
✓Check worker heat stress status every 20 minutes during roof space work - monitor for symptoms of heat exhaustion
✓Verify electrical isolation remains in place during all electrical connection work - check danger tags are secure
✓Monitor two-person lifting protocols being followed for outdoor condenser movement and positioning
✓Inspect brazing work area for fire hazards - remove combustible materials before commencing brazing operations

After work

✓Pressure test complete refrigerant system at specified test pressure for minimum 20 minutes before refrigerant charging
✓Verify all electrical connections are secure, correctly terminated, and protected by appropriate circuit protection devices
✓Test system operation including cooling mode, heating mode (if applicable), and all indoor unit functions
✓Measure and document refrigerant charge quantity - confirm system is charged to manufacturer specifications
✓Inspect all penetrations through walls and ceilings are sealed weather-tight with appropriate gap sealants
✓Verify outdoor condenser is securely mounted with adequate support, level positioning, and drainage away from unit
✓Test system operation including temperature differential between return air and supply air to confirm adequate performance
✓Clean installation area removing all packaging materials, copper off-cuts, drilling debris, and installation waste
✓Provide client with operating instructions and complete warranty documentation including refrigerant handling records
✓Complete commissioning documentation including system pressures, refrigerant charge quantities, and electrical test results for compliance records

Step-by-step work procedure

Give supervisors and crews a clear, auditable sequence for the task.

Field ready

Site Assessment and Preparation

Conduct comprehensive site assessment before commencing installation work. Measure indoor unit mounting location verifying adequate clearances - minimum 150mm from ceiling, 100mm from adjacent walls, and 2.1 to 2.4 metres above finished floor level. Locate wall studs using electronic stud finder and verify by drilling small pilot holes at marked locations. Indoor unit brackets must fix to solid timber or steel studs, never to plasterboard alone. Assess outdoor condenser location ensuring adequate ventilation clearances - minimum 300mm clearance on all sides for airflow, positioned away from bedroom windows where possible to minimise noise disturbance. Verify outdoor location provides solid mounting surface such as concrete pad or masonry wall capable of supporting condenser weight plus mounting bracket. Calculate refrigerant pipe run distance between indoor and outdoor units - runs exceeding manufacturer specifications require system recharge calculations. Identify cable route from switchboard to outdoor isolator location. Document all measurements and photograph site conditions before commencing work.

Safety considerations

Verify power is isolated at switchboard before commencing any work near electrical cables. Assess roof space access for confined space hazards if pipe run will penetrate roof cavity. Check for overhead power lines near outdoor condenser location - maintain minimum 3-metre clearance from any overhead conductors.

Indoor Unit Bracket Installation

Install indoor unit mounting bracket using platform ladder or scaffold providing stable working height. Position platform ladder base on firm, level surface ensuring stability before climbing. Verify ladder position allows worker to face wall squarely without twisting or overreaching. Hold bracket against wall at measured height and level position using spirit level. Mark fixing hole locations through bracket holes onto wall surface. Drill pilot holes at marked locations using appropriate drill bit for wall material - typically 7mm pilot holes for 10mm masonry anchors in brick or concrete walls, or appropriately sized holes for timber stud walls. If drilling through plasterboard into timber studs, drill carefully to avoid breaking through plasterboard surrounding hole. Install appropriate fixing for wall type - masonry anchors in brick walls, timber screws into timber studs. Minimum four fixings required for standard split system indoor units, all fixings must achieve minimum 35mm penetration into solid structural material. Verify bracket is firmly secured and level before proceeding. For heavy commercial indoor units exceeding 20kg, additional support brackets may be required - refer to manufacturer specifications.

Safety considerations

Maintain three points of contact when working on platform ladder. Never stand on top step or platform above marked limit. Wear safety glasses during drilling operations to protect from masonry dust and drilling debris. If drilling into external walls near electrical circuits, verify power isolation before drilling. Reposition ladder rather than overreaching to mark or drill fixing holes.

Core Drilling for Pipe Penetration

Core drill through external wall at indoor unit location to create penetration for refrigerant pipes and drain pipe. Position core drill to create hole with slight downward angle toward outside (approximately 5 degrees) ensuring condensate drains away from building. Use appropriate core bit diameter - typically 65mm for standard split system pipe set allowing space for refrigerant suction pipe, liquid pipe, drain pipe, and control cable. Connect core drill water supply to provide cooling during drilling operation. Operate core drill at correct speed for wall material - slower speeds for dense concrete, higher speeds for brick or rendered walls. Apply steady pressure without forcing - allow core bit to cut at its designed rate. If drilling through double-brick cavity walls, drill from external side once internal hole breaks through to prevent internal plasterboard damage. Clear drilling debris regularly to maintain core bit cutting efficiency. Once penetration is complete, clean hole removing all loose material and drilling slurry. Insert plastic sleeve into penetration to protect refrigerant pipes from contact with sharp masonry edges and provide sealed pipe entry point.

Safety considerations

Verify no electrical cables or plumbing pipes exist in drilling path - use cable detector to scan wall before drilling. Wear safety glasses with side shields during core drilling - masonry particles and water spray create eye hazard. Ensure adequate grip on core drill - equipment kickback can cause loss of control if core bit binds. Maintain stable stance on work platform during drilling. Connect core drill water supply before commencing drilling - dry cutting creates excessive dust and overheats core bit. If working near energised electrical circuits, verify isolation before drilling.

Outdoor Condenser Positioning and Securing

Position outdoor condenser unit at installation location using two-person lift for units exceeding 20kg. Use sack truck or trolley for transport if moving unit more than 10 metres from delivery point. Prepare mounting location - for ground mounting, provide concrete pad with minimum 100mm thickness extending at least 50mm beyond unit dimensions on all sides, or use purpose-built condenser mounting frame rated for unit weight. For wall-mounted installations, install wall brackets following manufacturer specifications ensuring fixings achieve minimum 35mm penetration into solid structural material - typically four heavy-duty masonry anchors rated to support unit weight plus safety factor of 2.5 times. Condensers weighing over 60kg require additional support brackets. Position condenser ensuring adequate clearances - minimum 300mm from walls on sides, 500mm clearance in front of fan discharge, raised minimum 100mm above ground level for drainage. Verify unit is level in both directions using spirit level. Check condenser feet are secured to mounting pad using appropriate fixings - typically M8 or M10 bolts through mounting feet into concrete anchors. For wall-mounted units, verify weight is fully supported by brackets before releasing manual hold. Check unit does not contact or vibrate against walls or structures during operation.

Safety considerations

Use two-person lift for all outdoor condenser units exceeding 20kg weight. Maintain straight back and bend knees when lifting - avoid twisting during carry. For wall-mounted units, ensure mounting brackets are secured before placing unit weight on brackets. Never work alone when installing wall-mounted condensers requiring worker to hold unit weight at height. If working on elevated locations such as balconies above ground floor, ensure edge protection or fall arrest systems are in place. Check for overhead power lines near condenser location - maintain minimum 3-metre clearance.

Refrigerant Pipe Installation and Connection

Measure and cut refrigerant pipes to required length allowing adequate service loop at both ends for future maintenance. Use proper tube cutter to cut copper pipes - never use hacksaw as this creates copper swarf that can contaminate system. Deburr pipe ends thoroughly using deburring tool removing all internal burrs and swarf. Flare pipe ends using flaring tool according to manufacturer specifications - flare must be symmetrical without cracks or excessive thinness. Typical flare dimensions for refrigeration work are 45-degree flare angle. Clean flare surfaces with lint-free cloth before assembly. Thread flare nuts onto pipes before flaring - common error is forgetting nuts requiring pipe re-flaring. Run refrigerant pipes from outdoor condenser to indoor unit through wall penetration. Protect pipes inside protective trunking or conduit where exposed to damage or ultraviolet light. Support pipes at maximum 1-metre intervals using appropriate brackets - refrigerant pipes must not contact building structure directly as vibration transfer causes noise. Insulate suction (larger diameter) pipe fully using closed-cell pipe insulation rated for temperature range. Connect refrigerant pipes to indoor and outdoor units following manufacturer torque specifications for flare nut tightening. Under-tightening causes refrigerant leaks, over-tightening damages flares or cracks copper pipes. Typical torque values are 15-20Nm for 1/4 inch liquid pipes and 45-55Nm for 3/8 inch suction pipes. Verify all connections are secure before proceeding to pressure testing.

Safety considerations

Wear cut-resistant gloves when handling copper pipes with sharp cut edges. Use proper tube cutter - hacksaw creates swarf hazards. Ensure adequate lighting when flaring pipes - poor flare quality causes refrigerant leaks. When running pipes through roof spaces, verify adequate ventilation and check roof space temperature - work during cooler morning hours if temperature exceeds 40 degrees Celsius. Do not rush flaring and connection work - refrigerant leaks from poor workmanship create gas exposure hazards and require system recovery and rework.

System Pressure Testing and Vacuum Purging

Pressure test refrigerant system using dry nitrogen before charging with refrigerant. Connect nitrogen cylinder to system via pressure regulator and test manifold. Install pressure relief valve on test equipment set to 110% of test pressure to prevent over-pressurisation. Slowly pressurise system to test pressure - typically 40 bar for residential split systems or pressure specified by manufacturer. Monitor pressure gauge continuously during pressurisation. Once test pressure reached, isolate nitrogen supply and monitor system pressure for minimum 20-minute hold period. Any pressure drop indicates refrigerant leak requiring investigation and correction. If system holds pressure successfully, release nitrogen slowly in controlled manner. After pressure testing confirms system integrity, connect vacuum pump to system using test manifold. Operate vacuum pump until system achieves deep vacuum of less than 500 microns absolute pressure. This removes air, moisture, and nitrogen from system. Maintain vacuum for minimum 15 minutes after target vacuum achieved - if vacuum level rises during hold period, residual moisture is present requiring extended evacuation. Once evacuation complete, close manifold valves and disconnect vacuum pump. System is now ready for refrigerant charging. Document all test pressures, hold times, and vacuum levels in commissioning records.

Safety considerations

Evacuate all personnel from immediate area once system pressurised to test pressure - maintain minimum 3-metre exclusion zone. Monitor pressure gauge from safe distance during hold period. Never exceed manufacturer maximum test pressure - over-pressurisation can cause catastrophic system failure with violent refrigerant discharge. Use pressure relief valve to prevent accidental over-pressurisation. When releasing nitrogen, vent slowly to atmosphere in ventilated area - rapid depressurisation creates loud noise and startles nearby persons. Ensure vacuum pump oil is clean and adequate - contaminated vacuum pumps cannot achieve deep vacuum required for proper system evacuation.

Electrical Connections and Isolation Installation

Install dedicated electrical circuit from switchboard to outdoor isolator location following AS/NZS 3000 wiring requirements. This work must be performed by licensed electrician or under electrical license exemption for refrigeration mechanics. Verify all circuits are isolated at switchboard using lock-out/tag-out procedure before commencing electrical work. Install isolating switch adjacent to outdoor condenser in weatherproof enclosure - isolator must be visible from condenser location and within 1 metre of unit. Connect supply cable from isolator to outdoor condenser terminals following manufacturer wiring diagram. Connect control cable between indoor and outdoor units as per wiring diagram - typically 4-core cable for standard split systems. Ensure all electrical connections are tight and properly terminated - loose connections cause overheating and potential fire hazards. Install appropriate circuit protection at switchboard - typically 20A circuit breaker for residential split systems up to 7kW capacity. Verify earth connections are secure and continuous from switchboard to both indoor and outdoor units. Test circuit continuity and insulation resistance using appropriate test equipment before energising. Document all electrical test results in commissioning records.

Safety considerations

Verify electrical isolation using voltage tester before commencing any connection work. Never rely on visual inspection or circuit breaker position alone - always test for voltage at work location. Apply personal lock and danger tag to circuit breaker during electrical work - each worker applies their own lock. Wear insulated electrical gloves rated to working voltage when making electrical connections. Ensure weatherproof integrity of outdoor electrical enclosures - water ingress creates electrocution hazards. Only licensed electricians may perform electrical connection work unless working under specific license exemption provisions. Re-test circuit for zero voltage before commencing work after any interruption.

Refrigerant Charging and System Commissioning

Charge system with correct refrigerant type and quantity according to manufacturer specifications. Modern split systems commonly use R32 or R410A refrigerant - never mix refrigerant types. Verify refrigerant cylinder is correct type before connecting to system. Set up gas detector at floor level in work area before opening refrigerant cylinder. Connect charging hose from refrigerant cylinder to system via test manifold. Charge system as liquid refrigerant through low-pressure port when system is operating. Start with conservative charge amount, then fine-tune based on system performance. Monitor system pressures and temperatures during charging - typical operating pressures for R32 systems are approximately 8-12 bar suction pressure and 24-28 bar discharge pressure depending on ambient conditions. Measure temperature differential between return air and supply air at indoor unit - adequate performance typically shows 8-12 degree temperature drop in cooling mode. Adjust refrigerant charge to achieve manufacturer-specified superheat and subcooling values - these require temperature and pressure measurements at specific points. Document final refrigerant charge quantity and system operating parameters in commissioning records. Test all system functions including cooling mode, heating mode if applicable, fan speeds, and remote control operation. Verify system operation is quiet without unusual vibration or noise. Provide client with operating instructions and warranty documentation.

Safety considerations

Position gas detector at floor level before opening refrigerant cylinder - refrigerant gases are heavier than air and accumulate at floor level. Ensure adequate ventilation during refrigerant charging - open windows and doors or operate extraction fan. Wear safety glasses during refrigerant connection work - escaping refrigerant under pressure can cause eye injuries. Never attempt to charge system in confined space without continuous atmospheric monitoring and forced ventilation. If gas detector alarm activates, immediately evacuate area and ventilate before re-entry. Wear gloves when handling refrigerant cylinders and charging equipment - liquid refrigerant causes cold burns on skin contact. Only ARCtick licensed technicians may handle refrigerant - verify license currency before commencing refrigerant work.

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Frequently asked questions

Do I need an ARCtick refrigerant handling licence to install air conditioning systems in Australia?

Yes, under the Ozone Protection and Synthetic Greenhouse Gas Management Act 1989, any person who handles refrigerant including during air conditioning installation, service, or disposal must hold a current ARCtick refrigerant handling licence. This applies even if the system comes pre-charged from the manufacturer, as installation involves opening refrigerant circuits, pressure testing, and charging operations. There are different licence levels - Refrigeration and Air Conditioning (RAC) licence covers most air conditioning work. Operating without appropriate refrigerant handling licence can result in significant penalties including fines exceeding $13,000 for individuals. Additionally, electrical connection work must be performed by licensed electricians unless working under specific licence exemptions available to refrigeration mechanics for limited electrical work on equipment they install.

What are the main differences in safety requirements between residential split system and commercial ducted air conditioning installations?

Commercial ducted installations present significantly more complex safety challenges than residential split systems. Ducted work requires extended periods in confined roof spaces with extreme temperatures often exceeding 50 degrees Celsius, creating serious heat stress hazards requiring heat management plans. Roof space work involves confined space entry hazards including limited egress, potential for refrigerant accumulation, and insulation fibre exposure requiring respiratory protection. Commercial systems use larger equipment requiring mechanical lifting aids or team lifting, three-phase electrical connections requiring higher electrical safety controls, and more complex commissioning procedures. Residential split systems typically involve shorter installation times, ground-level outdoor condensers, and simpler single-phase electrical connections. However, split systems still require height safety controls for indoor unit installation at 2.1 to 2.4 metre heights, refrigerant gas monitoring, and electrical isolation procedures. Both require ARCtick refrigerant licences and appropriate electrical licensing for connection work.

How do I safely handle refrigerant gases during air conditioning installation to prevent asphyxiation?

Safe refrigerant handling requires multiple controls working together. First, always use calibrated portable gas detectors positioned at floor level where heavier-than-air refrigerant gases accumulate - set alarm thresholds at appropriate levels for the refrigerant type. Second, establish forced ventilation using portable extraction fans when working in confined spaces, plant rooms, or poorly ventilated areas - maintain minimum 8 air changes per hour. Third, never perform refrigerant work alone in confined spaces - always have a second person monitoring from outside the space with emergency rescue capability. Fourth, plan refrigerant charging work to occur in well-ventilated areas where possible - charge outdoor condensers in open air rather than roof spaces when system design permits. Fifth, if working in roof spaces, limit time spent in the space and take regular breaks in fresh air. If gas detector alarms activate, immediately evacuate the area, force ventilate for minimum 15 minutes, and re-test atmosphere before re-entry. Keep refrigerant cylinders secured and closed when not actively charging to prevent accidental release.

What height safety equipment is required for installing wall-mounted air conditioning units?

For indoor units mounted at standard heights of 2.1 to 2.4 metres, platform ladders with minimum 450mm x 450mm platform area and handrails provide significantly safer access than conventional stepladders. Platform ladders allow both hands free for bracket installation and unit mounting while maintaining three points of contact. For multiple unit installations, mobile scaffold platforms with guardrails provide continuous work height access eliminating repeated ladder repositioning. If working on rooftops for outdoor condenser installation or accessing roof spaces for ducted work, fall arrest harnesses complying with AS/NZS 1891.1 are required when working above 2 metres with fall potential. Harnesses must attach to rated anchor points via energy-absorbing lanyards. Conduct fall clearance calculations to ensure adequate distance exists below work area to arrest falls before ground impact. For work on fragile roofs or near roof edges, edge protection systems or safety mesh must be installed before accessing roof areas. Never use conventional stepladders alone for air conditioning work - combination of height, equipment weight, and both hands occupied creates unacceptable fall risk.

What electrical safety procedures must I follow when connecting air conditioning systems?

Electrical safety begins with formal lock-out/tag-out isolation procedure. Identify the specific circuit breaker controlling the air conditioning circuit, switch to OFF position, apply your personal safety padlock (never share locks), attach danger tag with your details, and test circuit at work location using voltage tester to confirm de-energisation. Each worker applies their own lock - never rely on another person's isolation. Test voltage tester on known live circuit before and after testing isolated circuit to confirm tester is functioning. Only commence electrical work after confirmed zero voltage. For air conditioning installations, install dedicated circuits from switchboard with appropriate cable sizing for equipment load - typically 2.5mm² cable for split systems up to 6kW, larger cables for higher capacity systems. Install isolating switch within 1 metre of outdoor condenser in weatherproof enclosure. Ensure all connections are tight - loose connections cause overheating and fire hazards. Verify earth connections are secure from switchboard through to both indoor and outdoor units. Test insulation resistance and circuit continuity before energising. Only licensed electricians may perform electrical connection work unless working under refrigeration mechanic electrical licence exemption for limited electrical work on equipment they install. After completing work, remove all tools, verify area is clear, remove personal tag and lock, restore circuit to service, and test system operation.

How can I prevent manual handling injuries when installing heavy air conditioning equipment?

Manual handling injury prevention requires multiple approaches. First, mandate two-person lifting for all outdoor condenser units exceeding 20kg weight - never attempt single-person installation of standard residential condensers which typically weigh 30 to 80 kilograms. Second, provide and use mechanical handling aids including heavy-duty sack trucks rated to 150kg capacity for moving condensers across level surfaces, and trolleys for longer distance transport. Third, plan installation logistics to minimise carrying distances - position delivery points as close to installation location as possible. Fourth, use purpose-built wall mounting systems for wall-mounted condensers that allow unit weight to rest on brackets during final securing, eliminating need to hold full unit weight manually. Fifth, train installers in correct lifting technique - bend knees, keep back straight, lift with legs, maintain load close to body, avoid twisting during carry. Sixth, for ducted air handling units exceeding 100kg, use mechanical lifting equipment such as gantries, hoists, or mobile cranes - never attempt manual handling of equipment this heavy regardless of workforce available. Seventh, plan work to allow adequate rest between heavy lifts - fatigue significantly increases injury risk. Schedule physically demanding tasks during cooler parts of day to reduce heat stress compounding manual handling risks.

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Air Conditioning Installation Safe Work Method Statement

What this SWMS covers

Why this SWMS matters

Hazard identification

Falls from Heights During Indoor Unit Installation

Refrigerant Gas Exposure and Asphyxiation

Electrocution from Electrical Connections

Manual Handling of Heavy Air Conditioning Equipment

Heat Stress in Roof Spaces During Ducted Installations

Refrigerant System Pressure Hazards

Power Tool and Equipment Operation Hazards

Confined Space Entry for Ductwork Installation

Control measures

Engineered Height Access Systems for Indoor Unit Installation

Refrigerant Gas Monitoring and Ventilation Protocol

Lock-Out/Tag-Out Electrical Isolation Procedure

Two-Person Lift and Mechanical Aid Protocol for Heavy Equipment

Heat Stress Management Plan for Roof Space Work

Pressure Testing Safety Protocol

Personal Protective Equipment for HVAC Installation

Personal protective equipment

Inspections & checks

Before work starts

During work

After work

Step-by-step work procedure

Site Assessment and Preparation

Indoor Unit Bracket Installation

Core Drilling for Pipe Penetration

Outdoor Condenser Positioning and Securing

Refrigerant Pipe Installation and Connection

System Pressure Testing and Vacuum Purging

Electrical Connections and Isolation Installation

Refrigerant Charging and System Commissioning

Frequently asked questions

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