Job Hazard Analysis · HVAC

Job Hazard Analysis: Split system installation

Install a residential or light-commercial split AC or heat pump: set the outdoor condensing unit on a pad or wall bracket, set the indoor air handler or evaporator coil in an attic, closet, or crawlspace, run and braze the copper line set, wire the disconnect and controls, pressure test, evacuate, charge refrigerant, and start up. Attic and roof-side work may involve high heat, ladders, and tight spaces.

Published 2026-10-23

A general example for this task. Your JHA should reflect your crew, equipment and site — review it with a competent person before work starts.

Steps, hazards and controls

Step	Hazard	Risk	Controls
1. Unload the condenser, air handler, line set, and cylinders from the truck and move them to the work areas.	Back strain or crushed fingers lifting a 150–250 lb condenser or air handler.	Medium	Use a liftgate, appliance dolly, or hand truck with straps instead of carrying by hand. Use two people for any unit over 50 lb. Plan the path and clear it first. Wear cut-resistant work gloves and safety-toe boots.
	Compressed gas cylinders (nitrogen, acetylene, refrigerant) falling or rolling.	High	Transport cylinders upright and secured with chain or strap, valve caps on. Never roll a cylinder on its side or lift it by the valve or regulator.
2. Set the outdoor unit on the pad or wall bracket and drill the wall penetration for the line set.	Hidden wires, gas pipe, or water pipe hit while drilling through the wall.	High	Check both sides of the wall and use a stud/wire finder before drilling. Drill a small pilot hole first, then the full-size hole saw. Hold the drill with both hands and use the side handle; hole saws can bind and twist your wrist.
	Silica dust when drilling brick, block, stucco, or concrete.	Medium	Use a core drill with water feed or a drill with a dust shroud and HEPA vacuum. Keep other workers out of the dust area. Do not dry sweep the dust. Wear safety glasses and an N95 or better respirator if dust controls are not enough.
	Falling from a ladder while mounting a wall bracket.	Medium	Set an extension ladder at a 4:1 angle on firm ground and tie it off or have a helper hold it. Keep three points of contact and do not lift the unit while on the ladder; use a second person or a lift.
3. Set the indoor air handler or evaporator coil in the attic, closet, or crawlspace.	Falling through the ceiling drywall between attic joists.	High	Lay plywood walk boards across the joists from the hatch to the work area before moving equipment. Step only on joists or boards. Use a work light so you can see the joists.
	Heat illness in a hot attic.	High	Schedule attic work for the early morning. Run a fan at the attic hatch. Limit time in the attic, take breaks in the shade or AC, and drink water every 15 minutes. Use the buddy system and watch each other for dizziness, confusion, or stopping sweating.
	Fiberglass insulation irritating skin, eyes, and lungs.	Low	Wear long sleeves, gloves, safety glasses, and an N95 dust mask in the attic.
	Falling from a stepladder at the attic hatch.	Medium	Use a fiberglass stepladder fully opened and locked; do not stand on the top two steps. Pass the unit up with a helper or rope; do not climb carrying it.
4. Run the copper line set, condensate drain, and control wire between the units.	Cuts from tubing cutters, sheet metal, and sharp copper ends.	Low	Deburr cut ends right away and cap them. Wear cut-resistant gloves when handling sheet metal and cut tubing.
	Shock or kickback from a damaged cord or drill binding.	Medium	Inspect cords and tools before use; tag out any with damaged insulation or missing ground pin. Plug into a GFCI outlet or portable GFCI.
5. Braze the line set connections with a torch while flowing nitrogen.	Fire from the torch flame igniting wood framing, insulation, or siding.	High	Move combustibles away or use a heat shield blanket behind the joint. Keep a charged fire extinguisher within reach while brazing. Do a fire watch for at least 30 minutes after brazing, checking inside walls and the attic.
	Burns from the flame and hot copper.	Medium	Let joints cool or use a wet rag before touching. Wear leather gloves and shade 3–5 brazing glasses.
	Leaking acetylene or damaged hoses causing fire or explosion.	High	Check hoses and regulator for cracks and leaks with soap solution before lighting. Keep cylinders upright and secured, and close valves when done or when leaving.
	Nitrogen or brazing fumes building up in a tight attic or crawlspace, displacing oxygen.	Medium	Use a low nitrogen flow and ventilate with a fan. Have a second person outside the space who can see or hear you.
6. Install the disconnect and whip, and connect power and control wiring.	Electrocution from an energized 240V circuit or panel.	High	Turn off the breaker, then lock and tag it before any wiring. Test for voltage with a working meter at the disconnect and unit before touching wires. Only a qualified electrician or trained tech connects at the panel.
7. Pressure test with nitrogen, pull a vacuum, and charge refrigerant.	Hose or fitting blowout from overpressure.	High	Always use a nitrogen regulator; never connect a cylinder directly. Do not exceed the unit's test pressure. Check gauge hoses and seals before use. Stand to the side of fittings while pressurizing.
	Frostbite to hands or eyes from liquid refrigerant.	Medium	Wear safety glasses and insulated refrigerant gloves when connecting and disconnecting hoses. Use low-loss fittings and point hose ends away from people.
	Refrigerant leak in a closet, basement, or crawlspace reducing oxygen; some newer refrigerants are mildly flammable.	Medium	Read the SDS for the refrigerant. Ventilate the area and keep flames and sparks away. If you smell or detect a big leak, get out, ventilate, and do not re-enter until cleared.
8. Start up and test the system, then clean up the work areas.	Caught by the condenser fan or blower, or shocked while taking readings.	Medium	Install all panels and fan guards before starting. Keep hands and tools clear of moving parts. Use insulated meter leads and one hand when taking live readings; discharge capacitors before touching.
	Trips and cuts from scrap copper, sheet metal, boxes, and cords.	Low	Pick up scrap as you go and coil cords. Remove walk boards and debris from the attic. Secure cylinders upright in the truck before leaving.

Required PPE

Safety glasses — ANSI Z87.1 at all times; shade 3–5 lenses when brazing.
Work gloves — Cut-resistant for sheet metal and copper; leather for brazing; insulated for refrigerant hoses.
Safety-toe boots — When moving and setting equipment.
Hard hat or bump cap — Hard hat when overhead work or falling objects are present; bump cap in attics and crawlspaces.
Respirator — N95 for insulation dust; N95 or better for masonry drilling if dust controls are not enough.
Hearing protection — Earplugs when core drilling or using hammer drills.
Long sleeves and pants — Cotton or flame-resistant when brazing; covers skin from fiberglass.

Training

EPA Section 608 certification for anyone handling or charging refrigerant.
Ladder safety training by a competent person.
Brazing, torch, and compressed gas cylinder safety, including fire watch.
Lockout/tagout and electrical safety for working on 240V circuits.
Heat illness recognition and prevention.
Hazard communication: reading SDS for refrigerants, nitrogen, acetylene, and PVC cement.

Emergency

If someone is shocked, do not touch them until the power is off at the breaker. Call 911 and give the site address. Start CPR if they are not breathing and use an AED if available. For fire, shut the torch and cylinder valves, use the extinguisher only if small, otherwise get everyone out and call 911.

Official sources

29 CFR 1926.1053 — Ladders
29 CFR 1926.350 — Gas welding and cutting (cylinders)
29 CFR 1926.352 — Fire prevention (welding and cutting)
29 CFR 1926.416 — Electrical — general requirements
29 CFR 1926.417 — Lockout and tagging of circuits
29 CFR 1926.300 — Hand and power tools — general requirements
29 CFR 1926.102 — Eye and face protection
OSHA — Heat — hazard recognition and prevention

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General information, not legal advice. Templates and examples should be reviewed by a competent person before use. HardHat Binder is not affiliated with or endorsed by OSHA.