Nordyne Furnace LP Conversion Kit Manual

The Nordyne Furnace LP Conversion Kit is designed to convert natural gas furnaces to liquid propane operation. This comprehensive kit includes all necessary components, tools, and instructions for safe and proper conversion. The conversion process involves orifice replacement, gas valve adjustment, pressure regulation, and safety verification. Below are key sections covering safety warnings, kit contents, installation procedures, testing, and troubleshooting.

1. Safety Warnings and Precautions 2. Kit Contents and Components 3. Pre-Installation Requirements 4. Conversion Procedure 5. Pressure Adjustment and Testing 6. Post-Installation Verification 7. Technical Specifications 8. Maintenance Guidelines 9. Warranty Information 10. Troubleshooting Guide

Safety Warnings and Precautions

Critical safety information for LP conversion process.

Warning	Description
Gas Leak Hazard	Always check for leaks with soap solution after conversion
Professional Installation	Conversion must be performed by qualified technician
Proper Ventilation	Ensure adequate combustion air and proper venting
Gas Pressure Verification	Manifold pressure must be set to 10-11 inches WC for LP
Carbon Monoxide Risk	Install CO detectors in living areas
Electrical Safety	Disconnect power before beginning conversion
Gas Shutoff	Turn off gas supply at main valve before starting
Proper Tools	Use only approved tools and equipment
Local Codes	Comply with all local building and gas codes
Manufacturer Specifications	Follow Nordyne installation guidelines exactly

Kit Contents and Components

Complete inventory of conversion kit components.

LP Orifice Set: Complete set of propane orifices for all burner sizes
Gas Valve Conversion Kit: Pressure regulator springs and adjustment tools
Installation Manual: Step-by-step conversion instructions
Warning Labels: LP gas conversion identification stickers
Pressure Test Port Adapter: For manifold pressure measurement
Sealant: Approved pipe thread compound for gas connections

WARNING! Verify all components are present before beginning installation. Do not substitute components.

Pre-Installation Requirements

Preparation steps before beginning conversion.

Turn off electrical power to furnace at circuit breaker
Shut off gas supply at main valve upstream of furnace
Verify furnace model compatibility with conversion kit
Gather required tools: manometer, wrenches, screwdrivers, leak detection solution
Review local codes and obtain necessary permits
Ensure adequate workspace and lighting around furnace

CAUTION! Failure to properly shut off gas and electricity can result in fire, explosion, or electrocution.

Conversion Procedure

Step 1: Remove burner assembly access panel
Step 2: Replace natural gas orifices with LP orifices from kit
Step 3: Convert gas valve to LP operation using provided springs
Step 4: Adjust gas valve pressure setting for propane
Step 5: Install LP conversion warning labels on furnace
Step 6: Reassemble furnace components
Step 7: Restore gas supply and check for leaks
Step 8: Restore electrical power

Pressure Adjustment and Testing

Proper pressure settings and verification procedures.

Manifold Pressure: Set to 10-11 inches WC for LP gas operation. Use manometer connected to pressure tap.

Gas Valve Adjustment: Turn adjustment screw clockwise to increase pressure, counterclockwise to decrease.

Leak Testing: Apply soap solution to all gas connections. Bubbles indicate leaks.

Combustion Analysis: Verify proper CO2 levels and flame characteristics.

Post-Installation Verification

Final checks and system validation.

Start furnace and observe ignition sequence
Verify stable flame with proper blue color
Check for unusual noises or vibrations
Monitor furnace through complete heating cycle
Verify thermostat operation and temperature control
Complete installation checklist and customer briefing

Tip: Allow furnace to complete several heating cycles before final inspection.

Technical Specifications

Supported furnace models and technical requirements.

Compatible Models: Nordyne FG7RA, FG7SA, FG7TA series
Gas Type: Liquid Propane (LP)
Manifold Pressure: 10-11 inches WC
Input BTU: As specified for converted model
Orifice Size: #54 drill size for LP operation
Gas Valve: Convertible type with LP/NG selection
Venting: Category I venting system required
Clearances: Maintain manufacturer specified clearances

Maintenance Guidelines

Routine maintenance for LP furnace operation.

Annual inspection by qualified technician. Regular filter changes. Burner cleaning as needed. Vent system inspection. CO detector testing.

CAUTION! Only qualified personnel should perform maintenance on gas appliances.

Warranty Information

Limited warranty coverage and terms.

90-day limited warranty on conversion kit components. Original furnace warranty remains in effect when conversion is performed by authorized technician. Warranty void if installation instructions are not followed exactly.

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
Furnace won't ignite	Gas pressure incorrect	Verify manifold pressure setting (10-11" WC)
Yellow flame	Air mixture incorrect	Adjust primary air shutter; clean burners
Gas odor	Leaking connection	Shut off gas immediately; check all connections with soap solution
Furnace short cycles	Overheating	Check airflow; clean filter; verify venting
No heat output	Thermostat issue	Check thermostat settings and wiring

Technical Support: 1-800-422-4328; www.nordyne.com

Emergency Service: Contact qualified HVAC technician immediately for gas leaks or CO detection