Technical Support
NL / PL Phase Converter — Installation & Operation Manual
01Getting Started
02Important Installation Info
03Installation Location
04Service Requirements
05Wire & Breaker Chart
06Idler Motor Wiring
07230V Motor Connections
08Breaker Sizing Guide
09Single-Phase Connection
10Connecting Idler Motor
11Panel Wiring Diagram
12Startup & Voltage Check
13Support Decision Cards
14Warranty & Return Policy
01 — Getting Started
Built to perform. Engineered to last.
Thank you for choosing a Phoenix Phase Converter. Before installing your unit, review the layout below and the instructions in this manual. Identify all connection points and the wire size chart inside the panel before making any wiring connections.
This manual will guide you through the installation, wiring, and start-up of your NL or PL phase converter to ensure safe and reliable operation — turning single-phase utility power into clean three-phase power for machine shops, woodshops, farms, and commercial buildings.
Important — installation must be performed by a qualified, licensed electrician.Disconnect and lock out all power sources before installing or servicing this equipment.
📋 Standard NL / PL Reminder
Standard NL and PL units use one idler/generator motor. Do not follow Dual Zone two-motor startup or zone sequencing instructions for these models.
Getting started — identify all connection points and the wire size chart inside the panel before making any wiring connections.
02 — Read Before Installation
Important installation information
Critical safety, startup, and wiring reminders before energizing your converter. Failure to follow these instructions can result in equipment damage, serious injury, or death.
Read all 7 caution items and complete the Quick Startup Checklist before energizing.
Quick startup checklist
- No load connected during startup
- Input landed on T1 and T2 (or L1/L2 on NL model)
- Output/load wiring landed on L1, L2, and L3
- All lugs torqued, ground confirmed, breaker verified
- Idler turns freely and reaches full speed
When to stop immediately
- Startup is abnormal or idler won't reach full speed
- Unusual noises, vibration, or odors occur
- Any wiring or connection appears incorrect
- Shut down and consult a qualified electrician
03 — Installation Layer
Installation location
Install the phase converter as close to the power supply as possible. Keep the single-phase supply line under 50 feet whenever possible.
Keep the single-phase feed under 50 feet. For longer runs, increase wire size by one gauge per additional 50 feet.
✅ Do
- Install close to the power source
- Keep the single-phase line under 50 feet to reduce voltage drop
- Use properly sized wire for longer runs
- Increase wire size by one gauge for every additional 50 feet
⛔ Don't
- Don't use long runs of undersized wire — causes voltage drop, poor performance, overheating
- Don't assume 50 ft is a hard limit — longer runs can work with properly upsized wire
04 — Service Requirements
Single-phase power reference chart
Use this chart to determine the maximum amperage available from a single-phase 240V utility supply. Formula: AMPS = (kVA × 1000) / 240
Single-phase power reference chart and breaker & wiring quick reference for NL / PL models.
Important utility noteThe kVA number from the power company should not exceed the horsepower rating of the rotary phase converter you are trying to start. Oversizing the utility transformer can cause high inrush currents that may prevent proper startup or damage the converter.
05 — Installation & Electrical
Standard NL / PL wire size & breaker size chart
Recommended service size, breaker range, wire size, and common breaker references for standard Phoenix NL and PL models.
Standard NL / PL wire size & breaker chart — GP3NL/GP3PL through GP100NL/GP100PL. Use MOTOR LOAD type breakers only.
Use MOTOR LOAD type breakers only.Standard light-duty breakers may nuisance-trip due to high starting current. All wiring must be verified by a qualified licensed electrician.
| Model | HP | Service | Max Ind. | Max Res. | Motor Brkr | 1PH Wire | Idler Wire | Panel Size |
|---|---|---|---|---|---|---|---|---|
| GP3NL / GP3PL | 3 | 7.5 KVA / 40A | 8 | 4 | 10–20 | 10 AWG | 12 AWG | 20×12×8 |
| GP5NL / GP5PL | 5 | 15 KVA / 60A | 14 | 7 | 10–30 | 8 AWG | 10 AWG | 20×12×8 |
| GP7.5NL / GP7.5PL | 7.5 | 15 KVA / 60A | 20 | 10 | 20–50 | 6 AWG | 10 AWG | 20×12×8 |
| GP10NL / GP10PL | 10 | 25 KVA / 100A | 28 | 14 | 30–60 | 6 AWG | 8 AWG | 20×12×10 |
| GP15NL / GP15PL | 15 | 25 KVA / 100A | 41 | 21 | 40–100 | 4 AWG | 6 AWG | 20×16×8 |
| GP20NL / GP20PL | 20 | 37.5 KVA / 150A | 52 | 28 | 50–125 | 3 AWG | 6 AWG | 20×16×8 |
| GP25NL / GP25PL | 25 | 50 KVA / 200A | 68 | 35 | 50–150 | 2 AWG | 4 AWG | 20×16×8 |
| GP30NL / GP30PL | 30 | 50 KVA / 200A | 80 | 42 | 50–150 | 2 AWG | 3 AWG | 20×16×8 |
| GP40NL / GP40PL | 40 | 50 KVA / 200A | 104 | 56 | 80–200 | 1/0 AWG | 1 AWG | 20×16×8 |
| GP50NL / GP50PL | 50 | 50 KVA / 200A | 130 | 75 | 80–200 | 2/0 AWG | 2/0 AWG | 20×20×8 |
| GP60NL / GP60PL | 60 | 75 KVA / 300A | 160 | 90 | 100–250 | 3/0 AWG | 2/0 AWG | 20×20×8 |
| GP75NL / GP75PL | 75 | 100 KVA / 400A | 200 | 112 | 125–300 | 4/0 AWG | 3/0 AWG | 24×24×8 |
| GP100NL / GP100PL | 100 | 150 KVA / 600A | 260 | 150 | 150–400 | 350 MCM | 4/0 AWG | 24×24×8 |
Wire size based on 75°C copper conductors, max 50 ft total run. For longer runs or aluminum conductors, increase wire size as required by code. All wiring must comply with NEC and local codes.
Common motor-load breaker part numbers
| Manufacturer | Series (Motor-Load) | 1 Pole | 2 Pole | 3 Pole | Notes |
|---|---|---|---|---|---|
| Square D | QO™ | QO1xxx | QO2xxx | QO3xxx | HACR or motor-rated as required by code |
| Siemens | QP™ | QP1xxx | QP2xxx | QP3xxx | Verify interrupt rating and panel listing |
| Eaton | BR™ | BR115 | BR215 | BR315 | Suitable for motor-load applications |
| ABB | THQL® | THQL1115 | THQL2115 | THQL3115 | Verify panel compatibility and voltage rating |
| Murray | MP™ | MP115 | MP215 | MP315 | Used in Murray / Eaton panelboards |
| GE | THQL® | THQL1115 | THQL2115 | THQL3115 | Confirm panel type and application |
06 — Installation & Electrical
Idler motor wiring
The idler/generator motor must be wired according to the diagram inside the motor conduit box or on the motor nameplate. Verify the correct voltage before making connections.
For NL and PL models: use the 230V low-voltage connection. Find the wiring diagram inside the motor conduit box cover or on the motor nameplate.
NL and PL models — 230V low voltageFor standard NL and PL models, use the 230V low-voltage connection.
NH and PH models — 460V high voltageFor NH and PH models, use the 460V high-voltage connection. Covered in the separate 460V high-voltage motor manual.
Do NOT use wire nuts on the idler motor — even temporarily.Wire nuts are not approved for idler motor wiring connections.
Approved connection methods
Split Bolt Connector
Secure mechanical splice for copper conductors
✓ Approved
Screw-Down Lug
Reliable mechanical connection, various wire sizes
✓ Approved
Polaris Insulated
Pre-insulated, compact, stranded copper
✓ Approved
07 — Installation & Electrical
230V low-voltage motor connections
The wiring diagrams shown here are for 230V idler/generator motor connections only. 460V motor lead wiring is covered in the separate 460V high-voltage motor manual.
12-wire and 9-wire motor connection diagrams for 230V. Do not use wire nuts — use approved lugs or connectors only.
⚙ 12-Wire Motor — 230V Only
L1+ T1, T12, T6, T7 → Connect 1, 6, 7, 12 together to L1
L2+ T2, T10, T4, T8 → Connect 2, 4, 8, 10 together to L2
L3+ T3, T11, T5, T9 → Connect 3, 5, 9, 11 together to L3
⚙ 9-Wire Motor — 230V Only
L1+ T7, T1 → Connect 1 & 7 together to L1
L2+ T8, T2 → Connect 2 & 8 together to L2
L3+ T3, T9 → Connect 3 & 9 together to L3
T4, T5, T6 tied together (not to line)
08 — Installation & Electrical
Breaker sizing & wire sizing guide
For phase converter and equipment load at 230 volts. Do NOT use this chart for Dual Zone Phase Converters.
Scenario 1 (one machine) and Scenario 2 (multiple machines) with full 230V breaker and wire sizing table.
Example — multiple machines:
3 HP (13A) + 3 HP (13A) + Dust Collector (18A) + Planer (20A) = 64A total FLA
Apply 70% diversity: 64A × 0.70 = 44.8A → Add 125% of largest motor: 20A × 1.25 = 25A
Total load = 69.8A → Use 80A breaker → Use 1/0 AWG wire
3 HP (13A) + 3 HP (13A) + Dust Collector (18A) + Planer (20A) = 64A total FLA
Apply 70% diversity: 64A × 0.70 = 44.8A → Add 125% of largest motor: 20A × 1.25 = 25A
Total load = 69.8A → Use 80A breaker → Use 1/0 AWG wire
09 — Installation & Electrical
Connecting your single-phase wire
NL Model — 230V input. Connect utility power to L1 and L2. For smaller units with T1/T2 contactors, connect to T1 and T2.
NL Model — single-phase input. Connect the two hot conductors from your single-phase panel to L1 and L2. Start the phase converter first — do not start under load.
1
Run conductors from your panel
Run the two hot conductors from your single-phase panel to the phase converter.
2
Terminate at input terminals
Terminate at the phase converter input terminals marked L1 and L2 (or T1/T2 on smaller units).
3
Verify and torque connections
Verify all connections are tight and comply with local electrical codes before energizing.
Do not connect single-phase power to the generator output terminals.The L1, L2, L3 output terminals are for three-phase output/load connections only.
Before energizing: Verify input voltage is 230V single phase. Ensure all connections are clean, secure, and properly tightened.
Start the phase converter first. Do not start the converter under load. Always power up the converter before turning on connected equipment.
10 — Installation & Electrical
Connecting your idler motor
After wiring the idler motor, run a total of four conductors to the terminal block: three power lines and one ground wire.
Run three power conductors and one ground wire from the idler motor. Terminate at L1, L2, L3. Either side of the block may be used for termination.
Your idler motor and your load both connect to L1, L2, and L3. Use approved lugs/connectors only. Verify secure terminations before startup.
11 — Installation & Electrical
Completed panel wiring — NL model
230V low voltage. This diagram shows the three connections on the NL model terminal block: Load Output, Power Input, and Idler Motor.
Completed NL model panel wiring. Load Output (3-phase), Power Input (1-phase 230V Low), and Idler Motor (3-phase 230V Low) all terminate at the L1/L2/L3 terminal block.
Panel wiring diagram for smaller units — T1/T2 incoming single-phase input, right power block (Generator #1), left power block (Generator #2 if equipped), and L1/L2/L3 three-phase terminals.
Grounding
Backplate must be bonded to the system ground per NEC Article 250.
Disconnects
- Install a disconnect switch before the converter input line (NEC 430.102A)
- Install a second disconnect on the load side (NEC 430.102B)
✅ Before startup checklist
- Verify backplate is properly grounded
- Confirm all connections are tight and secure
- Verify both disconnects are installed: input and load side
- Verify input voltage is 230V (Low)
12 — Start-Up & Testing
Before testing & startup verification
Verify the panel, conduit, and idler motors are installed correctly and all wiring connections are complete, secure, and tightened properly before energizing.
Completed install ready for pre-start inspection. Verify all six checklist items before applying power.
Start-up sequence
1
Lock out & inspect
Lock out power. Inspect all wiring, conduit, and grounding.
2
Confirm single-phase input
Confirm single-phase input is connected to T1 and T2 only.
3
Check idler wiring
Confirm idler motor wiring matches the motor nameplate diagram.
4
Disconnect all load equipment
Switch off all load equipment before first start.
5
Energize converter
Energize the converter and allow the idler motor to reach full speed.
6
Start load equipment
Start load equipment one machine at a time and monitor voltage.
📊 Voltage test record
| Test | L1–L2 | L2–L3 | L1–L3 |
|---|---|---|---|
| No load | ___ | ___ | ___ |
| With load | ___ | ___ | ___ |
| Final check | ___ | ___ | ___ |
If something looks wrong
- Shut down immediately
- Recheck that single-phase input is connected only to T1 and T2
- Verify idler motor wiring and grounding
- Inspect for overheating, unusual smells, or abnormal noise
- Consult a qualified electrician if unstable voltage is observed
ImportantDo not energize until all covers, wiring, grounding, wire size, and breaker selection have been checked. Shut down immediately if abnormal noise, smoke, odor, overheating, or unstable voltage is observed.
13 — Troubleshooting
Support decision cards
Use these decision cards to quickly identify common issues and actions. Always follow safety procedures and the installation manual.
Six common issues and their troubleshooting steps. Call 800-417-6568 if you need factory support.
⛔ Will not start
Check disconnect, breaker, input voltage, control power, and start circuit. Never leave on more than 2 seconds if it does not start.
- Verify main disconnect is ON
- Verify breaker is ON and sized correctly
- Verify input voltage matches nameplate
- Check for voltage dropping while trying to start
- Never leave energized for more than 2 seconds if it does not start
⚠ Breaker trips
Record breaker size/type, feeder distance, service details, and whether the idler reaches speed.
- Verify motor-load type breaker is used
- Verify breaker size is correct
- Check for short circuits or ground faults
- Check feeder wire size and distance
- Verify idler motor reaches full speed
⚡ Voltage issue
Confirm meter placement phase-to-phase. Capture no-load and under-load readings.
- Verify meter is measuring phase-to-phase
- Record no-load voltage on all three phases
- Record under-load voltage on all three phases
- Check for loose connections
- Verify idler motor reaches full speed
⚙ Load will not start
Separate converter startup from machine startup. Confirm machine voltage and controls.
- Start converter first — let idler reach full speed
- Measure voltage at machine terminals
- Verify machine controls and wiring
- Check for overload or locked rotor condition
- Consult factory if issue persists
◐ High amp reading
Do not diagnose from one clamp reading. Measure all three output legs.
- Measure amperage on all three output legs
- Compare amperage on each leg
- Check for unbalanced loads
- Verify idler motor reaches full speed
- Verify wire size and breaker size are correct
☎ Support handoff
Send model, order/serial, photos, readings, breaker/service info, and machine nameplate.
- Include converter model and serial number
- Include photos of panel and connections
- Include voltage and amperage readings
- Include breaker size and service details
- Include machine nameplate and load HP
ImportantOnly qualified, licensed electricians should install, service, and troubleshoot this equipment. Disconnect and lock out all power before opening or working on the panel.
14 — Customer Policies
Warranty & return policy
Lifetime
Control Panel Warranty
3-Year
Electric Motor / Idler Warranty
Phase converter control panel warranty
All Phoenix Phase Converters Rotary Phase Converter Control Panels are backed by a lifetime warranty against defects in materials and craftsmanship. DIY panels are excluded. Warranty services must be conducted exclusively at a Phoenix Phase Converters authorized facility.
Electric motor / idler warranty
The Electric Motor/Idler is covered by a three-year warranty provided by North American Electric Motors or Techtop. The rotor has a lifetime warranty for the original owner covering defects in materials and workmanship.
Return policy — 90 days
- Only sealed, unopened packages are eligible
- Returns must be initiated within 90 days of purchase
- Contact customer service to obtain a Return Authorization (RA) number — returns without an RA number will not be accepted
- Refunds processed within 10–15 business days of receipt
Questions? Call (888) 379-3481
This page is a web rendering of the Phoenix NL / PL Phase Converter Installation & Operation Manual. Always defer to the manual shipped with your unit and to a qualified, licensed electrician. All electrical work must comply with the National Electrical Code (NEC) and local codes. © Phoenix Phase Converters (Applied Industrial Motors LC). All rights reserved.
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