Split bolt connector
- Secure mechanical splice connection
- Suitable for properly sized copper conductors
- Tighten to manufacturer specifications
- Insulate connection as required
Technical Support
Phoenix Precision Balanced · DualZone Series
DualZone Phase Converter
Installation & Operation Manual
Single phase to three phase, balanced and built to last — engineered for shops, machinists, and electricians who need a clean three-phase supply from a single-phase service. This DualZone phase converter manual walks the install end to end: mounting, wiring, sizing, startup, and the support handoff if something does not go to plan.
- Dual-idler design
- 230 V single-phase input
- 3-phase output
- Precision balanced
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 DualZone phase converter to ensure safe and reliable operation. The DualZone is a precision-balanced rotary phase converter that turns single-phase utility power into clean three-phase power — a dependable single phase to three phase power source for machine shops, woodshops, farms, and commercial buildings that need to run three-phase equipment from a single-phase service.
Every Dual Zone phase converter ships with the same phase converter control panel layout shown in this guide: a single-phase input on T1/T2, two precision-balanced idler motor outputs, and three-phase L1/L2/L3 terminals for your load.
Read this manual
Read this manual completely before installing or operating the unit. Keep this manual for future reference.
In this manual you will find
- Single-phase input power connection
- Idler / generator motor connection
- Three-phase output / load connection
- Wire and breaker sizing
- Start-up and operation
- Safety precautions and checks
Important — installation must be performed by a qualified, licensed electrician.
Disconnect and lock out all power sources before installing or servicing this equipment. Failure to follow safety instructions can result in serious injury or equipment damage.
02 — Installation Layer
Mounting and location
The phase converter panel must be mounted securely on a solid wall or structure, with the idler motors positioned on a stable, level surface.
Adequate clearance must be provided around the panel and motors for ventilation, wiring access, inspection, and service. The installation area should be dry, protected, and free of obstructions.
Service size and breaker sizes
Service size, wire size, and breaker sizing must be selected according to the model requirements, input voltage, and load conditions. The installer must follow the wire size chart and breaker recommendations provided in the manual or inside the panel.
All final sizing and overcurrent protection must be verified by a qualified, licensed electrician before energizing the unit.
Important.
Installation, service sizing, and breaker selection must be performed by a qualified, licensed electrician. Verify all wiring, grounding, and breaker sizes before startup.
03 — Dual Zone 230 V Series
Single-phase line connection
Connect the incoming single-phase power line to terminals T1 and T2.
Use bolt-down lugs and properly sized wire for the installation. Refer to the wire size chart for the correct wire gauge. The wire size chart is based on a maximum wire run of 50 feet.
It is recommended to keep the single-phase line as short as possible. If the wire run exceeds 50 feet, increase the wire size by one gauge size for every additional 50 feet of distance.
All wiring should be installed in accordance with applicable electrical codes and performed by a qualified electrician.
Important.
Verify utility transformer size, service capacity, breaker/fuse rating, and wire size before installation. Undersized supply equipment may cause low voltage, overheating, equipment damage, or failure to start. Installation must be performed by a qualified electrician.
04 — Smaller Units
Single-phase input power for smaller units
On smaller units, the incoming single-phase power connects to T1 and T2. Connect the two incoming single-phase power wires to the terminals marked:
- T1 Input Single Phase 230 V
- T2 Input Single Phase 230 V
Important.
On smaller units, connect incoming single-phase power only to T1 and T2.
Do not connect incoming single-phase power to the generator output terminals.
The L1, L2, L3 terminals are for the three-phase output/load connections only.
Before energizing:
- Verify the input voltage is 230 V single phase.
- Ensure all electrical connections are clean, secure, and properly tightened.
- Loose connections can cause overheating, voltage issues, or equipment damage.
For recommended wire and breaker sizes, refer to the wire size chart inside the panel or see Part #3PC60 in this manual.
05 — Panel Layout
Panel wiring diagram for smaller units
This diagram shows the general panel wiring layout for smaller units. Use it as a visual reference together with the detailed wiring instructions in this manual.
Connection sequence
- Connect incoming single-phase power to T1 and T2.
- Connect the primary idler motor to the power block on the right.
- If equipped, connect the second idler motor to the power block on the left.
- Verify all wiring and voltage before energizing the unit.
Important.
Installation must be performed by a qualified, licensed electrician. Disconnect and lock out all power before installation or service.
06 — Installation & Electrical
First idler motor connection
Wire the first idler motor to the power block on the right.
-
1
This is the primary idler motor and will always be the first motor to start when the phase converter is engaged.
-
2
Follow the wire size chart on the yellow sticker inside the panel. Wire sizing shown on the chart is based on a wire run of 50 feet or shorter.
-
3
Make sure all electrical connections are clean, secure, and properly tightened. Loose connections can cause overheating, voltage issues, nuisance breaker tripping, or equipment damage.
Important.
Verify wire size, breaker size, and terminal connections before energizing the unit. Installation must be performed by a qualified, licensed electrician.
07 — Operation
Second idler motor connection and operation
Important.
The second idler motor connects to the left power block. Do not energize or engage the second power block unless the second idler motor is connected. Operating the second power block without the motor connected may cause improper operation or equipment damage.
Green disable button.
A green disable button is located on the front of the unit. When the green button is pressed, the second idler motor is engaged.
There is normally no reason to disable the generator during operation. The green button may be left in the engaged position during normal use.
Normal operation
- The green button should remain pressed (engaged) during normal use.
- There is normally no reason to disable the generator.
Warning.
Always ensure the second idler motor is connected before engaging the left power block. Failure to do so may result in equipment damage.
08 — Idler Motor Wiring
Idler motor wiring
The idler/generator motor must be wired according to the wiring diagram located inside the motor conduit box or on the motor nameplate. Verify the correct voltage before making connections.
For standard NL and PL models, use the 230 V low-voltage connection. For NH and PH models, use the 460 V high-voltage connection.
12-wire motor (230 V only)
- L1 + T1, T12, T6, T7
- L2 + T2, T10, T4, T8
- L3 + T3, T11, T5, T9
Connect 1, 6, 7, 12 together to L1 · 2, 4, 8, 10 to L2 · 3, 5, 9, 11 to L3.
9-wire motor (230 V only)
- L1 + T7, T1 (also T6, T5, T4 referenced)
- L2 + T8, T2
- L3 + T3, T9
Connect 1 & 7 to L1 · 2 & 8 to L2 · 3 & 9 to L3 · 4, 5, 6 together.
Important.
The wiring diagrams shown above are for 230 V idler/generator motor connections only. 460 V motor lead wiring is not shown here and is covered in the separate 460 V high-voltage motor manual.
Recommended lugs for idler motor connections
Use one of the three lug styles below to terminate motor leads. Do not use wire nuts for idler motor wiring connections. All connections must be tight, secure, and enclosed in an approved junction box.
Screw-down lug
- Reliable mechanical connection
- Available for various wire sizes
- Tighten set screws to proper torque
- Suitable for motor lead terminations
Polaris insulated connector
- Pre-insulated for added safety
- Compact and easy to install
- Suitable for stranded copper conductors
- Tighten to manufacturer specifications
09 — Pre-start
Before testing
Before testing the phase converter, verify that the panel, conduit, and idler motors are installed correctly and that all wiring connections are complete, secure, and tightened properly. Confirm that the installation area is clear and safe before energizing the unit.
Before-testing checklist
- Verify incoming single-phase power is connected correctly.
- Verify the idler motor wiring is complete and matches the motor wiring diagram.
- Verify all power connections are tight and secure.
- Confirm the motors are mounted securely and able to rotate freely.
- Make sure the area around the motors and panel is clear of tools and debris.
- Do not energize the unit until all covers, wiring, and connections have been checked.
Pre-start inspection.
This page is intended as a visual pre-start inspection reference. Walk the install with this checklist before applying power.
Important.
Installation and testing must be performed by a qualified, licensed electrician. Disconnect and lock out all power before making wiring changes or servicing the unit.
10 — Installation & Electrical
Dual Zone wire size & breaker size chart
Use the chart below to determine the recommended service size, breaker size, and wire size for Dual Zone rotary phase converter models. All wiring must be sized and installed by a qualified licensed electrician in accordance with local electrical code.
Important.
Use MOTOR LOAD type breakers only. Standard (light-duty) breakers may nuisance-trip due to high starting current.
| Model | Total HP | Qty | Each HP | KVA | Service | Max Ind. | Max Res. | Min Brkr | Max Brkr | 1PH Wire | Idler Wire | Panel Size |
|---|---|---|---|---|---|---|---|---|---|---|---|---|
| GP5/10L | 10 | 2 | 5 | 9 | 10 | 30 | 15.5 | 10 | 60 | 8 | 10 | 20×12×10 |
| GP7/15L | 15 | 2 | 7.5 | 14 | 15 | 41 | 20.9 | 15 | 60 | 6 | 10 | 20×12×10 |
| GP10/20L | 20 | 2 | 10 | 19 | 15 | 52 | 25.8 | 20 | 100 | 6 | 8 | 20×12×10 |
| GP15/30L | 30 | 2 | 15 | 28.2 | 25 | 80 | 42.7 | 30 | 120 | 4 | 6 | 20×16×8 |
| GP20/40L | 40 | 2 | 20 | 37 | 30 | 104 | 50.2 | 40 | 150 | 4 | 6 | 20×16×8 |
| GP25/50L | 50 | 2 | 25 | 47 | 30 | 126 | 63.1 | 60 | 200 | 2 | 4 | 20×16×8 |
| GP30/60L | 60 | 2 | 30 | 56 | 50 | 160 | 84.5 | 60 | 200 | 3 | 3 | 20×20×8 |
| GP40/80L | 80 | 2 | 40 | 74 | 50 | 206 | 112.5 | 80 | 300 | 1 | 3 | 20×20×8 |
| GP50/100L | 100 | 2 | 50 | 94 | 75 | 250 | 148.9 | 80 | 350 | 1/0 | 2 | 24×24×8 |
| GP60/120L | 120 | 2 | 60 | 112 | 75 | 320 | 160 | 125 | 400 | 3/0 | 1/0 | 20×20×8 × |
| GP75/150L | 150 | 2 | 75 | 140 | 100 | 448 | 225 | 125 | 500 | 4/0 | 1/0 | 24×24×8 ×2 |
Wire sizing notes
- Wire size is based on 75°C copper conductors with a maximum of 100 feet total run (one-way).
- For longer runs or aluminum conductors, increase wire size as required by code.
- All wiring must be sized in accordance with the National Electrical Code (NEC) and local requirements.
- Idler motor wire size is for the individual idler/generator motor feed.
Installation notes
- Installation must be performed by a qualified licensed electrician.
- Verify all connections are tight and secure.
- Verify the voltage before energizing the unit.
- Use proper strain relief and cable support.
Warning.
Phase converters can draw high starting current. Use MOTOR LOAD type breakers only. Standard breakers may nuisance trip and cause downtime.
Important.
Refer to the model wiring diagram for correct wiring of input, output, and idler motor connections.
All electrical work must comply with the National Electrical Code (NEC) and local codes.
11 — Reference
Common motor-load breaker part numbers
The table below lists common motor-load breaker part numbers used with rotary phase converter installations. These are reference only. Always verify compatibility with your panel, voltage, and application requirements.
| Manufacturer | Breaker series (motor-load) | 1 pole | 2 pole | 3 pole | Notes |
|---|---|---|---|---|---|
| Square D by Schneider Electric | QO™ | QO1xxx | QO2xxx | QO3xxx | Standard QO series; use HACR or motor-rated as required by code. |
| Siemens | QP™ | QP1xxx | QP2xxx | QP3xxx | Type QP circuit breakers; verify interrupt rating and panel listing. |
| Eaton | BR™ | BR115 | BR215 | BR315 | BR Type breakers; suitable for motor-load applications. |
| ABB | THQL® | THQL1115 | THQL2115 | THQL3115 | THQL series; verify panel compatibility and voltage rating. |
| Murray by Eaton | MP™ | MP115 | MP215 | MP315 | MP series; used in Murray / Eaton panelboards. |
| GE | THQL® | THQL1115 | THQL2115 | THQL3115 | GE THQL series; confirm panel type and application. |
Important.
Breaker part numbers vary by amp rating, interrupt rating, voltage rating, and pole configuration. Always match the breaker to the service panel manufacturer and panel label. Do not install breakers that are not listed for use in the panel.
All electrical work must comply with the National Electrical Code (NEC) and local codes.
12 — Troubleshooting Layer
Support decision cards
Use these decision cards to quickly identify common issues and actions. Always follow safety procedures and the installation manual.
Will not start
Check disconnect, breaker, input voltage, control power, and start circuit. Check for voltage dropping while trying to start. Never leave the phase converter on for 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.
- Verify control power is present.
- Verify start circuit and connections.
- Never leave the converter 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.
- Inspect for overloading the converter.
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.
- Ensure load is balanced as possible.
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.
- Try reducing load and test again.
- Consult factory if issue persists.
High amp reading
Explain generated-leg behavior and where to measure. Do not diagnose from one clamp reading.
- Measure amperage on all three output legs.
- Compare amperage on each leg.
- Check for unbalanced loads.
- Verify idler motor reaches full speed.
- Inspect for tight or damaged connections.
- 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.
- Include a clear description of the issue.
Important.
Only qualified, licensed electricians should install, service, and troubleshoot this equipment. Disconnect and lock out all power before opening or working on the panel.
13 — FAQ
Frequently asked questions
What is the Phoenix DualZone phase converter?
The DualZone is a precision-balanced rotary phase converter that turns single-phase utility power into three-phase power for shop equipment. The DualZone uses two idler/generator motors so the operator can choose how much capacity to bring online from a single control panel.
Where does the incoming single-phase power connect?
Connect the incoming single-phase line to terminals T1 and T2 inside the control panel. Use bolt-down lugs and properly sized wire. Refer to the wire size chart on the yellow sticker inside the panel for the correct gauge.
Does each DualZone idler motor have to be running?
The primary idler always runs when the converter is engaged. The second idler is enabled by a green button on the front of the panel. The green button can be left engaged during normal use. Do not energize the second power block unless the second idler motor is actually connected.
What breakers should I use with a Phoenix rotary phase converter?
Use motor-load (HACR or motor-rated) breakers only. Standard light-duty breakers may nuisance-trip on the high inrush of a rotary phase converter. Common compatible series include Square D QO, Siemens QP, Eaton BR, ABB THQL, Murray MP, and GE THQL.
How long can the converter run if it does not start?
Never leave the converter energized for more than two seconds if it does not start. Disconnect power and troubleshoot the disconnect, breaker, input voltage, control power, and start circuit before retrying.
Who should install a Phoenix DualZone?
Installation must be performed by a qualified, licensed electrician in accordance with the National Electrical Code (NEC) and local codes. Disconnect and lock out all power sources before installing or servicing the unit.
How long can the single-phase line run be?
The wire size chart in the manual is based on a maximum wire run of 50 feet. Keep the single-phase line as short as possible. If the run exceeds 50 feet, increase the wire size by one gauge for every additional 50 feet.
What is the difference between NL/PL and NH/PH models?
NL and PL models use the 230 V low-voltage motor connection. NH and PH models use the 460 V high-voltage connection. 460 V motor lead wiring is covered in the separate 460 V high-voltage motor manual.
Need a hand?
Talk to Phoenix Phase Converters.
If you are sizing a DualZone, retrofitting an existing shop, or working through a startup issue, we will walk it through with you. Bring your machine nameplate, service details, and a photo of your panel.