Manual Ver825
PHOENIX Phase Converters
Complete All-in-One Technical Manual & Installation Guide
Publication Date: August 2025 | Document Version: 1.0
Covers: All HP Sizes (3-100 HP) | Both Voltages (230V & 460V) | Including Dual Zone Models
Product Overview
Phoenix Phase Converters manufactures precision-balanced rotary phase converters designed to convert single-phase power to three-phase power for industrial and commercial applications. Our complete product line covers 3 HP to 100 HP in both 230V and 460V configurations.
TEFC Generator
Totally enclosed fan-cooled design with cast iron frame
NEMA 4 Enclosure
Weather-resistant construction for indoor/outdoor use
Precision Balanced Voltage
Optimized three-phase output across all loads
Auto-restart Capability
Automatic recovery from power interruptions
Voltage Monitoring
Integrated display for system monitoring
Heavy-duty Construction
Powder-coated finish for corrosion resistance
Industry-leading warranty coverage on all control panels
Complete Model Lineup
230V Models (L Series)
Standard Models (GP3PL - GP100PL)
Single Phase 230V to Three Phase 230V conversion
- GP3PL - 3 HP
- GP5PL - 5 HP
- GP7.5PL - 7.5 HP
- GP10PL - 10 HP
- GP15PL - 15 HP
- GP20PL - 20 HP
- GP25PL - 25 HP
- GP30PL - 30 HP
- GP40PL - 40 HP
- GP50PL - 50 HP
- GP60PL - 60 HP
- GP75PL - 75 HP
- GP100PL - 100 HP
460V Models (H Series)
High Voltage Models (GP3PH - GP100PH)
Single Phase 460V to Three Phase 460V conversion
- GP3PH - 3 HP
- GP5PH - 5 HP
- GP7.5PH - 7.5 HP
- GP10PH - 10 HP
- GP15PH - 15 HP
- GP20PH - 20 HP
- GP25PH - 25 HP
- GP30PH - 30 HP
- GP40PH - 40 HP
- GP50PH - 50 HP
- GP60PH - 60 HP
- GP75PH - 75 HP
- GP100PH - 100 HP
Special Models: NL | PL | DZ Series
Dual Zone Phase Converters for maximum flexibility
240V operation with independent and combined idler output options
Technical Specifications Master Chart
230V Models (L Series) - Electrical Specifications
| Model | HP | Max Inductive (A) | Max Resistive (A) | Min KVA | Min Service (A) |
|---|---|---|---|---|---|
| GP3PL | 3 | 15 | 8 | 5 | 22 |
| GP5PL | 5 | 25 | 14 | 7.5 | 33 |
| GP7.5PL | 7.5 | 35 | 19 | 10 | 43 |
| GP10PL | 10 | 50 | 28 | 15 | 65 |
| GP15PL | 15 | 70 | 39 | 20 | 87 |
| GP20PL | 20 | 90 | 50 | 25 | 109 |
| GP25PL | 25 | 110 | 61 | 35 | 152 |
| GP30PL | 30 | 130 | 72 | 40 | 174 |
| GP40PL | 40 | 160 | 89 | 50 | 217 |
| GP50PL | 50 | 190 | 106 | 60 | 261 |
| GP60PL | 60 | 220 | 122 | 75 | 326 |
| GP75PL | 75 | 270 | 150 | 90 | 391 |
| GP100PL | 100 | 350 | 194 | 125 | 543 |
460V Models (H Series) - Electrical Specifications
| Model | HP | Max Inductive (A) | Max Resistive (A) | Min KVA | Min Service (A) |
|---|---|---|---|---|---|
| GP3PH | 3 | 8 | 4 | 5 | 11 |
| GP5PH | 5 | 13 | 7 | 7.5 | 16 |
| GP7.5PH | 7.5 | 18 | 10 | 10 | 22 |
| GP10PH | 10 | 25 | 14 | 15 | 33 |
| GP15PH | 15 | 35 | 20 | 20 | 43 |
| GP20PH | 20 | 45 | 25 | 25 | 54 |
| GP25PH | 25 | 55 | 31 | 35 | 76 |
| GP30PH | 30 | 65 | 36 | 40 | 87 |
| GP40PH | 40 | 80 | 45 | 50 | 109 |
| GP50PH | 50 | 95 | 53 | 60 | 130 |
| GP60PH | 60 | 110 | 61 | 75 | 163 |
| GP75PH | 75 | 135 | 75 | 90 | 196 |
| GP100PH | 100 | 175 | 97 | 125 | 272 |
Wire Sizing & Breaker Requirements
| Current Rating | Copper AWG Size | Application Range |
|---|---|---|
| Up to 20A | 12 AWG | Small motors, controls |
| 21-30A | 10 AWG | 3-7.5 HP applications |
| 31-40A | 8 AWG | 5-10 HP applications |
| 41-55A | 6 AWG | 10-15 HP applications |
| 56-75A | 4 AWG | 15-25 HP applications |
| 76-95A | 3 AWG | 25-30 HP idler connections |
| 96-125A | 2 AWG | 25-40 HP applications |
| 126-150A | 1 AWG | 40-60 HP idler connections |
| 151-175A | 1/0 AWG | 40-50 HP applications |
| 176-200A | 2/0 AWG | 50-60 HP applications |
| 201-230A | 3/0 AWG | 60-75 HP applications |
| 231-260A | 4/0 AWG | 75-100 HP applications |
| 261-300A | 300 MCM | 100 HP applications |
Installation Guidelines
Safety Notice
Always follow local electrical codes and safety regulations. Installation should be performed by qualified electrical personnel.
Installation Location Recommendations
For optimal performance, the phase converter should be installed as close to the power supply as possible. It is recommended to keep the single-phase supply line under 50 feet in length.
- Install the phase converter close to the power source
- Keep the single-phase line under 50 feet whenever possible
- Use properly sized wire for longer runs
- Plan for voltage drop calculations
- Ensure adequate ventilation around the unit
- Use proper grounding techniques per NEC requirements
- Don't use long runs of undersized wire
- Don't install in areas with restricted airflow
- Don't connect loads during startup sequence
- Don't use general purpose breakers instead of motor load breakers
- Don't exceed maximum recommended distances without wire upsizing
Voltage Drop Considerations
Electric current experiences voltage loss over distance due to conductor resistance. For phase converters, maintaining proper voltage is critical—especially during startup, when the converter draws high inrush current.
Wire Sizing for Extended Distances:
- 50-100 feet: Increase wire size by one gauge
- 100-150 feet: Increase wire size by two gauges
- 150-200 feet: Increase wire size by three gauges
- Over 200 feet: Consult factory for recommendations
Step 1: Install and Mount Control Panel
Mount the enclosure to a non-vibrating surface using the provided mounting brackets. Install the back plate with the four nuts provided.
Step 2: Run and Terminate Single-Phase Input Wiring
Connect both hot conductors (L1 and L2) from your single-phase electrical panel to the terminals marked L1 and L2 on the phase converter input.
Step 3: Install Idler Motor and Connect Motor Wiring
Follow the motor diagram for proper connections. Never use wire nuts on motor connections - use Polaris connectors or bolt-down lugs only.
Step 4: Run and Terminate Three-Phase Output Wiring
Connect the three-phase output (T1, T2, T3) to your load distribution panel or motor starter.
Step 5: Verify All Connections and Torque Specifications
Check all connections for proper torque and electrical continuity before energizing the system.
Step 6: Energize and Test System
Power up the converter first, then connect your load. Never start the phase converter under load.
Wiring Diagrams & Motor Protection
Motor Load Breaker Requirements
Motor load breakers are REQUIRED for all phase converter installations. Never use standard circuit breakers for motor applications. Motor load breakers are specifically designed to handle high inrush currents during motor startup, sustained motor loads, and provide motor protection requirements per NEC 430.52.
Why Motor Load Breakers Are Essential
When using a rotary phase converter to operate a 3-phase motor on single-phase power, motor load breakers are critical for several reasons:
Startup Protection
Motors draw 6–8 times their full-load amps at startup
Overcurrent Safeguard
Protects against mechanical jamming or overload conditions
Converter Load Coordination
Ensures proper matching and prevents overload
Code Compliance
Required by NEC 430.52 for motor circuits
Breaker Sizing Guidelines
For Single Equipment Loads
Identify Full Load Amperage (FLA)
Check the equipment's nameplate or manual for the FLA—this is the current the equipment draws under full load.
Determine Breaker Size Based on NEC Guidelines
Motors: Per NEC Article 430, breakers are sized 125% of the motor's FLA (for inverse time breakers).
Resistive loads: Breaker can be sized at 100% of the rated current (plus safety margin if continuous load).
Use Manufacturer Recommendations
Always refer to the equipment manual. Some equipment may require a dedicated breaker size due to sensitive electronics or startup characteristics.
For Multiple Equipment Loads
Add Up All Individual Loads
Calculate the total amperage of all connected equipment. Add the FLA of all machines that can run at the same time. Don't add everything blindly—only count simultaneous loads.
Apply Diversity Factors
If all equipment will not run at once, apply a diversity/load factor (e.g., 70–80%) to total amps. NEC allows certain reductions when sizing for non-continuous loads or when motors start in sequence.
Include Largest Motor Adjustment
Per NEC 430: Add 125% of the largest motor's FLA, then add the FLA of all other motors.
Choose the Right Breaker
Based on total adjusted amperage, choose the next standard breaker size up (per NEC 240.6). Verify the breaker is compatible with the panel and wire size.
Critical Motor Wiring Note
Do NOT use wire nuts on the idler motor, even if it is just temporary. Use Polaris plugs or bolt-down lugs only. Wire nuts can cause connection failures and equipment damage.
Motor Connection Diagrams
12 Wire Motor (For 230 Volts Only)
- Connect 1,6,7,12 together to L1
- Connect 2,4,8,10 together to L2
- Connect 3,5,9,11 together to L3
9 Wire Motor (For 230 Volts Only)
- Connect 1 & 7 together to L1
- Connect 2 & 8 together to L2
- Connect 3 & 9 together to L3
- 4, 5, and 6 together
Standard Connection Configuration
All Phoenix Phase Converters follow the same basic wiring pattern:
Input Connections
- L1, L2: Single-phase input from main panel
- Ground: Equipment grounding conductor
- Control Power: 120V for control circuits (where applicable)
Output Connections
- T1, T2, T3: Three-phase output to load
- Generated Phase: T3 is the generated phase leg
- Load Distribution: Connect to motor starter or distribution panel
Dual Zone Configuration
DUAL ZONE Models: Enhanced Flexibility
240V Operation with Independent & Combined Idler Output Options
Dual Zone Phase Converter Features
This system allows for flexible load connection options. The primary output load is typically connected to the left power block, utilizing the combined power of both idler motors. However, for smaller equipment or applications where only one idler motor is needed, the right power block can also be used to independently power the load via Idler Motor #1.
Independent Operation
Each idler motor can operate independently for smaller loads
Combined Operation
Both idler motors work together for heavy-duty applications
Flexible Load Application
Supports both heavy-duty and lighter load requirements efficiently
Enhanced Versatility
One system handles multiple application types
Dual Zone Wire Sizing Chart
| HP | Wire Size up to 50 feet | Wire Size up to 100 feet | Wire Size up to 150 feet |
|---|---|---|---|
| 5/10 | 8 AWG COPPER | 6 AWG COPPER | 4 AWG COPPER |
| 7.5/15 | 6 AWG COPPER | 4 AWG COPPER | 2 AWG COPPER |
| 10/20 | 4 AWG COPPER | 4 AWG COPPER | 2 AWG COPPER |
| 15/30 | 4 AWG COPPER | 2 AWG COPPER | 0 AWG COPPER |
| 20/40 | 2 AWG COPPER | 1/0 AWG COPPER | 2/0 AWG COPPER |
| 25/50 | 2 AWG COPPER | 1/0 AWG COPPER | 2/0 AWG COPPER |
| 30/60 | 1/0 AWG COPPER | 2/0 AWG COPPER | 3/0 AWG COPPER |
| 40/80 | 2/0 AWG COPPER | 3/0 AWG COPPER | 4/0 AWG COPPER |
| 50/100 | 3/0 AWG COPPER | 4/0 AWG COPPER | 300 MCM COPPER |
| 75/150 | 4/0 AWG COPPER | 300 AWG COPPER | 350 MCM COPPER |
| 100/200 | 350 MCM COPPER | 400 AWG COPPER | 400 MCM COPPER |
Connecting Dual Zone Systems
Connect Single Phase Input
Run both hot conductors (Line 1 and Line 2) from your single-phase electrical panel and connect them to the terminals marked L1 and L2 on the phase converter input.
Connect Idler Motors
Run a total of four conductors on each idler—three power lines and one ground wire—from each idler motor to the terminal block. Terminate at terminals labeled L1, L2, and L3.
Connect Output Load
Choose between independent operation (single idler) or combined operation (both idlers) based on your load requirements.
Troubleshooting Guide
Common Issues and Solutions
Converter Won't Start
- Check: Input voltage and connections
- Check: Control power (if applicable)
- Check: Idler motor connections
- Check: Input breaker sizing
Low Output Voltage
- Check: Input voltage level
- Check: Wire sizing for voltage drop
- Check: Connections for loose terminations
- Check: Load balance across phases
Converter Trips Breaker
- Check: Breaker sizing (use motor load breaker)
- Check: Starting sequence (converter first, then load)
- Check: Load amperage vs. converter capacity
- Check: Short circuit conditions
Poor Load Performance
- Check: Phase converter sizing vs. load
- Check: Voltage balance at load
- Check: Motor starter and overload settings
- Check: Load wiring connections
Load Examples by HP Size
3-5 HP Applications
- Small lathes and mills
- Drill presses
- Band saws
- Small air compressors
- Woodworking equipment
7.5-15 HP Applications
- CNC machine spindles
- Large compressor motors
- Industrial lathes
- Heavy machinery
- Production equipment
20-30 HP Applications
- CNC lathes
- Surface grinders
- Medium air compressors
- Industrial mixers
- Conveyor systems
40-60 HP Applications
- CNC machining centers
- Large air compressors
- Industrial pumps
- Plasma cutters
- Heavy-duty mixers
75-100 HP Applications
- Large CNC spindles
- Industrial compressors
- Heavy-duty lathes
- Production machinery
- Process equipment
Technical Support
For technical issues not covered in this guide:
Phone: 800-417-6568
Email: phoenixphaseconverters@gmail.com
Hours: 8am - 5pm PST Mon-Fri
Website: www.phoenixphaseconverters.com
Warranty Information
All Phoenix Phase Converters Rotary Phase Converter Control Panels are backed by a lifetime warranty, protecting against defects in materials and craftsmanship.
Control Panel Warranty Coverage
All Electrical Components
Control circuits and contactors
Capacitors
Start components and run capacitors
Enclosure & Hardware
NEMA 4 enclosure and mounting hardware
Lifetime Coverage
No time limit on warranty coverage
Warranty Exclusions
DIY panels are excluded from this warranty. Damage from misuse or improper installation is not covered. Normal wear items are excluded.
Electric Motor/Idler Warranty
The Electric Motor/Idler is covered by a three-year warranty provided by North American Electric Motors or Techtop. Additionally, the rotor has a lifetime warranty for the original owner.
Service Requirements:
- All warranty work must be performed by authorized service centers
- Prior written consent required from Phoenix Phase Converters
- Warranty inspection report and generator specification tags must be presented
Return Policy
90-Day Return Policy
Eligibility: Only sealed, unopened packages
Process:
- Contact customer service for RA number
- Package product in original, unopened packaging
- Ship to provided address with RA number clearly marked
- Customer responsible for return shipping costs
Refund Terms
Amount: Original purchase price minus shipping costs (both directions)
Processing: 10-15 business days
Non-Returnable:
- Transformers (except for defects)
- Opened packages
- Used products
- Custom configurations
Additional Features & System Options
Power Loss & Self-Starting
Automatic recovery from power interruptions
Rural Soft Starting
Optimized for rural electrical systems
AutoLink Technology
Device pairing and smart connectivity
Weather Resistant
NEMA 4 enclosure for outdoor use
Transformer Specifications (Optional)
240/480 Volt - 3 Phase Transformers
- Self-cooled (AA)
- Aluminum windings
- Voltage adjustment taps
- Impedance 5.75% (±7.5%)
- NEMA 3R indoor/outdoor enclosure
- High-grade silicon-steel core
- 150 degree C rise
- VPI windings
- UL/CSA compliance
Sales and Support
Phone: 800-417-6568
Website: www.phoenixphaseconverters.com
Email: phoenixphaseconverters@gmail.com
Customer Service Hours: 8am - 5pm PST Mon-Fri
Services Available:
- Product Selection: Expert assistance in choosing the right converter
- Technical Support: Installation and troubleshooting help
- Warranty Service: Authorized repair and replacement services
- Custom Solutions: Special applications and configurations
Shipping & Delivery: 12 Warehouses for fast delivery across the USA. Expedited shipping available. Next-day delivery available in most areas.
Important Safety Information
This manual contains important safety and installation information. Read all instructions carefully before installation. For technical support or questions not covered in this manual, contact Phoenix Phase Converters directly.
Document Control: PHOENIX-ALL-IN-ONE-001 | Revision 1.0 | August 2025
© 2025 Phoenix Phase Converters. All rights reserved.