Okay, let's break down the situation and the potential solutions. You've got an existing 2-phase service you want to convert to a more standard split-phase (120/240V) system to feed a commercial unit and three apartments. Here's a comprehensive analysis, focusing on safety, code compliance (NEC), and practical considerations.

Understanding the Situation 2-Phase Service

This is an older electrical system, not commonly used anymore. It typically involves two 'hot' legs with a specific voltage and phase relationship between them (often 90 degrees). This differs significantly from the standard North American split-phase (120/240V) single-phase service where the two 'hot' legs are 180 degrees apart.

Square D 4-Pole Fused Disconnect

This suggests the old 2-phase system had a neutral (or grounded conductor) and two hot legs. The fourth pole could be used to switch the neutral, but not always necessary.

No More 2-Phase Loads

This is a critical piece of information. It means you don't need to maintain the 2-phase service for any existing equipment.

Goal

Convert to a standard split-phase system to serve a commercial unit and three apartments. This will require a new service entrance.

Funding and L&I Issues

Limited funding and issues with the local authorities (L&I - Licenses and Inspections) make a clean, code-compliant solution even more crucial to avoid future problems.

Why You CANNOT Just "Break It Into 2 Single Phase Parallel Split/Phase Disconnects"

This is extremely important. You cannot simply reconfigure the existing 2-phase wiring and equipment into a split-phase system without major changes and likely a complete service upgrade. Here's why: Phase Relationship

The fundamental problem is the phase relationship between the two hot legs of the 2-phase system is different from the 180-degree phase relationship required for a standard split-phase system. You can't simply rewire to change this inherent property.

Voltage Levels

Even if you tried to use the existing conductors, the voltage levels may not be correct for standard 120/240V split-phase.

Conductor Size & Neutral

The existing conductors may not be adequately sized for the load requirements of the commercial unit and three apartments. Also, the existing neutral may be undersized. The NEC requires a properly sized neutral conductor.

Overcurrent Protection

The existing fused disconnect is designed for a 2-phase system. Its overcurrent protection characteristics won't be appropriate for a new split-phase system with different loads. You need circuit breakers sized correctly for each circuit.

NEC Violations

Attempting this without proper planning and adherence to the National Electrical Code (NEC) will result in numerous violations, creating a dangerous and non-compliant installation.

Safety Risk

Incorrectly wired electrical systems pose a significant fire and electrocution hazard.

The Correct Approach: Service Upgrade to Split-Phase

The proper solution is a complete service upgrade to a standard 120/240V split-phase system. Here's the process:1. Load Calculation

Perform a thorough load calculation for the commercial unit and the three apartments, in accordance with NEC Article 220. This will determine the total amperage requirement for the new service. Consider both general lighting/receptacle loads and any specific appliance loads (HVAC, cooking equipment, etc.). This is absolutely critical.
2.

Utility Company Coordination

Contact the utility company (PECO in West Philadelphia). They will determine the available service size and location, and specify the point of connection for the new service. They will also tell you if they are able to change the source from 2-phase to split-phase. They may be able to provide a transformer upgrade on their side of the service.3.

Service Entrance Equipment

Select appropriately sized service entrance equipment, including:

Main Disconnect

A properly rated main breaker disconnect switch.

Meter Socket

A meter socket compatible with the utility's requirements.

Distribution Panel(s)

One or more distribution panels with appropriately sized circuit breakers for each circuit in the commercial unit and the apartments. Consider individual meters for each apartment to allow them to be billed individually for their usage.4.

Wiring



Service Entrance Conductors

Install new service entrance conductors (from the utility connection to the main disconnect) sized according to the load calculation and NEC Table 310.16 (or appropriate table for the insulation type).

Feeders

Install properly sized feeder conductors from the main disconnect to the distribution panel(s).

Branch Circuits

Install new branch circuits (120V and 240V as needed) throughout the building, using appropriate wire sizes and overcurrent protection.

Grounding

Implement a proper grounding system, including a grounding electrode conductor connected to a grounding electrode (ground rod, water pipe, etc.) and bonding of all metallic enclosures and non-current-carrying metal parts. This is essential for safety.5.

Permitting and Inspection

Obtain all necessary permits from L&I (or the relevant local authority) before starting any work. Have the installation inspected by L&I to ensure it complies with the NEC and local codes. This is crucial given the past issues with L&I. Document everything.

Addressing Funding and L&I Issues Prioritize Code Compliance

Even with limited funding, prioritize meeting the minimum code requirements. A non-compliant installation will only lead to more problems (fines, shutdowns, liability) down the road.

Phased Approach (Possibly)

If funding is extremely tight, explore the possibility of a phased approach:

Phase 1

Upgrade the service entrance to a code-compliant split-phase system, sized to handle at least the essential loads.

Phase 2

Install the remaining branch circuits and complete the wiring in the commercial unit and apartments.

Professional Electrician

Hire a licensed and experienced electrician to perform the work. Don't try to cut corners by using unqualified labor. A qualified electrician will be familiar with the NEC and local codes, and will be able to ensure a safe and compliant installation.

Documentation

Keep detailed records of all work performed, including permits, inspections, wiring diagrams, and material specifications.

Communicate with L&I

Proactively communicate with L&I throughout the process. Explain the project, address any concerns they have, and be prepared to provide documentation to demonstrate compliance.

Consider alternative funding

Look into local programs that can provide funds for service upgrades and electrical work in low income communities.

In summary: You must perform a complete service upgrade to a split-phase system. Do not attempt to repurpose the existing 2-phase system, as it is unsafe and violates the NEC. Prioritize code compliance, use a licensed electrician, and work closely with the utility company and L&I. Flag for review