A few observations, I have found that T.M. motor specs drastically over rated, power wise, think about it, who hooks a treadmill up to a wall socket that will support a 3hp motor?
The drive only supplies the current demanded of it, you could use a 100amp controller, but if the motor only demands 6 amps, this is what will flow, regardless of the controller capability.
It is similar to the automotive rating for your car alternator, typically it may be rated for 100 or 150 amps, if you look at the size of it, how long do you think it would last if a constant current of this nature were demanded of it?
If the current controller will not supply the current that the motor is capable of, then maybe a larger drive could be looked at.
What is the issues right now with the present controller, if it goes into current limit or other symptoms, you could look at a KB or Baldor of sufficient size.
Many come up on ebay.
Is this a DC brushed (permanent magnet field) or AC/DC Universal motor?
Al.
CNC, Mechatronics Integration and Custom Machine Design
“Logic will get you from A to B. Imagination will take you everywhere.”
Albert E.