[SWATH]

Here is a concise documentation of my VFD conversion for anyone interested.

Starting off here are the components I used (all the following from Automation Direct):

Marathon 2HP inverter duty AC motor:
Y551-A772 | 2 hp Inverter-duty AC Motor w/encoder: 145TC, 1800 RPM

Durapulse GS3 3HP VFD:
GS3-23P0

GS3-FB encoder feedback card (since the motor has a Dynapar HS35 shaft mounted 1024ppr optical incremental encoder):
GS3-FB

10 pin encoder cable with military connector:
TRDA-25CBL-VWD-10 | Connection Cable for TRDA-25N series encoders: 10-pin MS conn., 10 ft.

300W 70ohm braking resistor:
GS-23P0-BR


There was a mishmash of Cat7 cables and Molex connectors

12ga stranded wire from Lowes, and liquidtite 1/2" PVC coated flexible metallic conduit from Home Depot (with the connectors)
http://www.homedepot.com/p/Southwire...-100346402-_-N

The REX84 card that I designed, had printed, then soldered all the chips, resistors, LEDs, and capacitors onto.

The motor mount itself that I designed and machined out of 6061-T6 Al:
2 3D files in zip file attached to post

The PMDX-106 Spindle control card:
http://www.pmdx.com/PMDX-106

[SWATH]

Crappy pic of the wiring (which I later realized wasn't completely hooked up. I must have taken the pic right before I replaced the VFD with a new one as I started undoing wires. I'll replace the pic with a current better one later when I get a chance. The wiring is the same though.
Attachment 240416