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SWATH
06-17-2014, 01:17 AM
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 (http://www.automationdirect.com/adc/Shopping/Catalog/Motors/AC_Motors_-_General_Purpose_and_Inverter_Duty_%280.25_-_300HP%29/AC_Motors_-_Inverter_Duty,_Marathon_%280.25_-_100HP%29/Marathon_Black_Max_w-z-_Encoder_%280.25HP_to_30HP%29/Y551-A772)

Durapulse GS3 3HP VFD:
GS3-23P0 (http://www.automationdirect.com/adc/Shopping/Catalog/Drives/DURApulse_-_GS3_%28230_-z-_460_VAC_Sensorless_Vector_Control%29/DURApulse_-_GS3_Drive_Units_%28230_-z-_460_VAC_SLV%29/GS3-23P0)

GS3-FB encoder feedback card (since the motor has a Dynapar HS35 shaft mounted 1024ppr optical incremental encoder):
GS3-FB (http://www.automationdirect.com/adc/Shopping/Catalog/Drives/GS_Configuration_-a-_Communications_-a-_Software/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. (http://www.automationdirect.com/adc/Shopping/Catalog/Sensors_-z-_Encoders/Optical_Rotary_Encoders/Encoder_Accessories/Cables_-a-_Connectors/TRDA-25CBL-VWD-10)

300W 70ohm braking resistor:
GS-23P0-BR (http://www.automationdirect.com/adc/Shopping/Catalog/Drives/AC_Drive_%28VFD%29_Spare_Parts_-a-_Accessories/GS_Braking_Options_%28Braking_Units_-a-_Resistors%29/Braking_Options_%28All_GS_Drives%29/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-1-2-in-X-25-ft-Liquidtite-Met-Titan-Conduit-55082621/100346402?MERCH=RV-_-RV_search_plp_rr-3-_-NA-_-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
06-18-2014, 08:28 PM
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.
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