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I think you'll find that if you push too hard you'll just clog up the sandpaper before you bog down the motor. I use both 120 and 180. Because I use my lathe I have two discs so I don't have to remove on grit to use a second. Unless the 120 is worn it'll eat the wood pretty quickly. I've used it to flatten the bottom of some boxes I made that were 8"x12". I guess if you were to use 60 grit but I have to believe that it would remove wood so fast it could be hard to control.
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With a vfd if the input amps is too low for full power you can just dial it down so it only runs at say 2.5 hp. If that is what your wiring can supply. rpm will be correct ,just set it for a nice slow start and I bet 3hp will be fine off 20 amps
If it is tripping the breake then reduce maximum amps down say, 20% and try that.
You can run a 5hp motor on a 2hp vfd but it will only deliver a max of 2hp.
Bill D
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