I just know everyone is holding their breath waiting to hear!

All those who predicted that FactoryMation would find nothing wrong were right! The unit checks out fine. I even heard a motor running off of it when I was on the phone with them. So the VFD is on it's way back to me. Apparently the problem lies with the motor itself. I had the motor bench tested today and it seems to work fine so the fact that the motor is a 5hp instead of a 3hp remains a "probable cause" of the anomaly. I have the motor for sale and hopefully will get it sold and acquire a 2 or 3hp replacement before I get the VFD back. Then it will be time for round 2...