Newbie- Newbie setting up a TC-22, blowing fuses. Detroit/Ferndale, MI

[Myself]

I'm a member of a not-for-profit community workshop, and we just acquired a Torq-Cut 22 from an environment where it'd been unused for a few years. We're trying to get a full CNC environment set up for members and students to tinker with. I've got some electronics experience but am in over my head here. (Translation: Total noob, please spell things out!)

The machine's nameplate says 480v, but it came out of a 240v environment, and had been used with a step-up transformer. Our shop is also wired with 240v. We got the transformer with it, but while arguing over where to park the transformer (it'd be really awkward in our setup), we noticed that the machine's wiring diagrams show alternate transformer strapping for various input voltages. According to the prints, it can run natively from 240v. My theory is that the nameplate simply indicates how the machine was configured from the factory, and that the sales engineer may have not known it could be reconfigured, or may have simply decided to pad the invoice (and thereby his commission) by selling the original owner a transformer they didn't need.

So, we changed the strapping on the transformer primaries, and now all the secondaries read the voltages they're supposed to. For a few minutes, things looked pretty good, and we were able to jog X, Y, and Z back and forth from the operator's controls. Then one of the axes apparently jogged too far and got itself stuck, presumably because the lube on the ways is a few years old and we didn't have the lube pump running yet.

So, there's a fresh load of way lube in the tank now, and I've been trying to figure out how to make the lube pump run continuously for a while. I'd like to just let it go until I see lube dripping around the ways. The only other way I know to run the lube pump is to try to enable the axis drives and run the machine a bit, but when I try that, it blows fuses.

The fuses being blown are the ones that feed the transformer which feeds, among other things, the servo drives. On the print, they're 20-amp breakers. When we got the machine, they weren't breakers at all, but KTK-10 fuses. Figuring that a 240v input will need to move twice the amperage as a 480v input, I replaced them with KTK-20s. They still blow instantly when the axis drives are enabled.

So, a bunch of questions here:

• What's the easiest way to manually run the lube pump for a few minutes?
• Am I insane for trying to omit the step-up transformer?
• If I need to manually back the axes off (I've heard the word "overtravel"), how do I do that?
• Any Detroit-area gurus wanna lend a hand? Specify favorite food and drink...

Thanks in advance for the advice, like I said, I'm new to all this and really appreciate the help. I'll do my best to monitor the thread and provide whatever additional information is required, but work and travel may impose several-day latencies on those responses.