TOS-KURIM CNC Upgrade

[Muzzer]

You may have that motor connected up incorrectly, as you say. If your A and B encoder wires are swapped over, it will think the motor is going in the opposite direction. That causes the servo to run away. Or you might have 2 or 3 of the phase connections swapped around.

130vdc doesn't sound bad. I don't recall precisely but I think the voltage clamp / braking module starts clipping at around 170V or so, so you shouldn't be seeing a problem.

Shouldn't take a lot of current to jog the axes. 35A should be more than enough. You would be overcoming a large force to require that sort of power, possibly break something. I've jogged my table against a hard end stop a couple of times. Luckily on my system, the drive trips before anything snaps but that's down to the design of your machine. You could really f*ck something up, like a ballscrew / ballnut or its mount / yoke. Worth seeing what would take the load in that event and convincing yourself it would be OK come the crunch.

Going into error when starting to move doesn't sound like overvoltage, which would only happen if you try to bring an axis to a rapid stop. I wonder if it's an encoder / motor issue?

I'd disconnect 2 of the drives and remove the belt / coupling from the third. Then try to run the servo just using the tuning software. No point getting the controller involved yet. When that works, reconnect the ballscrew and try tuning the response with the software. Finally, connect up the controller and see how it plays together.