Great! Glad it’s working!
Switching power on at your power distribution unit is no different than switching it on at your power supply. You can’t create a surge by turning something on. I don’t think that has anything to do with whatever caused the fuses to blow.
Regarding bullet point #1: what did your tech mean by “black to ground”? The COM probe to the chassis? If that’s what they meant I don’t agree with that unless you know the 0V or “ground” reference for the power supply output you’re measuring is bonded to the chassis. It should be, but it’s not always. Sometimes the “float”, and you have to reference the 0V conductor for the power supply which is, in the case of the +/-15V supply of the PS-520 on pins 8 & 9. They ideal way external power supplies like the PS-520 should be wired, as far as the grounding goes: three-prong power cable comes into PSU chassis…ground conductor is positively bonded to PSU chassis as close to where the cable enters the chassis as possible. All 0V references for each regulated unipolar or bipolar DC power supply should stay separate and not bond to the PSU chassis (yet), but propagate separately to the console chassis through the umbilical. Then, all 0V references should positively bond to a common point of the console chassis as close as possible to where the umbilical enters the chassis. Then, assuming all metal members of the console chassis or positively bonded together (this goes for the PSU chassis as well), signal and power grounds as well as shields also bond to the chassis in the most reasonable direct way as possible with only one path each…everything is tied together using the chassis…then the console chassis and PSU chassis should be positively bonded together via the (ideally) braided shield of the power supply umbilical. Again, this is ideal state. The M-520 deviates from this substantially. And now you make me want to look at really old pictures of work I did to correct all this on my prototype console, which was a prototype for the M-50/M-500 consoles…and I currently use a modified PS-520 to power it. And had to correct stuff in it. Teac is not alone in these discrepancies. But it becomes a problem when a device is inconsistent with itself as far as the ground scheme. Then we really get into trouble either with noise interference or worse yet safety. Both were the case with my Soundtracs MX console…a grounding abomination. The M-520 isn’t bad, just not ideal. And, IIRC, there is some inconsistency with how and where the different regulated SC rails’ 0V references bond to the chassis, either the console or PSU, and how the two bind together. So the most accurate and reliable way to measure the output of a power supply is to measure use the supply’s 0V reference. Unless you verify the 0V reference is correctly bonded to the chassis.