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Running in the low tap position, that is the tune up position is OK as the operator on the other end will not be able to tell the difference, I used my L7 for years like that, I'm still doing it most of the time in fact.

Now when doing so, running in the low tap tune position the grid current will be a little higher so watch it but I have never had an issue, 500 watts would be OK for output, why do you need much more you will only get 4.5 db more on the receive end at 1500 watts.

You switched tubes you noted and have not had a problem. The internal wiring of the 3-500Z happens to be very close together, on an ohm meter everything can check out OK but as you use the tube of course the wiring expands as it heats up and can short. This is another reason to never store these tubes on their side as they are not meant to support the weight, only store standing up.

Good luck

Tim

WB8UHZ