Troubles with low voltage Bruck Flight track system

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kde

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Hello, I am having an alarming problem with a Bruck Flight track system. This is a 12volt system with 300watt surface mounted transformers. After we installed and turned on some of the lighting, we went back to check connections and noticed the ground wire had virtually melted. We checked all connections and decided that was not an issue. The kicker here is this system is installed on a metal roof (very industrial for a residence). After more testing we felt the lighting system may have been conducting secondary voltage to the ceiling and therefore to the ground (the metal structure was bonded to the subpanel via #6). We isolated/insulated the standoffs from the metal building thinking we may have solved the problem. Unfortunately we did not. After about 30-60 seconds, the ground wire becomes warm and then actually very hot. If we disconnect the primary ground from the transformer there is no problem at all (the transformer is still grounded via the ground to the metal roof). We are baffled. Can anyone give me any ideas of what the heck may be going on.

Thank you, JJ
 
kde said:
Hello, I am having an alarming problem with a Bruck Flight track system. This is a 12volt system with 300watt surface mounted transformers. After we installed and turned on some of the lighting, we went back to check connections and noticed the ground wire had virtually melted. We checked all connections and decided that was not an issue. The kicker here is this system is installed on a metal roof (very industrial for a residence). After more testing we felt the lighting system may have been conducting secondary voltage to the ceiling and therefore to the ground (the metal structure was bonded to the subpanel via #6). We isolated/insulated the standoffs from the metal building thinking we may have solved the problem. Unfortunately we did not. After about 30-60 seconds, the ground wire becomes warm and then actually very hot. If we disconnect the primary ground from the transformer there is no problem at all (the transformer is still grounded via the ground to the metal roof). We are baffled. Can anyone give me any ideas of what the heck may be going on.

Thank you, JJ
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Are you referring to the ground wire feeding the transformer? This doen't make sense as the secondary of the xformer is not a grounded system and no current would flow on the xformer primary ground even if you had 1 leg of the secondary shorted to the metal roof.
 
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