The shield needs to be grounded at least at one end, are the chassis not grounded, (2 pin power)?
Did the hot and neutral of your power get swapped? (meter them to ground) is there any DC on your 120V power.
(aside: the power in a house here and in the US is two legs off a three phase distribution transformer so the two hots are 120 degrees out of phase and thats why you only get 220v not 240V between them)
DC on mains is not the case; if so, the xformer would have been burned. At any rate, DC doesn't go through a xformer last time I looked.
Also don't see any connection between swapping mains pins and gradual buildup of whatever on the chassis. What's your reasoning here?
Do the simple things first. If there's a potential difference between shield and chassis, connect them with a wire. That should be interesting.
Dead giveaway: what was the common piece of equipment with all those different configs that had the problem? If there is a problem at all.
jd
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