Site reported several contactors with a cracked rod that forms a critical part of the armature. At the time there was no solution available.
Modify armature to ensure weak point is removed.
ACS have now installed this modification in hundreds of contactors with zero failures.
"This modification, as well as the exchange contactor rebuild service, has virtually eliminated contactor failures on our 830EAC's. The cost OEM quad chopper upgrade which eliminates the RP contactors could not be justified due to our extremely low contactor failure rate. We stuck with the ACS rebuilt contactors & scheduled 3000 hour change outs."