John, these are all good suggestions for what might be causing the failures 
(coil snubber, operating contacts under load, etc.) But have you done any 
post-mortem on the failed contactors to see how they actually failed?

Perhaps I missed it; but was it the coil or the contacts that failed? Are the 
contacts welded closed, or burned open? You may have to cut it open to see.

Lee
--
Excellence does not require perfection. -- Henry James
--
Lee A. Hart https://www.sunrise-ev.com

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