�

Installation, Operation &Maintenance Instructions

Siemens Ltd.SGR-01-103-035

'Product development is a continuous process. Consequentlythe data indicated in this Booklet is subject to change withoutprior notice. For latest issue contact our Sales Office.'

4I-0089-0115980 001

DOL Starter Type 3TW42 00(open execution)

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For dependable service, it isof utmost importance thatinstructions given below arefollowed for selection,inspection, installation,commissioning, operationand maintenance.

Selection:

• Refer Table A,B,C and D forrecommended selection ofstarters.

• Table A: kW/HP rating,thermaloverload relay range & fuserating.

• Table B: Coil voltage

• Table C: Relay range codes.

• Table D: Max full load currentsfor different types of motors.

Inspection:

• Ensure that the relay rangeand coil voltage are as per yourrequirement.

• Inspect interior for breakage.

• If you find a serious defect, donot use the product but have itchecked by an authorizedSiemens dealer or anelectrician.

Installation:

• Mount the starter in anenclosure and the enclosureon a vertical rigid surface freefrom vibration. The drillingtemplate is enclosed forconvenience. Refer Fig.1 formounting dimensions andFig.2 for permissibledisplacement from verticalplane.

• The enclosure should notallow ingress of dust,dirt orcontamination.

• Connect the incoming andoutgoing cables as follows :

– Select the correct size ofcables from the table-1.

– Connect line & motor leadsexactly as per wiringdiagram.

– Terminal screws: M4

– Tightening Torque:80-110 N-cm

The Starter is now ready forcommissioning.

Fig. 1 : Dimensional Details

* Mounting Dimensions 64 x 108 (Use M4 screws)

Maximum 15O

permissible

Fig. 2 : Maximum permissible displacement from vertical plane

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Commissioning:

Caution:

• During commissioning ormaintenance always ensurethat the main supply isdisconnected by switchingoff the main switch.

• If the relay trips even whenset at the rated motorcurrent the suitability of thestarter/relay for theparticular applicationshould be checked with thenearest Siemens office.

• Setting of ‘Auto/hand reset’mode (Ref.Fig.3)

– In the delivered condition, therelay is set in H=Hand(manual) resetting mode. Tochange from H=Hand (manual)

resetting to A=Automatic(self) mode, press and turnthe Blue button on the relaycounter clockwise fromH to A.

Procedure for setting theoverlaod relay :

For closer protection, set theoverload relay to actual currentas measured by an ammeter.

In the absence of an ammeter,follow the procedure givenbelow:-

– Set the relay to rated currentmentioned on the motorname plate.

– Press the ‘ON’ button of thestarter or the green button ofthe contactor to start themotor and wait till it reachesto normal speed and let it runfor approximately 30 minuteson full load.Then graduallyreduce the relay setting till ittrips.Set the relay at a slightlyhigher value than this setting.

– Allow the reset time ofapproximately 4 min beforepressing the blue button onthe relay to reset it (in casethe relay is set in HR mode)or the relay resets on its ownafter approx 4 minutes after ittrips (in case the relay is setin SR mode).

Fig. 3 : Relay Front View

BlueResetKnob

H - Hand ResetA - Auto Reset

– Restart the motor. If the relaydoes not trip, consider it to beproperly set. If it trips, set it ata little higher value thanbefore and recheck.

– Overload relay characteristicsshown in fig. 4 can be used toestimate the average trippingtime at different multiples ofthe set current.

Operating Characteristics

The given characteristics (Fig.4)are average values of all theranges and sizes of bimetalrelays and are mainly intendedto indicate the inverse timecurrent characteristics of thesame. The tripping times shownare for relays starting from thecold state. At operatingtemperatures (heated at ratedcurrent) these are reduced toabout 25% of the valueobtained from thecharacteristics.

Operation:

– For starting the motor, install‘ON’ push button (Green)-contact element (NO)combination on enclosurecover and wire-up as shownin the wiring diagram. PressGreen push button to startthe motor.

– For stopping the motor, install‘OFF’ push button (Red) -contact element (NC)combination on enclosurecover and wire-up as shownin the wiring diagram. PressRed push button to stop themotor.

– For reseting the relay frompanel door,use accessory-resseting cord with holder orreset funnel. (refer spares/accessories list for ordering).

– In case you want the starterto be in ‘Self-Reset’mode,the blue knob on the relay isto be pressed and rotated inthe anti-clockwise direction,so that it comes in position‘A’ and its edge is flush withthe surface. In this modeeven if the relay trips onoverload,it will beautomatically reset in amaximum of 4 minutes. Themotor can be restarted onlyafter the relay is reset.

– In hand reset mode forresetting, press buttonmarked ‘R’ if the relay hastripped due to overload (useresetting cord with holder). Inthis case the motor can berestarted only after you resetthe relay. Allow a minimumtime of 4 minutes, beforeresetting it.

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Fig. 4 : Operating characteristics of 3UW50 relays

6 7

Minutes

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Note :

It is recommended that relay beset in the ‘HR’ (hand reset)mode in case of applicationsinvolving maintained ‘ON’command e.g.use of auto-switch or float switch, etc. inorder to avoid damage to thestarter/motor.

Maintenance:

Switch off the starter anddisconnect the main supplyby switching off the mainswitch before doing anymaintenance.

• Keep the interior dust free.

• Re-tighten the terminal screwsfrom time to time.

• No maintenance is needed foroverload relay. Please do notopen the relay.

• Blackening of silver/alloyedcontacts does not affectoperational life. If necessary,clean the contacts ofcontactor with CRC 2-26.Remove the globules with ascrapper or a screw-driverwith minimal force. Under nocircumstances should thecontacts be filed or dressedas it will reduce the electricallife drastically.

• If the contactor hums, cleanthe magnet pole with a softcloth/CRC2-26/Chamoisleather/ size 00 emry paper iffound rusty.

• Replace contacts of thecontactor if they are severelypitted or when only 40% ofthe original contact tipremains.

For details of contactormaintenance refer to our ‘Guideto Contactor Installation &Maintenance’.

• Replacement of ArcChamber:

– Remove the existing arcchamber as shown in (Fig.5)

– Replace it by a new arcchamber (refer the spares listfor item no.)

– Ensure that the arc chamberis flush with the contactorbody.

• Replacement of overloadrelay

– Removal

i. Disconnect the wiresconnected to the relayterminals.

ii. Loosen the outgoingterminal screws of thecontactor.

iii.Lift the overload relayvertically upwards todisengage its hook (Fig.6)from the slot of the bracketmounted on the base plate.

iv.Pull the overload relay awayfrom contactor and inoutward direction.

– Refixing

i. Select the overload relay ofproper range by referring totable A and spares list.

ii. Set the relay either in ‘Handreset ‘ or ‘Auto reset’ modeas per your requirement.

iii.Connect the relay terminals(L1 L2 L3) to the contactorterminals(T1 T2 T3).

iv.Ensure that the relay hook(Fig.6-1) is engaged in theslot of the relay mountingbracket (Fig.6-2) and slidethe relay inwards till thecover is flush with contactorribs.(Fig.6-3)

v. Tighten the contactorterminal screws.

vi.Reconnect the disconnectedrelay wires and check thecorrectness of the starterwiring.

Fig. 6 : Contactor-Birelay Connection

1. Hook for relay engagement2. Relay mounting bracket3. Contactor ribs flush with relay edge.Fig. 5 : Removal of arc chamber

1

2

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1 2 3 4

5

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• Replacement of the MainContacts: (Fig.7 & 8)

– Remove the arc chamber.(Fig.5)

– Remove and inspect thecontacts.

– When contact tips get erodedand base material is seen,refer spares list to replacecontacts.

– Put back the Arc Chamber.

• Replacement of Coil: (Fig.9)

– Disconnect all the wiresconnected to the contactor.Disconnect the relay from thecontactor and remove thecontactor from the base plateby loosening the mountingscrews.

– Turn the contactor upsidedown,unscrew the bottomcover and remove it.

– Ensure that the new coil is ofproper voltage. (Table B).

– Ensure all springs are placed atproper location.

– Put back the bottom cover.

Fig. 8(A) :Replacement of movingcontacts

Nose plier

Fig. 7 : Fixed/moving, main/auxiliarycontacts inspection.

1, 2, 3 : Main contacts4 : Auxiliary contacts5, 7 : Fixed contacts6 : Moving contacts

Fig. 8(B) Replacement of fixed contacts

Fig. 9 Replacement of Coil

1 : Bottom Cover2 : Liner for shock absorption3 : Fixed Magnet4 : Bracket Assembly5 : Return Spring

6 : Return Spring7 : Coil8 : Contactor housing along with moving magnet9 : Aux. Contact10 : Coil terminals

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Ensure that the liner (Fig.9-2) isproperly put.

Fix the contactor on the baseplate, connect the relay andreconnect the disconnected wiresand ensure that the connectionsare proper as per circuit diagram.

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Table A : Selection Table for RAJA Starter in open execution

1) RAJA DOL Starter for Monobloc pumps

Rating for 4P,Relay

Back-up Fuse Recomm- 415V, 3Ph,

Type Range Rating ended

50hz Motor3UW50

HRC fuse Rewir- Cu cableHP# kW Rating (A) able size (mm2)

5 3.7 3TW4200-0A*74 6.3-10 25 21 SWG 1.5

- - 3TW4200-0A*75 8-12.5 25 19 SWG 1.5

7.5 5.5 3TW4200-0A*77 10-16 32 18 SWG 2.5

10 7.5 3TW4200-0A*78 12.5-20 32 18 SWG 4

2) RAJA DOL Starter for Submersible Pumps

Rating for 4P,Relay

Back-up Fuse Recomm- 415V, 3Ph,

Type Range Rating ended

50hz Motor3UW50

HRC fuse Rewir- Cu cableHP# kW Rating (A) able size (mm2)

5 3.7 3TW 4200-0A*75 8-12.5 25 19 SWG 1.5

7.5 5.5 3TW 4200-0A*77 10-16 32 18 SWG 2.5

* Enter code for coil voltage (Table B)# While selecting pl. ensure that rated AC3 current rating ( 20 A ) of the starter is

not exceeded.

Spares List

Sr.Description Order No.No.

1 Contactor 3TW0 290-0A * 51(Refer Table B for*)

2 Birelay 3UW50 02 - **(Refer Table C for **)

3 Main contact kit (Each set comprises of 3TX0 200-0YA06 Fixed Contacts and 3 Moving Contacts)

4 Contact Kit - Single Pole (Each set 3TX0 200-0YA1comprises of 2 fixed contacts and1 moving contact.)

5 Coil 3TX 203-0Y*6(Refer Table B for *)

6 Cover (Arc chamber) 3TX0 202-0YA0

7 Aux. fixed contact 3TX0 200-1YB0

8 Aux. moving contact 3TX0 200-1YC0

Table B

Voltage Code

200-400 V B

130-230V P

415 V W

220 V M

Table C

Relay Range Code for

6.3 - 10 1J

8 - 12.5 1K

10 - 16 2A

12.5 - 20 2B

12

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Wiring Diagrams:

Raja Direct-On-Line Starter(For Single Phase Motors)

3TW42 00-0A

* Connect 3/L2 to 2/T1 by cable of suitable size. (max 4 mm2)* Diagram shows connections made for contactor coils rated

at 130-230V, 50Hz and 220V, 50Hz.

S01 - Remote OFF Push ButtonS11 - Remote ON Push ButtonS4 - Reset knob (Blue)Q1 - ContactorK1 - Bimetal Relay with SPP featureR - Remote Reset Push Button

Accessories List

Sr.No. Description Order No.

1. Complete Push-button Unit 3SB1202-0AE01Green normal actuator + 1NO contact block

2. Complete Push-button Unit 3SB1203-0AC01Red normal actuator + 1NC contact block

3. Reset Cord with holder400 mm length 3UX1015600 mm length 3UX1016

4. Resetting plunger & funnel arrangementPlunger 3UX1011Funnel 3UX1013

5. Inscription PlatesSTART 2SY2 507-2ASTOP 2SY2 508-2B

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RAJA Direct-On-Line Starter(for Three Phase Motors)

3TW42 00-0A

S01 - Remote OFF Push ButtonS11 - Remote ON Push ButtonS4 - Reset Knob (Blue)Q1 - ContactorK1 - Bimetal RelayR - Remote Reset Push Button

* Diagram shows connections made for contactor coils rated 200V-400V(wide-band), 415V(320-455V), 50Hz.

* For coils rated 130-230V, 50Hz and 220V, 50Hz disconnect the wire betweenL3-S01 and connect the neutral of the supply system to the terminal of S01.

17

Table D

MotorRating

HP kW

0.33 0.25 – – 3.8

0.5 0.37 1.4 – 6

0.75 0.55 1.7 – 7

1 0.75 2.2 – 7

1.5 1.1 2.9 3.25 13

2 1.5 3.8 4.5 18

3 2.2 5.1 6.5 –

5 3.7 8.1 10 –

7.5 5.5 11.4 14.5 –

10 7.5 15.4 19.5 –

12.5 9.3 19.5 25 –

15 11 23 29 –

20 15 32 39 –

25 18.5 38.5 – –

Note : The above table gives the max. full load current for various motors commonlyused. It is recommended that the above table be referred to in conjunction withmotor name plate data, before selecting the starter with appropriate relay range.

Max. Full Load Current (Amp)

3 Ph, 415V, 4PSquirrel CageIS 8789 : 1996

Table 4

3 Ph, 415V, 2PSubmersible

MotorIS 9283 : 1995

Table 2

1 Ph, 240VCSIR or Split-

PhaseIS 996 : 1979

Table 9

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NotesNotes

18 19

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Electrician registration form

I have installed starter Type No : /

at village district

State

Motor HP Type of Motor

Brand

Please register my name for the future updates about your MotorStarter range

My Name :

Shop’s Name :

Address :

Pin

STD Code : Tel : Fax :

Date of Purchase :

Date of Installation :

Name & address of Siemens Authorised dealeror Siemens Starter House

Name & address of Sub-dealer��

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Spares List

Sr. No. Description Order No.

1 Contactor 3TW0 290-0A * 51(Refer Table B for*)

2 Birelay 3UW50 02 - **(Refer Table C for **)

3 Main contact kit (Each set comprises of 3TX0 200-0YA06 Fixed Contacts and 3 Moving Contacts)

4 Contact Kit - Single Pole 3TX0 200-0YA1

5 Coil 3TX 203-0Y*6(Refer Table B for *)

6 Cover (Arc chamber) 3TX0 202-0YA0

7 Aux. fixed contact 3TX0 200-1YB0

8 Aux. moving contact 3TX0 200-1YC0

9 ‘ON’ SPA 3TX0 204-1YA0

10 ‘OFF’ SPA 3TX0 204-1YB0

11 'Reset' SPA 3TX0 204 - 1YR0

12 Contact Holder 3TX0 200-0YD0

13 'ON/OFF' contact Element 3SX1 551 - 1YA

14 Switch for HSD starter 3LA0 204 - 4YB

Table C

Relay Range Code for

0.63 - 1 0J1 - 1.6 1A1.6 - 2.5 1C2 - 3.2 1D3.2 - 5 1F4 - 6.3 1G6.3 - 10 1J8 - 12.5 1K

10 - 16 2A12.5 - 20 2B

16

Table B

Voltage Code

200-400 V B

130-230V P

415 V W

220 V M

Fig. 11(A) Replacement of moving contacts Fig. 11(B) Replacement of fixed contacts

Fig. 12 Replacement of Coil1 : Bottom Cover2 : Liner for shock absorption3 : Fixed Magnet4 : Bracket Assembly5 : Return Spring

6 : Return Spring7 : Coil8 : Contactor housing along with moving magnet9 : Aux. Contact10 : Coil terminals

9

Nose plier

10

5

4

2

1

3

6

7

89

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RAJA Direct-On-Line Starter (for Single Phase connection)

3TW42 90-1A

• Wiring Diagram for Single-Phase Motors

Note :Connect 3/L2 to 2/T1 by cable of suitable size. (max 4 mm2)

18

Fig. 9 Contactor - Birelay Connection1. Hook for relay engagement2. Relay mounting bracket3. Contactor ribs flush with relay edge.

– Refixing

i. Select the overload relayof proper range byreferring to table A andSpares list. Ensure it'sblue knob in ‘Auto reset’position marked with ‘A’.

ii. Connect the relayterminals (L1 L2 L3) tothe contactor terminals(T1 T2 T3).

iii. Ensure that the relayhook (fig. 9-1) is engagedin the slot of the bracket(fig. 9-2) welded to thehousing and slide therelay inwards till thecover is flush withcontactor ribs. (fig. 9.3)

iv. Tighten the contactorterminal screws.

v. Reconnect thedisconnected relay wiresand check thecorrectness of the starterwiring as shown on theinside of the front cover.

� Replacement of maincontacts: (fig. 11)

– Remove the Arc Chamber.

7

3

1

2

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Dimensional Drawings:

RAJA Direct-On-Line Starter

20

Fig. 5 Setting the relay dial

Operation� ON/OFF Operation

– Switch ‘ON’ the starter bypressing the green pushbutton (marked ‘I’)(Fig. 6-1) on the starter cover.

– Switch ‘OFF’ the starter bypressing the red push button(marked ‘O’) (fig. 6-2) on thestarter cover.

� Reset Operation

– If the overload relay trips,it resets automatically.(*Allow a reset time ofapprox. 4 min.)

� It is recommended that theDOL Starter (Self reset type)is not to be used inapplications involvingmaintained 'ON' command.In such applications handreset type of starter isrecommended.

iv. Pull the overload relayaway from contactor andin outward direction.

Fig. 6 Starter in closed position1. ‘ON’ push button (Green)2. ‘OFF’ Push button (Red)3. Cover fixing screws4. Housing5. Cover6. Name Plate

5

4

1

2

3

3

5

6

* Mounting diamensions 154 x 70 Kanch

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Fig. 3 A.B. Connection of outgoing and incoming cable, using cable gland.

outgoing cable connections. (fig.2)

� Connect incoming andoutgoing cables as follows :(fig. 3)

– Select correct size of cablefrom Table-A. (max. cable sizeallowed is 4 mm2)

– Remove approx. 10 mm ofinsulation.

– Pass the cable throughproper cable gland to avoidingress of material.

– Connect the cables andtighten the screws firmly.

3

(Terminal Screws : M4,Stripped Length : 10 mm)

� Set the overload relay scale(fig. 4A-4) using properscrew driver as per theprocedure given below :(fig. 5)

– Set the relay to rated currentmentioned on motor nameplate.

– Press green button of thecontactor (fig. 4B-7) to startthe motor and wait till itreaches to normal speed.Reduce the relay setting till ittrips.

Incoming Cable gland

Table D

Motor Rating

HP kW

0.33 0.25 – – 3.8

0.5 0.37 1.4 – 6

0.75 0.55 1.7 – 7

1 0.75 2.2 – 7

1.5 1.1 2.9 3.25 13

2 1.5 3.8 4.5 18

3 2.2 5.1 6.5 –

5 3.7 8.1 10 –

7.5 5.5 11.4 14.5 –

10 7.5 15.4 19.5 –

12.5 9.3 19.5 25 –

15 11 23 29 –

20 15 32 39 –

25 18.5 38.5 – –

Max. Full Load Current (Amp)

3 Ph, 415V, 4PSquirrel CageIS 8789 : 1996

Table 4

3 Ph, 415V, 2PSubmersible Motor

IS 9283 : 1995Table 2

1 Ph, 240VCSIR or Split-Phase

IS 996 : 1979Table 9

Note : The above table gives the max. full load current for various motorscommonly used. It is recommended that the above table be referred to inconjunction with motor name plate data, before selecting the starter withappropriate relay range.

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Sie

men

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(Sta

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0601

.

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Aff

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Electrician registration form

I have installed starter Type No : 3TW4290-1A /

3LW4290-0A

at village district

State

Motor HP Type of Motor

Brand

Please register my name for the future updates about your MotorStarter range

My Name :

Shop’s Name :

Address :

Pin

STD Code : Tel : Fax :

Date of Purchase :

Date of Installation :

Name & address of Siemens Authorised dealeror Siemens Starter House

Name & address of Sub-dealerKanch

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RAJA Direct-On-Line Starter

Auto / Hand

Reset

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