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How do I connect a contactor and overload to create a Direct On Line (DOL) Starter?

Attached is a .pdf file with pictorial diagrams (1) of how you would connect the four most common variants of a DOL starter.
They show diagrams for 240 and 415 VAC control. The most common for small DOLs is 415VAC as this requires no neutral to be fed to the starter.
Options are also given for using either a remote stop switch or for using the stop button which is integral with the overload. In the latter case the stop button is not a switch, it is a plunger type device fitted into the lid/door of the enclosure, which will physically press the overload stop.

Remote and Emergency stops(2) are shown fitted between terminals A2 and 96, though they can also be fitted between 14 and 95, or even both if multiple stops are involved.

Particular care must be taken to accurately fit the stop button when using the plunger type stop without any additional remote stop, as if for any reason the plunger does not activate the stop button on the overload, there will be no way of stopping the motor without disconnecting the supply.

(1) These drawings are functional schematics. It remains the responsibility of the installer to ensure that the requirements of local directives and legislation are met and that appropriate circuit protection is provided.
(2) Inclusion of E stops in these circuits is purely for illustrative purposes and may be acceptable in simple relatively low risk safety systems. However, depending on the risk assessment carried out on the plant it may not be appropriate, other Emergency Stop facilities may be necessary, particularly in high risk applications. Consult you safety consultant.

The circuits are based upon Tesys D range contactors and overloads. Terminal numbering is to a common standard so most other contactors can be wired similarly. However, be aware that there are contactors that use different numbering systems.

Telemecanique/Schneider "K" range contactors and overloads have additional pins on their overloads to make direct connection to terminals 14 and A2. These diagrams do not relate to such systems unless the 2 right hand pins are first removed (these pins are specially weakened for this purpose and my easily be snapped off by bending backwards with a pair of pliers). However, doing this is just making extra work. It is better to wire in accordance with the K Series diagram.
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