SERVICE MANUAL 2378J

DP-25 POLARIZED RELAY

Without Magnetic Blowout Contacts
For Low Voltage Switch Movement Control

THIS MANUAL IS NOW OBSOLETE

Rev. 12-9-47
ID0148F-0051F
PRINTED IN USA

DP-25 POLARIZED RELAYS WITHOUT MAGNETIC BLOWOUT CONTACTS

FOR LOW VOLTAGE SWITCH MOVEMENT CONTROL
These relays can also be used for control of 110 volt
movements. THIS RELAY IS NOW OBSOLETE

25 or

60 cycle AC

For DP-25 Relays with Magnetic Blowout contacts, see Service Manual 2378-K.
**********

This service specification covers the adjustment and calibration of

Polarized Relays for Low Voltage switch Movement Control.

DP-25

These relays have been furnished in two designs: the original design and an
improved efficiency design. The improved efficiency design can be identified
by the backstrap, which is held by a clamp attached to the permanent magnet
rather than by two bolts screwed directly into the neutral cores as on the
original design, and also by the short (DN-11 type) contact fingers instead of
the long (DP-14 type) contact fingers that were used on the original design.
All of the information given in Service Manual 2378 for standard DP-14 relays
applies to these relays with the following exceptions:
1.
-

PERMANENT MAGNET AND YOKE

Per Service Manual 2378, Section 2, except that the DP-14 relay charging
outfit is not applicable to the DP-25 relay, a special charger as shown by
Figure 1 being used instead.
BACKSTRAP SHOULD BE DRAWN AGAINST
MAGNET & CHARGER CORE

PERMANENT MAGNET &

CORE ASSEMBLED TO
TOP PLATE

CHARGING COIL
NO GAP HERE

......
:

._ __ _

...

Figure 1
NOTE:

The backstrap end of permanent magnet shall attract the pole

of a magnetic compass which points toward Geographic North.

2378-J, p.

2.

NEUTRAL ARMATURE HOLD-DOWN SPRINGS

The supports for the hold-down springs should be in approximate alignment
with the guide holes in the top plate so that the springs are entirely
free from the sides of the guide holes in all positions of the armature.
The springs must be seated squarely on the supports. The adjustment of
the hold-down springs may be changed as necessary to meet the calibration
requirements, provided the pressure does not go below a minimum value to
be checked as follows.
With the relay inverted, a pressure or weight specified below
applied to the armature at a point in line with the safety stop
pin should not move the armature enough to open the back contacts.

Force or weight,
to check hold-down

Original Design

Improved Design

7.1 ounces (202 grams)

8.1 ounces (231 grams)

Both adjusting screws should be set approximately the same. After adjustments have been completed, the lock nuts should be securely tightened.
3.

POLAR ARMATURE
Per Service Specification 2378, Section 4, except air gap to be 0.019 inch.

4.

CONTACT ADJUSTMENT
Per Service Specification 2378, Section 5 and 6, except the following:
A.

Front contact Adjustment

The low voltage
tabulated below.

front

contacts

should

be

adjusted

with

spacers

The spacers used for front contact adjustment may be changed as

necessary to get calibration values, except that spacers smaller than
the minimum specified should not be used.

Nominal Spacer
Minimum Spacer

Original Design

Improved Design

0.019 Inch
0.017 Inch

0.021 Inch
0.018 Inch

The high voltage front contacts should be adjusted to make 0.027 inch
before the low voltage front contacts.
This adjustment should be
made with a spacer . 0.008 inch thicker than that used for adjusting
the low voltage contacts of the original design and 0.011 inch
thicker than that used for adjusting the low voltage contacts of the
improved design.

2378-J, p. 2

For example, when an 0.019 inch spacer is used for the low voltage
contacts of the original design, an 0.027 inch spacer should be used
for the high voltage contacts.
The high voltage front contacts should be in line when adjusted and
tightened and should extend beyond the carbon on the contact spring
at least 1/64 inch on each side with the armature end play taken up
on the inspected side. With the relay energized, the carbon on the
contact spring should be approximately centered on the front contact
carbon.
B.

Back Contacts
Back contacts should be adjusted to give an O.030 inch maximum back
contact opening when the high voltage front contacts of the original
design are just made.
On the improved design, the back contacts should be adjusted to give
an 0.050 inch minimum back contact opening with the armature in the
fully deenergized position.
With the relay deenergized, the armature back stop screw should be
tightened against the armature to give a back contact compression of
0.040 inch.
This adjustment can be obtained by inserting an 0.012
inch spacer for original design relays and an 0.020 inch spacer for
improved design relays between the bottom edge of the armature and
the armature back stop screw and tightening the back stop screw until
the back contacts just touch.

In no case should the high voltage contact opening be less than 0.060
inch.
5.

POLAR ARMATURE HOLDING TORQUE

Per Service Specification 2378, Section 12, except the polar armature
should require a force of more than 200 grams to force it away from the
pole face of the last energized position.

2378-J, p. 3

Iv

-.I
CD

..c..

Table 1.

'O

Calibration Values for DP-25 Polarized (Original Design) Relays

For Low Voltage Switch Movement control

No Extra Contacts (2 L.V. & 2 H.V. Neutral and 4N-4R Polar Contacts)

RELAY
RESIS.

CHARGE
(4X DPU)

MINIMUM
DIRECT
PICK-UP

MINIMUM
RELEASE

MAXIMUM
DIRECT
PICK-UP

IN OHMS

Amps.

Volts

Amps.

Volts

Amps.

Volts

110

.138

15.2

.020

2.2

.0303

3.33

1000

.048

48.0

.007

7.0

.0105

Table 2.

10.5

Amps.
.036
.0125

MAXIMUM
POLAR ARM.
REVERSAL

Volts

Amps.

Volts

3.96

0212
.0074

12.5

REV. NEUTRAL
ARM. TO STOP
Amps.

Volts

2.32

.050

5.5

7.4

.0175

17.5

Calibration Values for DP-25 Polarized (Original Design) Relays

For Low Voltage Switch Movement Control

2 Extra Contacts (4 L.V. & 2 H.V. Neutral and 4N-4R Polar Contacts)

RELAY
RESIS.
IN OHMS

CHARGE
(4X DPU)
Amps.

MAXIMUM
DIRECT
PICK-UP

MINIMUM
DIRECT
PICK-UP

MINIMUM
RELEASE

MAXIMUM
POLAR ARM.
REVERSAL

REV. NEUTRAL
ARM. TO STOP

Volts

Amps.

Volts

Amps.

Volts

Amps.

Volts

Amps.

Volts

Amps.

Volts

44

.217

9.56

.0333

1.47

.0478

2.10

.0567

2.49

.0333

1.47

.1244

5.47

70

.183

12.81

.0269

1.88

0385

2.70

.0458

3.21

.0269

1.88

.1005

7.04

110

.138

15.2

.0212

2.32

.0303

3.33

.036

3.96

.0212

2.32

.079

8.69

Table 3.

Calibration Values for DP-25 Polarized (Improved Design) Relays

For Low Voltage Switch Movement control

No Extra contacts (2 L.V. & 2 H.V. Neutral and 4N-4R Polar contacts)

RELAY
RESIS.

CHARGE
(4X DPU)

MINIMUM
DIRECT
PICK-UP

MINIMUM
RELEASE

MAXIMUM
DIRECT
PICK-UP

MAXIMUM
POLAR ARM.
REVERSAL

REV. NEUTRAL
ARM. TO STOP

IN OHMS

Amps.

Volts

Amps.

Volts

Amps.

Volts

Amps.

Volts

Amps.

Volts

Amps

Volts

110
280
450
700
1000

138
.086
.068
.057
. 048

15.2
24.1
30.6
40.0
48.0

.0188
.0117
.0092
.0078
.0065

2.07
3.28
4.14
5.46
6.5

.0303
.0189
.0149
.0125
0105

3.33
5.29
6. 71
8.75
10.5

.0345
0215
.017
.0143
.012

3.80
6.02
7.65
10.0
12.0

.0212
.0132
.0105
.0088
.0074

2.33
3.70
4.73
6.16
7.4

.0345
.0215
.017
.0143
.012

3.80
6.02
7.65
10.0
12.0

Table 4.

Calibration Values for DP-25 Polarized (Improved Design) Relays

For Low Voltage Switch Movement Control

2 Extra Contacts (4 L.V. & 2 H.V. Neutral and 4N-4R Polar Contacts)

RELAY
RESIS.
IN OHMS

-.I
CD

..c...
.
'd

,
V1

0\

110
280
450
700
1000

MAXIMUM
MINIMUM
MAXIMUM
REV. NEUTRAL
CHARGE
MINIMUM DIRECT
DIRECT
POLAR ARM.
REVERSAL
(4X DPU)
RELEASE
PICK-UP
PICK-UP
Amps.
.138
.086
.068
.057
.048

Volts
15.2
24.1
30.6
40.0
48.0

Amps.
.0197
.0123
.0097
.0081
.0068

Volts
2.17
3.44
4.37
5.67
6.8

Amps.
.0303
.0189
.0149
.0125
.0105

Volts
3.33
5.29
6.71
8.75
10.5

Amps.
.0345
.0215
.017
.0143
.012

Volts
3.80
6.02
7.65
10 .o
12.0

Amps.
.0212
.0132
.0105
.0088
.0074

ARM. TO STOP
Volts
2.33
3.70
4.73
6.16
7.4

Amps.
.0345
.0215
.017
.0143
.012

volts
3.80
6.02
7 . 65
10.0
12.0