CG relay - Safety critical, 9 contacts, gold

Datasheet plated
Features

• Instantaneous relay
• Ultra compact package size
• Safety critical relay
• Plug-in design with secure locking feature
for maximum ease of maintenance
• 9 double break contacts in all N/O and
N/C combinations
• Weld no transfer safety contacts standard
• Contact life (mechanical) of 100 million
cycles
• -40°C...+80°C operating temperature

Benefits

• Proven reliable in heavy duty application

• Space Saving package size
• Long life cycle cost
• Easy to maintain and replace
• Used in safety critical application
Description • Low life cycle cost
The CG relay is an instantaneous and safety critical relay equipped with 9 double
break contacts (Form X & Y - per customers specification) in all N/O and N/C
combinations, gold plated. The plug-in design offers secure locking feature for
maximum ease of maintenance (no wires need to be disconnected or other
hardware removed for relay inspection or replacement).

The resistance to impact and vibration is conforming the standards for Railway compliancy
Railway Transported Equipment. Positive mechanical keying of relay to • NF F 62-002 Rolling stock -
socket is built into relay and socket during manufacturing and terminal Instantaneous relays contacts and sockets
identifications are clearly marked on identification plate that is permanently • NF F 16-101/102 Fire behaviour -
attached to the relay. Railway rolling stock

The CG relays is pluggable in the COR NJ socket.

Application
The CG relay is designed to offer ultra-compact space saving size for safety
critical applications such as door control, emergency brake failure,
interlocking between traction and breaking, around the world in countless
railcars.

1
www.morssmitt.com
CG relay
Technical specifications

Functional and connection diagrams

Timing diagram Relay pin correspondence

Keying Plate 0 1 2 3 4
A
Relay pin correspondence B
(rear view of relay shown) C
D

Connection diagram

A0 A0 A0

B0 B0 B0

2 N/C - 7 N/O 4 N/C - 5 N/O 9 N/O

A1 B1 A1 B1 A1 B1
A2 B2 A2 B2 A2 B2
A3 B3 A3 B3 A3 B3
A4 B4 A4 B4 A4 B4
C0 D0 C0 D0 C0 D0
C1 D1 C1 D1 C1 D1
C2 D2 C2 D2 C2 D2
C3 D3 C3 D3 C3 D3
C4 D4 C4 D4 C4 D4

Schematic #1 Schematic #2 Schematic #3

A0 shown with A0 A0
Transil Protection
option

B0 B0 B0

5 N/C - 4 N/O 3 N/C - 6 N/O 7 N/C - 2 N/O

A1 B1 A1 B1 A1 B1
A2 B2 A2 B2 A2 B2
A3 B3 A3 B3 A3 B3
A4 B4 A4 B4 A4 B4
C0 D0 C0 D0 C0 D0
C1 D1 C1 D1 C1 D1
C2 D2 C2 D2 C2 D2
C3 D3 C3 D3 C3 D3
C4 D4 C4 D4 C4 D4

Schematic #4 Schematic #5 Schematic #6

2
www.morssmitt.com
CG relay
Technical specifications

Coil data - DC versions

Unom (VDC) Uoperating (VDC) Pnom (W) Uhold (VDC) Udrop-out (VDC) R coil (Ω) (1) L/R (ms) (2)

24 16 / 33 4.8 13.5 2.5 120 25

36 25 / 45 4.8 21 3.5 270 25
48 33 / 60 4.6 28.5 4.5 500 25
72 48 / 90 5.2 40.5 6.5 1000 25
110 77 / 138 5 60 11.5 2400 25
(1) Coil resistance tol.: ± 8% at 20 °C
(2) Valid for closed relay.

Coil data - AC versions

Unom (VAC) Uoperating (VAC) Pnom (VA) Uhold (VAC) Udrop-out (VAC) R coil (Ω) (1) L/R (ms) (2)
220 176 / 242 4 129 21 12000 25
(1) Coil resistance tol.: ± 8% at 20 °C
(2) Valid for closed relay.

Contact data – dry circuit application (gold contacts)

Contact design Stationary contact 2 single contacts (contacts are in series)
Movable contact Solid blade
Maximum contact rating Operating 20 mA max. at 72 VDC
Carry only (no make and break) 5 A max. at 5 VDC
Minimum current rating 10 mA at 12 VDC
Number of contacts 9 double make / double break contacts (form X & Y)
Contact material Stationary contact Gold plated over hard silver
Movable contact Gold over hard silver overlay laminated to copper
Contact resistance < 20 mΩ max at 5 A (Carry only)

3
www.morssmitt.com
CG relay
Technical specifications

Contact design
Weld no transfer function: Double break contacts
Extend the contact life
If one N/O contact welds, no N/C on highly inductive DC
contact can close (and vice versa) currents.
and cause an overlapping of func-
tions.
A type test is realized to insure the
relays meet this important safety
requirement.
150% of max. operating voltage is
applied to the relay while holding
1 NC contact closed by mechanical
means. A1 B1
A1 B1 C0 D0
Under these conditions, it is verified
that no N/O contact makes.

Electrical characteristics
Dielectric strength 2200 VAC, 1 min between contacts,
2600 VAC, 1 min between contacts, coil and frame
Insulation resistance ≥ 1000 MΩ at 500 VDC

4
www.morssmitt.com
CG relay
Technical specifications

Mechanical & environmental characteristics

Vibration NF F 62-002 The tests are conducted in the X, Y , Z planes at frequency between
10 & 150 cycles (sinusoidal) at 2 g
Shock NF F 62-002 Tests are applied in both directions in the X, Y & Z planes. Then
successive shocks are administered consisting of the positive component of
sinusoidal with a value of 30 g, 18 ms
Other vibration and shock tests can be performed on request
Mechanical life > 100 x 106 operations
Weight 400 g
Temperature -40 °C...+80 °C
Humidity 93% RH, 40° C for 4 days
Salt mist 5% NaCl, 35° C for 4 days
Protection IP40 (relay on socket)
Fire & smoke Materials: Polycarbonate resin (cover) / Phenalic compound (base)
Note: These materials have been tested for fire propagation and smoke emission
according to standards NF F 16-101, NF F 16-102, and have been approved to
be used on the English/French train channel shuttle.

5
www.morssmitt.com
CG relay
Technical specifications

Dimensions (mm)

45.3mm Allow clearance dimensions shown to ths

Allow clearance dimensions shown to this
(1.783") lineto
line to unplug
unplug and
andremove
removeororreplac relayrelay.
replace
ELEVATION VIEW - SHOWS RELAY PLUGGED INTO SOCKET WITH LOCKING SPRING ENGADED & ALSO

Optional green LED

90mm (3.543")
WTIH LOCKING SPRING DIS-ENGADED & RELAY UNPLUGGED FOR REMOVAL OR REPLACEMENT.

ELEVATION VIEW SHOWS RELAY PLUGGED INTO indicates coil is ernergized

SOCKET WITH LOCKING SPRING ENGAGED & ALSOwhen lit.
WITH LOCKING SPRING DIS-ENGAGED & RELAY
UNPLUGGED FOR REMOVAL OR REPLACEMENT.
145mm (5.709")

22.5mm
(.886")
32.1mm
(1.264")
255mm (10.039")
Clearance of relay

PERMANENTLY
PERMANENTLY
ATTACHED
ATTACHED I.D.I.D.
PLAPLATE
TE
WITH
WITHTERMINAL
TERMINAL
IDENTIFICATIONS
IDENTIFICATIONS
CLEARLY MARKED.
RELAY SHOWN PLUGGED INTO SOCKET

CLEARLY MARKED.
167mm ( 6. 575" )

WITH LOCKING SPRING ENGAGED

110mm (4.331")

110mm (4.330")

179mm (7.047")
Max. thickness: 4 mm (.157")

37.5mm Mounting studs have M5 thread.

(1.476") Tightening torque : 1,7 Nm ( 1.25 ft-lbs)
12.5mm 62 ±0,5mm
(.492") (2.441 ±.020")
25,5
holes ø 5,5 ± 0,1 mm
± 0,1mm
(.216 ± .004")Dia.-2 holes
31mm
(1.220")
73mm(2.874")

Mounting hole
WIRING SIDE
VIEW FROM

centers - 45mm
Mounting hole centers - 45mm (1.772'')
50 ±0,5mm (1.772")
min. min.
this plan
(1.969 ±.020") this plane
Mounting
Mountinghole
holecenters
centers - 80mm
- 80 mm (3.150")
(3.150") min. thismin
plane
this plan
Mounting hole layout

6
www.morssmitt.com
CG relay
Technical specifications

Dynamic relay selection curve - No. 1

AC Current breaking capacity versus life expectancy in millions of cycles.
Rate of contacts opening and closing = 1200 operations per hour.
AC Current breaking
Curves shown forcapacity versus
resistive (Power life
factor expectancy in millions of cycles.
= 1)
Rate of contacts opening and closing = 1200 operations per hour.
Curves shown for resistive load (Power Factor = 1).

Curve 1 2 3 4
VAC 220 125 48 24
Curves 1 2 3 4
VAC 220 125 48 24

60
50 4

40

30
3

20

10
2

1
5
Millions of Cycles

2,5

0,5

0,2

0,1
0
0,75 1 1,5 2 2,5 3 3,5 4 4,5 5 6 7,5 9
Amps

7
www.morssmitt.com
CG relay
Technical specifications
Dynamic relay selection curve - No. 2
DC Current breaking capacity versus life expectancy in millions of cycles.
Rate of contacts
DC Current breaking opening and closing
capacity versus= 1200 operations perin
life expectancy hour.
millions of cycles.
Rate Curves shownopening
of contacts for inductive
andload -
closing = 1200 operations per hour.
shown
Curves L/R
for= inductive
20 ms continuous
load: current
L/R = 40 ms continuous current
L/R= 20 ms continuous current
L/R= 40 ms continuous current

Curves 1-3 2-4 5-7 6-8

Curves 1-3 2-4 5-7 6-8
VDC 220 125 48 24
VDC 220 125 48 24

60
50
40

30
25
20

15
Millions of Cycles

10 4 6 8
5
9
8
3
7
2 7
6
1
5
4

1,5

0
0,15 0,2 0,4 0,75 1 1,5 2 3 4 4,5 6 7,5 9

Amps

8
www.morssmitt.com
CG relay
Technical specifications
Dynamic relay selection curve - No. 3
DC Current breaking capacity versus life expectancy in millions of cycles.
Rate of contacts opening and closing = 1200 operations per hour.
DC Current breaking
Curves shown capacity
for resistive versus
load (L/R = 0).life expectancy
Continuous in millions of cycles.
current.
Rate of contacts opening and closing = 1200 operations per hour.
Curves shown for resistive load (L/R = 0). Continuous current.

Curve 1Curves
2 3 1 4 2 3 4
VDC VDC
220 125 48 22024 125 48 24

60
4
50
40

30
3
25
20
2
15
1
Millions of Cycles

10
9
8
7
6
5
4

1,5

0
0,15 0,2 0,4 1 1,5 2 3 4 4,5 6 7,5 9

Amps

9
www.morssmitt.com
CG relay
Technical specifications

Dynamic relay selection curve - No. 4

Maximum contact breaking capacity versus voltage for a given L/R

Rate of contacts opening and closing = 600 operations per hour.
Curves shown for resistive load (L/R = 0) and inductive loads. Continuous current.

Maximum contact breaking capacity versus voltage for a given L/R.

Rate of contacts opening and closing = 600 operations per hour.
Curves shown for resistive load (L/R=0) and inductive loads. Continuous current.

Curves 1 2 3 4 5 6
L/R= 0 ms 15 ms 20 ms 40 ms 60 ms 100 ms
Curve 1 2 3 4 5 6
L/R= 0ms 15ms 20ms 40ms 60ms 100ms

280
270
260
250
240
230
220
210
200
190
180
170
160
150
Volts

1
140
130
2
120
3
110
100 4
90
80
70
5
60
50
40
30
6
20
10
0
0,75 1,5 2,25 3 3,75 4,5 5,25 6 6,75 7,5 8,25 9 9,75

10
www.morssmitt.com
CG relay
Technical specifications

Dynamic relay selection curve - No. 6

AC current breaking capacity versus life expectancy in millions of cycles.

AC of
Rate Current
contactsbreaking capacity
opening and closing =versus life expectancy
1200 operations per hour.in millions of cycles.
Rate of contacts opening and
Values shown for inductive loads: closing = 1200 operations per hour.
Values shown for inductive loads:
Cos Øcapacity
AC Current breaking = 0.7 versus life expectancy in millions of cycles.
Cos Ø
Rate of contacts opening= 0.5 Curves
and closing = 1200 operations 1,3 &4 2,5 &7
per hour. 6,9 &10 8,11 &12
Cos Ø = 0.3
Values shown for inductive loads: VAC 220 125 48 24
Cos Ø = 0.7
Cos Ø = 0.5 Curves 1,3 &4 2,5 &7 6,9 &10 8,11 &12
Cos ØCurves
= 0.3 1,3 & 5 2 , 4 & 6VAC6, 9 & 10
220
8, 11
125
& 12 48 24
60
VAC
50
220 125 48 24
12
40

60 30
50 12 11
40 20
10
30
9
11
20 10
10
8
9
7
10 5
6
Millions of Cycles

8
5
7 4
5 2,5
6
Millions of Cycles

5
3
4
2,5
1
2
3

1 0,5
2
1

0,5
0,2 1

0,2 0,1
0
0,75 1 2 2,5 2,5 3 3,5 4 4,5 5 6 7,5 9

0,1
Amps
0
0,75 1 2 2,5 2,5 3 3,5 4 4,5 5 6 7,5 9

Amps

11
www.morssmitt.com
CG relay
Mounting possibilities

COR NJ

Mounting possibilities/sockets
Panel mounting
153879 COR NJ X* Socket (alkyde compound) with locking spring

* X indicates keying code from relay table

12
www.morssmitt.com
CG relay
Keying

Mechanical keying of relay & socket

Mechanical keying of the relay to the socket is accomplished in the factory.

Keying slots are located by their keying code numbers on the relay board. Keying rivets are located
in the steel socket frame in the correct (and corresponding) coded rivet holes to mate with the relay.

Once keying has been completed during manufacturing, it is permanent and cannot be changed.
This is intentional in the design to insure that only the correct relay can be plugged into the socket.

They keying is completed by a colorcode on the top of the relaycover and on the side of the socket
for better identification on the train.

They keying details are illustrated below.

I.D. Plate
I.D. Plate Relay shown in position
just prior to relay terminals

Keying board
(securely riveted
to relay) Relay
terminals
Factory
machined
key slots
47
69
Coded rivet
holes

47
69 Welded steel Socket
socket frame
Factory installed
keying rivets

Permanently marked keying code

on both relay and socket

13
www.morssmitt.com
CG relay
User specifications
Installation
Install socket and connect wiring correctly according identification to terminals. Plug relay into socket. Reverse
installation into socket not possible due to mechanical blocking by snap-lock.
Don’t reverse polarity of coil connection.
Relays can be mounted (tightly) next to each other and in any attitude. However, we recommend the folowing:
- If the relay is mounted vertical; the direction of contact closure should be oriented transverse to the direction
of forward motion.
- If the relay is mounted horizontal; the direction of contact closure should be oriented so that gravity will cause
the contacts to revert to their de-energised position.
Warning! Never use silicon spray near by relays

Operation
Before operating always apply voltage to coil to check correct operation.
Long term storage may corrode the silver on the relay pins. Just by plugging the relay into the socket, the female
bifurcated receivers will automatically clean the corrosion on the pins and guarantee a good connection.
Do not use the relay in places with flammable gas as the arc generated from switching could ignite gasses.

Maintenance
Correct operation of relay can easily be checked as transparent cover gives good visibility on the moving
contacts. When the relay doesn’t seem to operate correct, please check presence of coil voltage. Use a multimeter.
If LED is used, coil presence should be indicated. If coil voltage is present, but the relay doesn’t work, a short
circuit of suppression diode is possible (The coil connection was reversed). If relay doesn’t work after inspection,
please replace relay unit by a similar model. Send defective relay back to manufacturer. Normal wear and tear
excluded.

14
www.morssmitt.com
CG relay
Ordering scheme

CG 027 24 47 S V
1. Relay model 2. Basic part number 3. Coil 5. LED
OVP indicator

This example represents a CG 027 24 47 S V

Description: CG relay, contact configuration: 2 N/C + 7 N/O, Unom 24 VDC, keying 47, transil coil
protection, LED indicator

1. Relay model 2. Relay basic part number*

027 24 47 2 N/C + 7 N/O 24 VDC Sch. #1

CG 027 36 16 2 N/C + 7 N/O 36 VDC Sch. #1

027 48 89 2 N/C + 7 N/O 48 VDC Sch. #1
027 72 11B 2 N/C + 7 N/O 72 VDC Sch. #1
027 110 4F 2 N/C + 7 N/O 110 VDC Sch. #1
3. Coil overvoltage protection 027 220 1011 2 N/C + 7 N/O 220 VAC Sch. #1

– No coil protection 045 24 45 4 N/C + 5 N/O 24 VDC Sch. #2

S Transil coil protection 045 36 35 4 N/C + 5 N/O 36 VDC Sch. #2
P Avalanche diode coil protection 045 48 19 4 N/C + 5 N/O 48 VDC Sch. #2
045 72 69 4 N/C + 5 N/O 72 VDC Sch. #2

4. LED voltage indicator 045 110 38 4 N/C + 5 N/O 110 VDC Sch. #2
045 220 4C 4 N/C + 5 N/O 220 VAC Sch. #2
– No LED
009 24 3D 0 N/C + 9 N/O 24 VAC Sch. #3
V LED voltage indicator
009 36 46 0 N/C + 9 N/O 36 VDC Sch. #3
009 48 6C 0 N/C + 9 N/O 48 VDC Sch. #3
009 72 15 0 N/C + 9 N/O 72 VDC Sch. #3
009 110 1J 0 N/C + 9 N/O 110 VDC Sch. #3
009 220 5C 0 N/C + 9 N/O 220 VAC Sch. #3

054 24 49 5 N/C + 4 N/O 24 VDC Sch. #4

054 36 48 5 N/C + 4 N/O 36 VDC Sch. #4
054 48 711 5 N/C + 4 N/O 48 VDC Sch. #4
054 72 8D 5 N/C + 4 N/O 72 VDC Sch. #4
054 110 14 5 N/C + 4 N/O 110 VDC Sch. #4
054 220 611 5 N/C + 4 N/O 220 VAC Sch. #4

036 24 811 3 N/C + 6 N/O 24 VDC Sch. #5

036 48 410 3 N/C + 6 N/O 48 VDC Sch. #5
* Description
036 72 2E 3 N/C + 6 N/O 72 VDC Sch. #5
0 2 7 2 4 4 7
036 220 4E 3 N/C + 6 N/O 220 VAC Sch. #5
Keying code
Nominal voltage 072 24 68 7 N/C + 2 N/O 24 VDC Sch. #6
Number of N/O contacts 072 36 511 7 N/C + 2 N/O 36 VDC Sch. #6
Number of N/C contacts
072 72 1F 7 N/C + 2 N/O 72 VDC Sch. #6
Number of C/O contacts
072 110 7F 7 N/C + 2 N/O 110 VDC Sch. #6

15
www.morssmitt.com
 Mors Smitt France SAS
DS-CG relay V2.1 July 2016

Tour Rosny 2, Avenue du Général de Gaulle,

F - 93118 Rosny-sous-Bois Cedex, FRANCE
T +33 (0)1 4812 1440, F +33 (0)1 4855 9001
E sales.msf@wabtec.com

Mors Smitt Asia Ltd.

29/F., Fun Towers, 35 Hung To Road
Kwun Tong, Kowloon, HONG KONG SAR
T +852 2343 5555, F +852 2343 6555
E sales.msa@wabtec.com

Mors Smitt B.V.

Vrieslantlaan 6, 3526 AA Utrecht,
NETHERLANDS
T +31 (0)30 288 1311, F +31 (0)30 289 8816
E sales.msbv@wabtec.com

Mors Smitt Technologies Inc.

1010 Johnson Drive,
Buffalo Grove, IL 60089-6918, USA
T +1 847 777 6497, F +1 847 520 2222
E salesmst@wabtec.com

Mors Smitt UK Ltd.

Graycar Business Park, Barton under Needwood,
Burton on Trent, Staffordshire, DE13 8EN, UK
T +44 (0)1283 722650 F +44 (0)1283 722651
E sales.msuk@wabtec.com

RMS Mors Smitt

6 Anzed Court, Mulgrave,
VIC 3170, AUSTRALIA
T +61 (0)3 8544 1200 F +61 (0)3 8544 1201
E sales.rms@wabtec.com

www.morssmitt.com
(c) Copyright 2016
All rights reserved. Nothing from this edition may be multiplied, or made public in any form or manner, either electronically, mechanically, by photocopying, recording, or in any manner, without prior
written consent from Mors Smitt. This also applies to accompanying drawings and diagrams. Due to a policy of continuous development Mors Smitt reserves the right to alter the equipment specification
and description outlined in this datasheet without prior notice and no part of this publication shall be deemed to be part of any contract for the equipment unless specifically referred to as an inclusion
within such contract. Mors Smitt does not warrant that any of the information contained herein is complete, accurate, free from potential errors, or fit for any particular purpose. Mors Smitt does not
accept any responsibility arising from any party’s use of the information in this document.