TE Connectivity 1-1546209-1 Terminal Block Header Equivalent & Substitute Parts

Part Overview

The TE Connectivity 1-1546209-1 is an 11-position terminal block header with male pins, shrouded on four sides, featuring 0.197" (5.00mm) pitch and 90° right-angle orientation for through-hole solder mounting. This component is classified as obsolete, necessitating identification of active equivalent and substitute parts that maintain electrical and mechanical compatibility for new designs and production continuity.

Key Parameters

Parameter	Value
Number of Positions	11
Pitch	0.197" (5.00mm)
Header Orientation	90°, Right Angle
Mounting Type	Through Hole / Solder
Voltage - UL	300 V
Current - UL	15 A
Operating Temperature	-40°C ~ 110°C
Material Flammability Rating	UL94 V-0
Contact Tail Length	0.138" (3.50mm)
Insulation Height	0.329" (8.36mm)
Moisture Sensitivity Level	1 (Unlimited)

Substitute Part Grouping Explanation

Substitution eligibility for the TE Connectivity 1-1546209-1 is determined by the following critical parameters:

Primary Compatibility Criteria:

11 positions with 0.197" (5.00mm) pitch spacing
90° right-angle header orientation
Through-hole solder mounting capability
300 V UL voltage rating minimum
15 A UL current rating minimum
Operating temperature range encompassing -40°C to 110°C
UL94 V-0 flammability rating

Secondary Compatibility Considerations:

Contact tail length of 0.138" (3.50mm)
Insulation height within acceptable tolerance range
Shrouding configuration (4-side or 2-side acceptable)
Housing material composition (Polyamide, Nylon, or Polybutylene Terephthalate)

Substitute parts meeting all primary criteria are electrically and mechanically interchangeable. Variations in housing color, contact material composition, and specific housing polymer formulation do not affect functional compatibility when all primary parameters align.

Parameter Comparison

Parameter	1-1546209-1 (Main)	1-796644-1	1-796645-1	1757556	EDSTL950/11	ELFH11110	ELFH11120	ELFH11130	ELFH11140
Manufacturer	TE Connectivity	TE Connectivity	TE Connectivity	Phoenix Contact	On Shore Technology	Amphenol PCD	Amphenol PCD	Amphenol PCD	Amphenol PCD
Number of Positions	11	11	11	11	11	11	11	11	11
Pitch	0.197" (5.00mm)	0.197" (5.00mm)	0.197" (5.00mm)	0.197" (5.00mm)	0.197" (5.00mm)	0.197" (5.00mm)	0.197" (5.00mm)	0.197" (5.00mm)	0.197" (5.00mm)
Header Orientation	90°, Right Angle	90°, Right Angle	90°, Right Angle	90°, Right Angle	90°, Right Angle	90°, Right Angle	90°, Right Angle	90°, Right Angle	90°, Right Angle
Mounting Type	Through Hole	Through Hole	Through Hole	Through Hole	Solder	Through Hole	Through Hole	Through Hole	Through Hole
Voltage - UL	300 V	300 V	300 V	300 V	300 V	300 V	300 V	300 V	300 V
Current - UL	15 A	15 A	15 A	15 A	—	15 A	15 A	15 A	15 A
Operating Temperature	-40°C ~ 110°C	-40°C ~ 110°C	-40°C ~ 110°C	—	-30°C ~ 105°C	-40°C ~ 105°C	-40°C ~ 105°C	-40°C ~ 105°C	-40°C ~ 105°C
Material Flammability Rating	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	—	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0
Contact Tail Length	0.138" (3.50mm)	0.138" (3.50mm)	0.138" (3.50mm)	0.138" (3.50mm)	0.138" (3.50mm)	—	0.155" (3.94mm)	—	0.155" (3.94mm)
Insulation Height	0.329" (8.36mm)	0.329" (8.36mm)	0.329" (8.36mm)	0.339" (8.61mm)	0.138" (3.50mm)	0.319" (8.10mm)	0.319" (8.10mm)	0.319" (8.10mm)	0.319" (8.10mm)
Moisture Sensitivity Level	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)
Product Status	Obsolete	Active	Active	Active	Active	Active	Active	Active	Active
RoHS Status	Not applicable	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	RoHS Compliant	RoHS Compliant	RoHS Compliant	RoHS Compliant

Engineering Selection Recommendations

Tier 1 - Direct Substitutes (Highest Compatibility):

The TE Connectivity parts 1-796644-1 and 1-796645-1 provide direct substitution with identical electrical specifications, matching pitch, orientation, voltage, current, and operating temperature range. Both are active products with ROHS3 compliance. Selection between these two is determined by housing color requirement (green for 1-796644-1, black for 1-796645-1).

Tier 2 - Functional Equivalents (Full Electrical Compatibility):

The Amphenol PCD ELFH series parts (ELFH11110, ELFH11120, ELFH11130, ELFH11140) maintain all critical electrical parameters and mechanical pitch specifications. These components are active products with RoHS compliance. Operating temperature range is -40°C to 105°C, which covers the primary operating window of the original part. Selection within this series depends on shrouding configuration requirement (4-side for ELFH11110 and ELFH11130; 2-side for ELFH11120 and ELFH11140) and contact tail length specifications.

Tier 3 - Conditional Substitutes:

Phoenix Contact 1757556 meets all primary electrical and mechanical criteria with active product status and ROHS3 compliance. Operating temperature specification is not provided in available documentation.

On Shore Technology EDSTL950/11 maintains pitch, position count, and voltage specifications with active product status and ROHS3 compliance. Insulation height of 0.138" (3.50mm) differs significantly from the main part specification of 0.329" (8.36mm), requiring mechanical fit verification in the target application. Current rating specification is not provided.

Compliance Considerations:

All substitute parts listed carry RoHS compliance certifications (ROHS3 or RoHS Compliant), addressing regulatory requirements for new production. The original 1-1546209-1 carries "Not applicable" RoHS status due to obsolete classification.

Frequently Asked Questions (FAQ)

Q: Can I use 1-796644-1 or 1-796645-1 as direct replacements for the obsolete 1-1546209-1?

A: Yes. Both TE Connectivity parts 1-796644-1 and 1-796645-1 are direct electrical and mechanical substitutes. They maintain identical pitch (0.197" / 5.00mm), position count (11), voltage rating (300 V UL), current rating (15 A UL), and operating temperature range (-40°C to 110°C). The primary difference is housing color: 1-796644-1 is green and 1-796645-1 is black. Both are active products with current availability.

Q: What is the difference between the Amphenol ELFH series parts?

A: The ELFH series parts differ in shrouding configuration and contact tail length. ELFH11110 and ELFH11130 feature 4-side shrouding, while ELFH11120 and ELFH11140 feature 2-side shrouding. Contact tail lengths vary: ELFH11110 and ELFH11130 do not specify tail length, while ELFH11120 and ELFH11140 specify 0.155" (3.94mm). All maintain the required 11-position, 5.00mm pitch configuration and 300 V / 15 A electrical ratings.

Q: Are there any temperature limitations when substituting with Amphenol ELFH parts?

A: The Amphenol ELFH series operates from -40°C to 105°C, compared to the original part's -40°C to 110°C range. The upper temperature limit is 5°C lower. For applications operating continuously above 105°C, this difference must be evaluated against specific thermal requirements.

Q: What is the significance of the insulation height variation in the EDSTL950/11?

A: The EDSTL950/11 specifies an insulation height of 0.138" (3.50mm), substantially lower than the original part's 0.329" (8.36mm) and other substitutes' 0.319" to 0.339" range. This dimensional difference affects the physical profile and mounting clearance. Mechanical fit verification in the target PCB layout and enclosure is required before selection.

Q: Which substitute part offers the best compliance for new production?

A: All listed substitute parts carry current RoHS compliance certifications (ROHS3 or RoHS Compliant). The TE Connectivity 1-796644-1 and 1-796645-1 offer the most direct compliance path, as they are from the same manufacturer as the original part and maintain identical specifications. Amphenol ELFH series parts also provide full RoHS compliance with active product status.

Q: Can I mix different substitute parts in the same design?

A: Mixing substitute parts is not recommended within a single assembly. While all listed parts meet the primary electrical specifications, variations in housing material, contact composition, and physical dimensions may introduce inconsistencies in assembly processes and long-term reliability. Standardize on a single substitute part number per design.

Q: What packaging options are available for these substitutes?

A: TE Connectivity 1-796644-1 and 1-796645-1 are supplied in bulk packaging. Amphenol ELFH series parts are supplied in tray packaging. Phoenix Contact 1757556 and On Shore Technology EDSTL950/11 are supplied in bulk packaging. Packaging selection should align with production volume and handling requirements.

Q: Is the Phoenix Contact 1757556 a suitable substitute?

A: The Phoenix Contact 1757556 meets all primary electrical and mechanical criteria: 11 positions, 5.00mm pitch, 90° orientation, 300 V UL rating, 15 A UL rating, and through-hole mounting. It is an active product with ROHS3 compliance. However, operating temperature range is not specified in available documentation. Verification of thermal performance against application requirements is necessary before selection.

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