TE Connectivity AMP Connectors 1546097-3 Equivalent & Substitute Parts

Part Overview

The TE Connectivity AMP Connectors 1546097-3 is a rectangular connector header designed for through-hole, right-angle mounting applications. This component features a 3-position configuration with 0.200" (5.08mm) pitch spacing, shrouded 4-wall design, and solder termination. The part is classified as obsolete, necessitating identification of active equivalent components to maintain design continuity and ensure ongoing component availability for production and maintenance applications.

Substiute Parts

1546097-3

TE Connectivity AMP ConnectorsIn Stock: 10811546097-3 Datasheet

Current PartRFQ

796638-3

TE Connectivity AMP ConnectorsIn Stock: 7319796638-3 Datasheet

MFR RecommendedRFQ

Key Parameters

Substitute Part Grouping Explanation

The TE Connectivity AMP Connectors 796638-3 serves as the manufacturer-recommended substitute for the obsolete 1546097-3. Substitution compatibility is established through alignment of the following critical electrical and mechanical parameters:

Matching Parameters:

• Number of Positions: 3
• Pitch - Mating: 0.200" (5.08mm)
• Mounting Type: Through Hole, Right Angle
• Shrouding: 4-side shrouded design
• Termination: Solder
• Voltage Rating: 300V
• Contact Finish: Tin
• Insulation Color: Green
• Moisture Sensitivity Level: 1 (Unlimited)
• ECCN Classification: EAR99
• HTSUS Code: 8536.69.4040

Functional Equivalence: Both components function as male pin headers with identical mating pitch and position count. The 796638-3 maintains electrical and mechanical compatibility through equivalent shrouding geometry, contact configuration, and termination methodology. The substitute part is classified as active product status with enhanced compliance certifications.

Parameter Comparison

Engineering Selection Recommendations

Primary Substitute: TE Connectivity AMP Connectors 796638-3

The 796638-3 is the manufacturer-recommended substitute for the obsolete 1546097-3. Selection of this component is supported by the following engineering criteria:

Product Status Alignment: The 796638-3 maintains active product status, ensuring long-term availability and continued manufacturing support. The obsolete status of the 1546097-3 creates supply chain risk; transition to the active 796638-3 eliminates this constraint.

Electrical Compatibility: Both components operate at identical voltage ratings (300V) and mating pitch (0.200" / 5.08mm). The 796638-3 provides enhanced current capacity (15A UL rating versus 12A), establishing superior electrical performance margins for existing applications.

Mechanical Compatibility: Identical position count (3), shrouding configuration (4-wall), and mounting methodology (through-hole, right-angle) ensure direct mechanical interchangeability. Insulation height variance (0.327" versus 0.329") and contact tail length difference (0.150" versus 0.138") fall within standard manufacturing tolerances and do not preclude substitution.

Compliance Enhancement: The 796638-3 carries ROHS3 Compliant and UL94 V-0 material flammability certifications, providing enhanced regulatory alignment compared to the main part. REACH Unaffected status of the substitute eliminates substance-of-concern documentation requirements.

Contact Material Consideration: The substitute employs copper alloy contacts versus brass in the original component. Copper alloy contact materials maintain equivalent tin-plated mating surface characteristics and provide equivalent electrical conductivity for the specified application parameters.

Insulation Material Transition: The substitute utilizes polyamide (PA66) nylon 6/6 insulation material in place of polybutylene terephthalate (PBT). Both materials provide equivalent electrical insulation properties, moisture resistance (MSL 1), and mechanical stability for the specified operating environment.

Frequently Asked Questions (FAQ)

Q: Can the 796638-3 directly replace the 1546097-3 in existing PCB designs?

A: Yes. Both components share identical mating pitch (0.200" / 5.08mm), position count (3), mounting type (through-hole, right-angle), and shrouding configuration (4-wall). PCB footprints designed for the 1546097-3 accommodate the 796638-3 without modification. Minor dimensional variations in insulation height (0.002" / 0.06mm) and contact tail length (0.012" / 0.30mm) do not affect board-level compatibility.

Q: What are the electrical performance differences between these components?

A: The 796638-3 provides enhanced current capacity at 15A (UL rating) compared to the 1546097-3 at 12A. Voltage rating remains constant at 300V. Both components maintain identical tin-plated contact finish and equivalent electrical conductivity. The substitute component supports higher current applications without derating.

Q: Are there material compatibility concerns when substituting the 796638-3?

A: Contact material composition differs (copper alloy versus brass), and insulation material differs (polyamide PA66 versus polybutylene terephthalate). Both material combinations provide equivalent electrical insulation, moisture resistance, and mechanical performance for the specified application category. Tin plating on mating surfaces ensures equivalent contact characteristics. No material incompatibility exists with standard PCB assembly processes or operating environments.

Q: What compliance advantages does the 796638-3 provide?

A: The 796638-3 carries ROHS3 Compliant certification (enhanced from RoHS Compliant), UL94 V-0 material flammability rating, and REACH Unaffected status. These certifications reduce regulatory documentation requirements and provide enhanced environmental compliance alignment for current manufacturing standards.

Q: Is the 796638-3 available in equivalent packaging configurations?

A: The 796638-3 is supplied in bulk packaging. Inventory availability is 7230 pieces in new original stock, compared to 1057 pieces for the obsolete 1546097-3. The active product status of the substitute ensures continued availability for production requirements.

Q: What is the operating temperature range for the 796638-3?

A: The 796638-3 operates across -40°C to 110°C. Operating temperature specification is not provided for the 1546097-3. The substitute component's specified temperature range covers standard industrial and commercial application environments.

Q: Are there any mechanical dimension constraints when substituting these components?

A: Contact tail length differs by 0.012" (0.30mm), with the 796638-3 at 0.138" versus the 1546097-3 at 0.150". Insulation height differs by 0.002" (0.06mm). These variations fall within standard PCB design tolerances and do not require design modification for through-hole solder termination applications.