TE Connectivity 1546518-3 Terminal Block Header Equivalent & Substitute Parts

Part Overview

The TE Connectivity 1546518-3 is a 3-position terminal block header manufactured under the Buchanan series. This component features male pins with 2-side shrouding, 90° right-angle orientation, and 0.200" (5.08mm) pitch spacing for through-hole solder termination. The part is classified as obsolete, necessitating identification of active equivalent and substitute components that maintain functional compatibility within the same terminal block category.

Key Parameters

Parameter	Value
Manufacturer Part Number	1546518-3
Manufacturer	TE Connectivity AMP Connectors
Category	Terminal Blocks
Number of Positions	3
Pitch	0.200" (5.08mm)
Header Orientation	90°, Right Angle
Type	Header, Male Pins, Shrouded (2 Side)
Termination Style	Solder
Mounting Type	Through Hole
Housing Material	Polyamide (PA66), Nylon 6/6
Contact Material	Phosphor Bronze
Contact Mating Finish	Tin
Color	Black
Material Flammability Rating	UL94 V-0
RoHS Status	RoHS Compliant
Product Status	Obsolete

Substitute Part Grouping Explanation

Substitution of the TE Connectivity 1546518-3 is determined by the following critical parameters:

Primary Compatibility Criteria:

Number of positions: 3
Pitch spacing: 0.200" (5.08mm) or 0.197" (5.00mm)
Header orientation: 90° right angle
Termination style: Solder
Mounting type: Through hole
Shrouding configuration: 2-side or 4-side
Material flammability: UL94 V-0

Substitution Logic:

Exact pitch match (0.200" / 5.08mm) substitutes are preferred for direct mechanical and electrical compatibility. These include Molex 0395320003, Molex 0395320503, and Adam Tech EBQA-03-D.

Near-pitch substitutes (0.197" / 5.00mm) provide functional equivalence with minimal dimensional variance. These include Molex 0395220003, Molex 0395221003, Molex 0395226003, Amphenol PCD ELFH03120, Amphenol PCD ELFH03110, Amphenol PCD ELFH03130, and Amphenol PCD ELFH03140.

All substitute parts maintain 3-position configuration, through-hole solder termination, UL94 V-0 flammability rating, and RoHS compliance. Shrouding configuration (2-side vs. 4-side) and contact material (brass vs. phosphor bronze) are secondary parameters that do not prevent substitution but may affect mechanical fit and electrical performance in specific applications.

Parameter Comparison

Parameter	1546518-3 (TE)	0395320003 (Molex)	0395320503 (Molex)	EBQA-03-D (Adam Tech)	ELFH03120 (Amphenol)	0395220003 (Molex)	0395221003 (Molex)
Manufacturer	TE Connectivity	Molex	Molex	Adam Tech	Amphenol PCD	Molex	Molex
Number of Positions	3	3	3	3	3	3	3
Pitch	0.200" (5.08mm)	0.200" (5.08mm)	0.200" (5.08mm)	0.200" (5.08mm)	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
Type	Header, Male Pins, Shrouded (2 Side)	Header, Male Pins, Shrouded (2 Side)	Header, Male Pins, Shrouded (2 Side)	Header, Male Pins, Shrouded (2 Side)	Header, Male Pins, Shrouded (2 Side)	Header, Male Pins, Shrouded (2 Side)	Header, Male Pins, Shrouded (4 Side)
Termination Style	Solder	Solder	Solder	Solder	Solder	Solder	Solder
Mounting Type	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole
Contact Material	Phosphor Bronze	Brass	Brass	Brass	Brass	Brass	Brass
Contact Mating Finish	Tin	Tin	Gold	Tin	Tin	Tin	Tin
Housing Material	Polyamide (PA66), Nylon 6/6	Polyamide (PA66), Nylon 6/6	Polyamide (PA66), Nylon 6/6	Polyamide (PA66), Nylon 6/6	Polybutylene Terephthalate (PBT)	Polyamide (PA66), Nylon 6/6	Polyamide (PA66), Nylon 6/6
Color	Black	Black	Black	Green	Black	Black	Black
Material Flammability Rating	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0
Current - UL	Not Specified	15 A	15 A	15 A	15 A	15 A	15 A
Voltage - UL	Not Specified	300 V	300 V	300 V	300 V	300 V	300 V
Operating Temperature	Not Specified	-40°C ~ 105°C	-40°C ~ 105°C	-40°C ~ 105°C	-40°C ~ 105°C	-40°C ~ 105°C	-40°C ~ 105°C
RoHS Status	RoHS Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	RoHS Compliant	ROHS3 Compliant	ROHS3 Compliant
Product Status	Obsolete	Active	Active	Active	Active	Active	Active

Engineering Selection Recommendations

Tier 1 - Exact Pitch Match (0.200" / 5.08mm):

Molex 0395320003 and Molex 0395320503 are direct mechanical and electrical equivalents with identical 5.08mm pitch spacing. Both parts are active products with ROHS3 compliance and UL ratings of 15 A at 300 V. The 0395320003 features tin contact mating finish, while 0395320503 provides gold plating for enhanced corrosion resistance. Both maintain 2-side shrouding and through-hole solder termination. Adam Tech EBQA-03-D also matches the 5.08mm pitch with identical mechanical configuration and active product status.

Tier 2 - Near-Pitch Match (0.197" / 5.00mm):

Molex 0395220003, 0395221003, and 0395226003 provide functional equivalence with 5.00mm pitch spacing. The 0395220003 and 0395221003 differ in shrouding configuration (2-side vs. 4-side respectively), while 0395226003 offers 4-side shrouding in green housing. All three maintain active product status and ROHS3 compliance.

Amphenol PCD ELFH03120, ELFH03110, ELFH03130, and ELFH03140 are active alternatives with 5.00mm pitch and polybutylene terephthalate (PBT) housing material. ELFH03120 and ELFH03140 feature 2-side shrouding, while ELFH03110 and ELFH03130 provide 4-side shrouding. All Amphenol parts maintain RoHS compliance and UL ratings of 15 A at 300 V.

Compliance Considerations:

All substitute parts maintain UL94 V-0 flammability rating and RoHS compliance status. The original TE Connectivity 1546518-3 is RoHS Compliant; substitute parts are either RoHS Compliant or ROHS3 Compliant, both acceptable for new designs. All substitute parts are active products, eliminating obsolescence risk associated with the original component.

Frequently Asked Questions (FAQ)

Q: Can Molex 0395320003 directly replace TE Connectivity 1546518-3?

A: Yes. Both parts share identical 0.200" (5.08mm) pitch spacing, 3-position configuration, 90° right-angle orientation, 2-side shrouding, and through-hole solder termination. The Molex part is active and RoHS3 compliant, eliminating obsolescence concerns.

Q: What is the difference between 5.08mm and 5.00mm pitch substitutes?

A: The pitch difference is 0.08mm (0.003"). This represents a 1.6% dimensional variance. Near-pitch substitutes (5.00mm) are functionally compatible but require verification of mechanical fit within the specific application's PCB layout and mating connector specifications.

Q: Why do some substitutes have 4-side shrouding instead of 2-side?

A: Shrouding configuration affects mechanical protection and EMI shielding. 4-side shrouding provides enhanced protection but may alter the component's footprint. Selection depends on application requirements for mechanical robustness and electromagnetic compatibility.

Q: What is the significance of contact material differences (phosphor bronze vs. brass)?

A: The original TE Connectivity 1546518-3 uses phosphor bronze contacts; all substitutes use brass contacts. Both materials are suitable for solder termination and tin or gold plating. Brass provides adequate electrical conductivity and contact reliability for the specified 15 A / 300 V rating.

Q: Does contact mating finish (tin vs. gold) affect substitution compatibility?

A: Contact mating finish affects corrosion resistance and long-term reliability in specific environments. Tin finish is standard for general applications; gold plating (Molex 0395320503) provides enhanced corrosion resistance in harsh or high-humidity environments. Both finishes are compatible with standard mating connectors.

Q: Are all substitute parts suitable for new designs?

A: Yes. All substitute parts listed are active products with current manufacturing status and RoHS compliance. They are appropriate for new design implementations and eliminate obsolescence risk.

Q: What is the difference between RoHS Compliant and ROHS3 Compliant?

A: Both designations indicate compliance with Restriction of Hazardous Substances regulations. ROHS3 represents the current revision of the directive. Both are acceptable for component selection; ROHS3 represents the most current compliance standard.

Q: Can housing material differences (PA66 vs. PBT) affect performance?

A: Both polyamide (PA66) and polybutylene terephthalate (PBT) materials maintain UL94 V-0 flammability rating and are suitable for the specified operating temperature range (-40°C to 105°C). Material selection affects mechanical properties such as stiffness and chemical resistance but does not prevent functional substitution.

Q: What inventory considerations apply to these substitutes?

A: Molex 0395320003 has 6,577 pieces in stock, providing high availability. Molex 0395221003 has 5,154 pieces. Amphenol PCD ELFH03120 has 699 pieces. Availability varies by distributor and should be verified for production requirements.

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