TE Connectivity 1546518-4 Terminal Block Header Equivalent & Substitute Parts

Part Overview

The TE Connectivity 1546518-4 is a 4-position terminal block header with male pins, shrouded on 2 sides, featuring 0.200" (5.08mm) pitch and 90° right-angle orientation for through-hole mounting. This component is classified as obsolete, necessitating identification of active equivalent and substitute parts for ongoing design requirements and procurement needs. The part belongs to the Buchanan series and is constructed from polyamide (PA66) nylon housing with phosphor bronze contacts.

Key Parameters

Parameter	Value
Manufacturer Part Number	1546518-4
Manufacturer	TE Connectivity AMP Connectors
Category	Terminal Blocks
Number of Positions	4
Pitch	0.200" (5.08mm)
Header Orientation	90°, Right Angle
Type	Header, Male Pins, Shrouded (2 Side)
Mounting Type	Through Hole
Termination Style	Solder
Contact Mating Finish	Tin
Housing Material	Polyamide (PA66), Nylon 6/6
Contact Material	Phosphor Bronze
Material Flammability Rating	UL94 V-0
Product Status	Obsolete

Substitute Part Grouping Explanation

Substitution of the TE Connectivity 1546518-4 is determined by the following critical parameters:

Primary Matching Criteria:

Number of positions: 4
Pitch: 0.200" (5.08mm) or 0.197" (5.00mm) with mechanical compatibility
Header orientation: 90°, right angle
Mounting type: Through hole
Termination style: Solder
Shrouding configuration: 2-side or 4-side shrouded

Secondary Compatibility Factors:

Material flammability rating: UL94 V-0
Contact mating finish: Tin
Housing material: Polyamide or polybutylene terephthalate
Contact material: Brass or phosphor bronze

Substitute parts are grouped into two categories based on pitch specification:

Group 1 – Exact Pitch Match (0.200" / 5.08mm): Parts maintaining identical 5.08mm pitch spacing for direct mechanical and electrical compatibility.

Group 2 – Near-Pitch Match (0.197" / 5.00mm): Parts with 5.00mm pitch offering functional equivalence with minimal dimensional variance suitable for applications where pitch tolerance permits substitution.

Parameter Comparison

Parameter	1546518-4 (TE)	0395220004 (Molex)	0395320004 (Molex)	0395321004 (Molex)	0395326004 (Molex)	EBQA-04-D (Adam Tech)	ELFH04120 (Amphenol)	ELFH04210 (Amphenol)
Positions	4	4	4	4	4	4	4	4
Pitch	0.200" (5.08mm)	0.197" (5.00mm)	0.200" (5.08mm)	0.200" (5.08mm)	0.200" (5.08mm)	0.200" (5.08mm)	0.197" (5.00mm)	0.200" (5.08mm)
Orientation	90°	90°	90°	90°	90°	90°	90°	90°
Shrouding	2 Side	2 Side	2 Side	4 Side	4 Side	2 Side	2 Side	4 Side
Mounting	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole
Termination	Solder	Solder	Solder	Solder	Solder	Solder	Solder	Solder
Contact Finish	Tin	Tin	Tin	Tin	Tin	Tin	Tin	Tin
Housing Material	PA66 Nylon 6/6	PA66 Nylon 6/6	PA66 Nylon 6/6	PA66 Nylon 6/6	PA66 Nylon 6/6	PA66 Nylon 6/6	PBT	PBT
Contact Material	Phosphor Bronze	Brass	Brass	Brass	Brass	Brass	Brass	Brass
Flammability	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0
Product Status	Obsolete	Active	Active	Active	Active	Active	Active	Active
RoHS Status	Not Applicable	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	RoHS Compliant	ROHS3 Compliant

Engineering Selection Recommendations

Primary Substitutes – Exact Pitch Match (0.200" / 5.08mm):

For applications requiring direct mechanical and electrical compatibility with the 1546518-4, the following active parts provide equivalent functionality:

Molex 0395320004 – 2-side shrouded configuration matching the original part's shrouding design. ROHS3 compliant with active product status. Brass contacts with polyamide housing. Suitable for direct replacement in existing PCB layouts.

Molex 0395321004 – 4-side shrouded variant of the 5.08mm pitch family. ROHS3 compliant with high inventory availability (14,885 units). Increased shrouding provides enhanced EMI shielding compared to 2-side configuration.

Molex 0395326004 – 4-side shrouded, 5.08mm pitch with green housing option. ROHS3 compliant. Functionally equivalent to 0395321004 with color differentiation for circuit identification.

Amphenol PCD ELFH04210 – 4-side shrouded, 5.08mm pitch. ROHS3 compliant with polybutylene terephthalate housing. Active status with 1,104 units in stock.

Secondary Substitutes – Near-Pitch Match (0.197" / 5.00mm):

For applications where 0.08mm pitch tolerance is acceptable:

Molex 0395220004 – 2-side shrouded, 5.00mm pitch. ROHS3 compliant. Suitable for new designs where pitch standardization to 5.00mm is permissible.

Amphenol PCD ELFH04120 – 2-side shrouded, 5.00mm pitch. RoHS compliant with polybutylene terephthalate housing. Active status.

Amphenol PCD ELFH04140 – 2-side shrouded, 5.00mm pitch. RoHS compliant with polyamide (PA46) nylon housing. Active status.

Alternative Configuration – 2-Side Shrouded, 5.08mm Pitch:

Adam Tech EBQA-04-D – 2-side shrouded, 5.08mm pitch, green housing. ROHS3 compliant. Brass contacts with polyamide housing. Functionally equivalent to 0395320004 with alternative manufacturer sourcing.

All substitute parts maintain UL94 V-0 flammability rating, tin contact mating finish, and through-hole solder termination consistent with the original specification.

Frequently Asked Questions (FAQ)

Q: Can the Molex 0395220004 (5.00mm pitch) be used as a direct replacement for the 1546518-4 (5.08mm pitch)?

A: The 0395220004 features 0.197" (5.00mm) pitch compared to the original 0.200" (5.08mm) pitch. This 0.08mm difference represents a 1.6% dimensional variance. Substitution is mechanically feasible only if the receiving connector or mating component accommodates the pitch tolerance. For applications with tight mechanical constraints or existing mating connectors, exact pitch matching is required.

Q: What is the difference between 2-side and 4-side shrouded configurations?

A: 2-side shrouding provides insulation on two opposing sides of the terminal block, suitable for standard applications. 4-side shrouding extends insulation coverage to all four sides, offering enhanced protection against accidental contact and improved EMI shielding. Selection depends on application requirements for electrical isolation and environmental protection.

Q: Are all substitute parts RoHS compliant?

A: All active substitute parts listed are RoHS compliant (either RoHS or ROHS3 designation). The original 1546518-4 carries "Not Applicable" RoHS status due to its obsolete classification. For new designs or procurement requiring RoHS compliance, all listed substitutes meet current regulatory requirements.

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

A: The original 1546518-4 uses phosphor bronze contacts, while all substitute parts use brass contacts. Both materials provide adequate electrical conductivity and tin plating compatibility. Brass is the industry standard for modern terminal block designs and is functionally equivalent for the electrical performance parameters of this component category.

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

A: Both polyamide (PA66) nylon and polybutylene terephthalate (PBT) housing materials maintain UL94 V-0 flammability rating and are suitable for through-hole solder termination. Material selection affects thermal and chemical resistance characteristics. For applications with standard operating conditions (-40°C to 105°C), both materials are functionally equivalent. Applications with extreme thermal or chemical exposure require material-specific evaluation.

Q: Which substitute offers the highest inventory availability?

A: Molex 0395321004 provides the highest inventory availability with 14,885 units in stock, followed by Molex 0395320004 with 955 units. For procurement planning, these parts offer the shortest lead times and most reliable supply chain access.

Q: Is the Adam Tech EBQA-04-D suitable for applications requiring black housing?

A: The Adam Tech EBQA-04-D features green housing, not black. For applications requiring black housing with 5.08mm pitch and 2-side shrouding, the Molex 0395320004 or Amphenol PCD ELFH04210 (4-side shrouded) are appropriate selections.

Q: What packaging formats are available for these substitutes?

A: Substitute parts are available in Bulk or Tray packaging. Molex parts (0395220004, 0395320004, 0395321004, 0395326004) are supplied in Bulk packaging. Amphenol PCD parts (ELFH04120, ELFH04210) are supplied in Tray packaging. Packaging selection affects handling, storage, and automated assembly compatibility.

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