TE Connectivity 1546518-8 Terminal Block Header Equivalent & Substitute Parts

Part Overview

The TE Connectivity 1546518-8 is an 8-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 from current manufacturers. Substitute parts maintain functional compatibility through matching electrical specifications, mechanical dimensions, and termination methods while offering active product status and continued availability.

Key Parameters

Parameter	Value
Number of Positions	8
Pitch	0.200" (5.08mm)
Header Orientation	90°, Right Angle
Mounting Type	Through Hole
Termination Style	Solder
Shrouding Configuration	2 Side or 4 Side
Contact Mating Finish	Tin
Housing Material	Polyamide (PA66), Nylon 6/6 or equivalent
Flammability Rating	UL94 V-0
RoHS Compliance	RoHS Compliant or ROHS3 Compliant
Moisture Sensitivity Level	1 (Unlimited)

Substitute Part Grouping Explanation

Substitution logic is based on the following critical parameters that determine functional and mechanical compatibility:

Primary Matching Criteria:

Number of positions: 8 (fixed requirement)
Pitch: 0.200" (5.08mm) or 0.197" (5.00mm) with mechanical tolerance compatibility
Header orientation: 90° right angle (fixed requirement)
Mounting type: Through hole (fixed requirement)
Termination style: Solder (fixed requirement)
Contact mating finish: Tin (fixed requirement)

Secondary Compatibility Factors:

Shrouding configuration: 2-side shrouded parts provide direct mechanical replacement; 4-side shrouded parts offer enhanced insulation with compatible footprint
Housing material: Polyamide (PA66), Nylon 6/6, Liquid Crystal Polymer (LCP), or Polybutylene Terephthalate (PBT) all provide equivalent electrical and thermal performance
Flammability rating: UL94 V-0 required for safety compliance
RoHS compliance: Active parts must meet RoHS or ROHS3 standards
Contact tail length: Variations between 0.059" (1.50mm) and 0.170" (4.32mm) accommodate different PCB thicknesses and assembly requirements

Substitute parts are grouped by shrouding configuration and pitch specification, with electrical ratings and operating temperature ranges provided for application-specific selection.

Parameter Comparison

Manufacturer Part Number	Manufacturer	Pitch	Shrouding	Color	Contact Material	Housing Material	Current Rating (UL)	Voltage Rating (UL)	Operating Temperature	Product Status	RoHS Status
1546518-8	TE Connectivity	0.200" (5.08mm)	2 Side	Black	Phosphor Bronze	PA66, Nylon 6/6	—	—	—	Obsolete	RoHS Compliant
0395224008	Molex	0.197" (5.00mm)	4 Side	Black	Brass	PA66, Nylon 6/6	15 A	300 V	-40°C ~ 140°C	Active	ROHS3 Compliant
0395226008	Molex	0.197" (5.00mm)	4 Side	Green	Brass	PA66, Nylon 6/6	15 A	300 V	-40°C ~ 105°C	Active	ROHS3 Compliant
0395320008	Molex	0.200" (5.08mm)	2 Side	Black	Brass	PA66, Nylon 6/6	15 A	300 V	-40°C ~ 105°C	Active	ROHS3 Compliant
0395324008	Molex	0.200" (5.08mm)	4 Side	Black	Brass	PA, Nylon	18 A	300 V	-40°C ~ 115°C	Active	ROHS3 Compliant
0395325008	Molex	0.200" (5.08mm)	2 Side	Green	Brass	PA66, Nylon 6/6	15 A	300 V	-40°C ~ 105°C	Active	ROHS3 Compliant
0395326008	Molex	0.200" (5.08mm)	4 Side	Green	Brass	PA66, Nylon 6/6	15 A	300 V	-40°C ~ 105°C	Active	ROHS3 Compliant
1774822001	Weidmüller	0.200" (5.08mm)	2 Side	Black	Copper Alloy	LCP, Glass Filled	18.5 A	300 V	-50°C ~ 100°C	Active	RoHS Compliant
1780010000	Weidmüller	0.200" (5.08mm)	2 Side	Black	Copper Alloy	LCP, Glass Filled	18.5 A	300 V	-50°C ~ 100°C	Active	RoHS Compliant
ELFH08110	Amphenol PCD	0.197" (5.00mm)	4 Side	Black	Brass	PBT	15 A	300 V	-40°C ~ 105°C	Active	RoHS Compliant
ELFH08120	Amphenol PCD	0.197" (5.00mm)	2 Side	Black	Brass	PBT	15 A	300 V	-40°C ~ 105°C	Active	RoHS Compliant

Engineering Selection Recommendations

Direct Mechanical Replacement (Identical Pitch 0.200" / 5.08mm, 2-Side Shrouded):

The following parts provide direct mechanical and electrical compatibility with the original 1546518-8:

Molex 0395320008: Active product with matching 0.200" (5.08mm) pitch, 2-side shrouding, and black color. Rated 15 A at 300 V with operating range -40°C to 105°C. ROHS3 compliant.
Molex 0395325008: Active product with matching pitch and 2-side shrouding in green color. Identical electrical ratings and compliance to 0395320008.
Weidmüller 1780010000: Active product with matching pitch and 2-side shrouding. Rated 18.5 A at 300 V with extended operating range -50°C to 100°C. RoHS compliant. Contact tail length 0.126" (3.20mm).
Weidmüller 1774822001: Active product with matching pitch and 2-side shrouding. Rated 18.5 A at 300 V with operating range -50°C to 100°C. RoHS compliant. Contact tail length 0.059" (1.50mm).

Enhanced Shrouding Alternative (Identical Pitch 0.200" / 5.08mm, 4-Side Shrouded):

Molex 0395324008: Active product with matching 0.200" (5.08mm) pitch and 4-side shrouding. Rated 18 A at 300 V with operating range -40°C to 115°C. ROHS3 compliant. Provides increased insulation protection.
Molex 0395326008: Active product with matching pitch and 4-side shrouding in green color. Identical electrical ratings to 0395324008.

Metric Pitch Alternative (0.197" / 5.00mm Pitch):

Parts with 0.197" (5.00mm) pitch accommodate metric-based PCB designs while maintaining 8-position, 90° right-angle, through-hole configuration:

Molex 0395224008: 4-side shrouded, rated 15 A at 300 V, operating range -40°C to 140°C.
Molex 0395226008: 4-side shrouded, rated 15 A at 300 V, operating range -40°C to 105°C.
Amphenol PCD ELFH08110: 4-side shrouded, rated 15 A at 300 V, operating range -40°C to 105°C. PBT housing material.
Amphenol PCD ELFH08120: 2-side shrouded, rated 15 A at 300 V, operating range -40°C to 105°C. PBT housing material.

All substitute parts maintain UL94 V-0 flammability rating and MSL 1 (Unlimited) moisture sensitivity level. Selection should be based on PCB pitch specification, shrouding requirement, and operating temperature range of the target application.

Frequently Asked Questions (FAQ)

Q: Can I use a 0.197" (5.00mm) pitch part as a direct replacement for the 1546518-8 which has 0.200" (5.08mm) pitch?

A: No. The 0.197" (5.00mm) pitch parts (Molex Eurostyle ESE 39522 series and Amphenol PCD ELFH series) are not mechanically compatible with PCBs designed for 0.200" (5.08mm) pitch. These represent alternative designs for applications using metric-based PCB layouts. Pitch specification must match the target PCB design.

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

A: 2-side shrouded headers provide insulation on two opposing sides, suitable for standard applications. 4-side shrouded headers provide insulation on all four sides, offering enhanced protection against accidental contact and crosstalk. Both configurations maintain the same electrical performance and current ratings. Selection depends on application-specific insulation requirements.

Q: Are Weidmüller parts compatible with Molex and Amphenol PCD parts in the same application?

A: Yes, provided the pitch specification matches. Weidmüller 1780010000 and 1774822001 (0.200" / 5.08mm pitch, 2-side shrouded) are mechanically and electrically compatible with Molex 0395320008 and 0395325008. All parts share identical pitch, position count, orientation, and termination method. Differences in contact material (Copper Alloy vs. Brass) and housing material (LCP vs. PA66) do not affect functional compatibility.

Q: What is the significance of contact tail length variations?

A: Contact tail length determines solder joint depth and PCB penetration. The original 1546518-8 specifies 0.138" (3.50mm). Substitute parts range from 0.059" (1.50mm) to 0.170" (4.32mm). Shorter tails suit thin PCBs; longer tails accommodate thicker boards. PCB thickness and assembly process requirements determine the appropriate contact tail length for your application.

Q: Do all substitute parts meet RoHS compliance?

A: Yes. All listed substitute parts are either RoHS Compliant or ROHS3 Compliant. The original 1546518-8 is RoHS Compliant. All parts meet current environmental and hazardous substance restrictions.

Q: What is the difference between the Molex Eurostyle ESE 39522 series (5.00mm pitch) and ESE 39532 series (5.08mm pitch)?

A: These are distinct product families designed for different pitch standards. ESE 39522 series uses 0.197" (5.00mm) pitch for metric-based designs. ESE 39532 series uses 0.200" (5.08mm) pitch matching the original 1546518-8. Selection depends on your PCB design specification.

Q: Can I substitute the original part with a higher current-rated alternative?

A: Yes. Substitute parts with higher current ratings (18 A or 18.5 A) are backward compatible with applications designed for lower ratings (15 A). The higher rating provides additional design margin. However, the application circuit must be designed to operate within the specified voltage (300 V) and temperature ranges of the selected part.

Q: What is the operating temperature range difference between substitute options?

A: Operating temperature ranges vary: Molex parts range from -40°C to 105°C or 140°C; Weidmüller parts range from -50°C to 100°C; Amphenol PCD parts range from -40°C to 105°C. Selection should match your application's thermal environment. Weidmüller parts offer the lowest minimum temperature (-50°C).

Q: Are there inventory considerations when selecting a substitute?

A: Yes. Current inventory levels vary significantly: Molex 0395326008 has 10,924 pieces in stock; Weidmüller 1780010000 has 675 pieces; Amphenol PCD ELFH08120 has 708 pieces. For high-volume production, parts with larger inventory provide supply security.

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