TE Connectivity 204509-1 D-Sub High Density Connector Plug 78 Position

Part Overview

The TE Connectivity 204509-1 is a D-Sub high density connector plug housing designed for male contacts in military applications. This 78-position connector operates within the MIL-DTL-24308 AMPLIMITE 90 series and serves as a plug for male contact assemblies in high-density D-Sub configurations. The part is currently active in production with 947 units in stock. Alternative equivalent parts may be required due to material finish specifications, compliance requirements, or supply chain considerations.

Substiute Parts

204509-1

TE Connectivity Aerospace, Defense and MarineIn Stock: 964204509-1 Datasheet

Current PartRFQ

1757823-5

TE Connectivity Aerospace, Defense and MarineIn Stock: 10211757823-5 Datasheet

DirectRFQ

Key Parameters

Substitute Part Grouping Explanation

Substitution of the TE Connectivity 204509-1 is determined by strict equivalence across the following critical parameters:

Mandatory Matching Parameters:

• Connector Style: D-Sub, High Density
• Connector Type: Plug for Male Contacts
• Number of Positions: 78
• Number of Rows: 4
• Shell Size, Connector Layout: 5 (DD, D) High Density
• Contact Type: Signal
• Mounting Type: Free Hanging (In-Line)
• Flange Feature: Housing/Shell (Unthreaded)
• Series: Military, MIL-DTL-24308, AMPLIMITE 90

Variable Parameters Allowing Substitution:

• Shell Material Finish (Cadmium Plated vs. alternative finishes)
• Dielectric Material specifications
• Color designation
• RoHS compliance status
• REACH compliance status

The substitute part 1757823-5 maintains full electrical and mechanical compatibility through identical connector geometry, position count, row configuration, and mounting characteristics. Differences in shell finish material and compliance certifications do not affect functional interchangeability in applications where the specific finish or compliance requirement is not mandated.

Parameter Comparison

Engineering Selection Recommendations

Selection Based on Compliance Requirements:

The 204509-1 and 1757823-5 are electrically and mechanically equivalent D-Sub high density connector plugs. Selection between these parts depends on regulatory and compliance requirements specific to the application.

For RoHS3 Compliant Applications: Part 1757823-5 is the appropriate selection. This part carries ROHS3 compliance certification and is REACH Unaffected, making it suitable for applications subject to European Union environmental directives and regulations.

For Non-Compliant or Legacy Applications: Part 204509-1 remains available for applications where RoHS compliance is not required. This part is REACH Affected and RoHS non-compliant, reflecting its cadmium-plated steel finish.

Material Finish Considerations: The 204509-1 features a cadmium-plated steel shell, while the 1757823-5 uses yellow chromate plated zinc with a specified finish thickness of 200µin (5.08µm). Both finishes provide corrosion protection suitable for military applications within the MIL-DTL-24308 standard.

Product Status: Both parts maintain active production status with adequate inventory levels, ensuring availability for new designs and replacement applications.

Frequently Asked Questions (FAQ)

Q: Are the 204509-1 and 1757823-5 mechanically interchangeable?

A: Yes. Both parts are D-Sub high density connector plugs with identical 78-position, 4-row configurations in shell size 5 (DD, D). They share the same mounting type (free hanging, in-line), flange feature (unthreaded housing/shell), and contact type (signal). Mechanical fit and mating characteristics are identical.

Q: What is the primary difference between these two parts?

A: The primary differences are shell finish material and compliance certifications. The 204509-1 uses cadmium-plated steel, while the 1757823-5 uses yellow chromate plated zinc. The 1757823-5 is ROHS3 compliant and REACH Unaffected, whereas the 204509-1 is RoHS non-compliant and REACH Affected.

Q: Can I substitute 1757823-5 for 204509-1 in an existing design?

A: Substitution is possible when the application does not require cadmium plating specifically and when RoHS3 compliance is acceptable or required. Verify that the yellow chromate plated zinc finish meets the corrosion protection requirements of your application environment.

Q: Can I substitute 204509-1 for 1757823-5?

A: Substitution is possible only when RoHS compliance is not mandated and REACH compliance is not required. Applications subject to EU environmental regulations or customer RoHS requirements must use the 1757823-5.

Q: Do these connectors include contacts?

A: No. Both the 204509-1 and 1757823-5 are housing plugs only. Contacts are not included and must be ordered separately.

Q: What is the moisture sensitivity level for these parts?

A: Both parts carry MSL 1 (Unlimited), indicating no moisture sensitivity restrictions during storage or handling.

Q: Are both parts certified to MIL-DTL-24308?

A: Yes. Both the 204509-1 and 1757823-5 are part of the Military, MIL-DTL-24308, AMPLIMITE 90 series and meet military connector specifications.

Q: What is the shell finish thickness specification for the 1757823-5?

A: The 1757823-5 specifies a shell finish thickness of 200µin (5.08µm) for the yellow chromate plated zinc finish. The 204509-1 does not provide a finish thickness specification.