TE Connectivity AMP Connectors 645522-1 Equivalent & Substitute Parts

Part Overview

The TE Connectivity AMP Connectors 645522-1 is a pin receptacle connector terminal designed for 0.034" to 0.037" pin diameters with solder termination and no tail configuration. This component is classified as obsolete, indicating that direct procurement may face availability constraints. The part belongs to Series 4 of the AMP Connectors terminal line and features beryllium copper contact material with tin finish. Due to its obsolete status, identifying compatible substitute parts with equivalent or expanded electrical and mechanical specifications is necessary for ongoing design support and production continuity.

Substiute Parts

645522-1

TE Connectivity AMP ConnectorsIn Stock: 993645522-1 Datasheet

Current PartRFQ

5645522-1

TE Connectivity AMP ConnectorsIn Stock: 101465645522-1 Datasheet

DirectRFQ

Key Parameters

Substitute Part Grouping Explanation

The substitute part 5645522-1 is classified as a direct equivalent with expanded pin diameter acceptance range. Substitution compatibility is determined by the following parameters:

Critical Compatibility Parameters:

• Overall length (0.260" / 6.60mm) — identical
• Mounting hole diameter (0.071" / 1.80mm) — identical
• Flange diameter (0.089" / 2.26mm) — identical
• Socket depth (0.253" / 6.43mm) — identical
• Contact material (Beryllium Copper) — identical
• Contact finish (Tin) — identical
• Tail type (No Tail) — identical
• Termination method (Solder) — identical
• Board thickness range (0.031" ~ 0.125" / 0.79mm ~ 3.18mm) — identical
• Series designation (4) — identical

Expanded Parameter:

• Accepts pin diameter range expanded from 0.034" ~ 0.037" to 0.034" ~ 0.041" (0.86mm ~ 1.04mm)

The substitute part maintains all mechanical and electrical interface specifications while providing a wider pin diameter acceptance window. This expanded range encompasses the original specification, making the substitute part backward compatible with designs using the 645522-1.

Parameter Comparison

Engineering Selection Recommendations

The 5645522-1 substitute part is suitable for applications currently specified with the 645522-1 based on the following engineering factors:

Mechanical Compatibility: All mounting and interface dimensions are identical between the main part and substitute. The expanded pin diameter acceptance range (0.034" ~ 0.041" versus 0.034" ~ 0.037") provides backward compatibility with the original specification while accommodating a broader range of pin sizes within the same connector footprint.

Electrical Compatibility: Contact material, finish type, and termination method are identical. The contact finish thickness reduction from 150.0µin to 100.0µin on the substitute part remains within acceptable tin plating specifications for solder termination applications.

Compliance Status: The substitute part 5645522-1 holds active product status with ROHS3 compliance and REACH unaffected designation, whereas the main part 645522-1 is obsolete and RoHS non-compliant. Selection of the substitute part aligns with current regulatory requirements and ensures long-term supply chain availability.

Inventory Availability: The substitute part maintains significantly higher inventory levels (10,109 pieces) compared to the main part (922 pieces), supporting production continuity and reducing procurement lead times.

Frequently Asked Questions (FAQ)

Q: Can the 5645522-1 substitute directly replace the 645522-1 in existing designs?

A: Yes. The substitute part maintains identical mechanical dimensions, contact material, finish type, and termination method. All interface specifications including mounting hole diameter, flange diameter, socket depth, and board thickness compatibility are preserved. The expanded pin diameter acceptance range is backward compatible with the original specification.

Q: What is the significance of the expanded pin diameter range in the substitute part?

A: The 5645522-1 accepts pins from 0.034" to 0.041" diameter, compared to the original 0.034" to 0.037" range. This expanded tolerance window encompasses the original specification, allowing the substitute to accommodate a wider range of mating pin sizes while maintaining the same physical footprint and electrical performance.

Q: How does the reduced contact finish thickness affect performance?

A: The substitute part features 100.0µin (2.54µm) tin finish compared to 150.0µin (3.81µm) on the original part. Both thicknesses are within standard specifications for tin-plated beryllium copper contacts used in solder termination applications. The reduced thickness does not compromise electrical conductivity or solder joint reliability.

Q: Why is the substitute part listed as active while the main part is obsolete?

A: The 645522-1 has been discontinued by the manufacturer and is no longer in active production. The 5645522-1 represents the current production equivalent within the Series 4 terminal line, ensuring ongoing availability and compliance with modern regulatory standards.

Q: What are the compliance differences between the two parts?

A: The main part 645522-1 is RoHS non-compliant with undefined REACH status. The substitute 5645522-1 is ROHS3 compliant and REACH unaffected, meeting current environmental and regulatory requirements for electronic components in most markets.

Q: Are there any packaging differences between the main part and substitute?

A: The main part packaging information is not specified in the available data. The substitute part 5645522-1 is supplied in Cut Tape (CT) packaging, which is standard for terminal components and facilitates automated assembly processes.