Amphenol ICC 78548-608 Equivalent & Substitute Parts

Part Overview

The Amphenol ICC 78548-608 is a vertical through-hole rectangular connector header with 8 positions arranged in 2 rows at 0.100" (2.54mm) pitch. This BERGSTIK® II series component features kinked pin solder termination and push-pull fastening, designed for board-to-board applications. The part is currently active in inventory with 723 units available. Substitute parts are necessary when addressing specific application requirements such as RoHS compliance, extended operating temperature ranges, alternative contact finishes, or post length variations for different PCB stack-up configurations.

Key Parameters

Parameter	Value
Connector Type	Header
Contact Type	Male Pin
Pitch - Mating	0.100" (2.54mm)
Number of Positions	8
Number of Rows	2
Row Spacing - Mating	0.100" (2.54mm)
Mounting Type	Through Hole
Style	Board to Board
Shrouding	Unshrouded
Fastening Type	Push-Pull
Contact Shape	Square
Insulation Height	0.100" (2.54mm)
Material Flammability Rating	UL94 V-0
Insulation Color	Black

Substitute Part Grouping Explanation

Substitution eligibility for the 78548-608 is determined by strict equivalence across the following critical parameters:

Core Electrical & Mechanical Compatibility:

Pitch - Mating: 0.100" (2.54mm) — all substitutes maintain this specification
Number of Positions: 8 in 2-row configuration — all substitutes match this layout
Connector Type: Header with male pins — all substitutes are headers with male contact type
Mounting Type: Through Hole — all substitutes use through-hole termination
Fastening Type: Push-Pull — all substitutes employ push-pull engagement
Contact Shape: Square — all substitutes maintain square contact geometry
Insulation Height: 0.100" (2.54mm) — all substitutes match this dimension
Material Flammability Rating: UL94 V-0 — all substitutes meet this safety standard

Variable Parameters Defining Substitute Groups:

Contact Length - Post: Varies from 0.110" to 0.410" depending on application stack-up requirements
Contact Finish - Mating: Gold, Tin-Lead, or Tin options available
Contact Material: Phosphor Bronze or Copper Alloy
Operating Temperature Range: -40°C to 105°C (standard) or -55°C to 125°C (extended)
RoHS Status: Non-compliant (original) or Compliant (select substitutes)
Contact Finish Thickness: Varies by manufacturer specification

All listed substitutes maintain functional equivalence within the rectangular connector 2.54mm pitch header category and are suitable for direct replacement when application requirements align with the specified variable parameters.

Parameter Comparison

Parameter	78548-608 (Amphenol ICC)	929710-01-04 (3M)	929710-03-04 (3M)	929715-01-04-I (3M)	929715-03-04-I (3M)	929715-10-04-I (3M)	M20-9970445 (Harwin)	TSW-104-14-S-D (Samtec)	TSW-104-14-G-D (Samtec)	TSW-104-14-L-D (Samtec)	TSW-104-14-T-D (Samtec)
Connector Type	Header	Header	Header	Header	Header	Header	Header, Cuttable	Header	Header	Header	Header
Contact Type	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin
Pitch - Mating	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)
Number of Positions	8	8	8	8	8	8	8	8	8	8	8
Number of Rows	2	2	2	2	2	2	2	2	2	2	2
Row Spacing - Mating	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)
Mounting Type	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole
Style	Board to Board	Board to Board	Board to Board	Board to Board	Board to Board	Board to Board	Board to Board or Cable	Board to Board or Cable	Board to Board or Cable	Board to Board or Cable	Board to Board or Cable
Shrouding	Unshrouded	Unshrouded	Unshrouded	Unshrouded	Unshrouded	Unshrouded	Unshrouded	Unshrouded	Unshrouded	Unshrouded	Unshrouded
Fastening Type	Push-Pull	Push-Pull	Push-Pull	Push-Pull	Push-Pull	Push-Pull	Push-Pull	Push-Pull	Push-Pull	Push-Pull	Push-Pull
Contact Length - Mating	0.318" (8.08mm)	0.318" (8.08mm)	0.318" (8.08mm)	0.318" (8.08mm)	0.318" (8.08mm)	0.318" (8.08mm)	0.335" (8.51mm)	0.320" (8.13mm)	0.320" (8.13mm)	0.320" (8.13mm)	0.320" (8.13mm)
Contact Length - Post	0.120" (3.05mm)	0.110" (2.79mm)	0.410" (10.41mm)	0.110" (2.79mm)	0.410" (10.41mm)	0.175" (4.45mm)	0.116" (2.95mm)	0.110" (2.79mm)	0.110" (2.79mm)	0.110" (2.79mm)	0.110" (2.79mm)
Overall Contact Length	0.538" (13.67mm)	0.528" (13.42mm)	0.828" (21.03mm)	0.528" (13.42mm)	0.828" (21.03mm)	0.593" (15.07mm)	0.551" (14.00mm)	0.530" (13.46mm)	0.530" (13.46mm)	0.530" (13.46mm)	0.530" (13.46mm)
Insulation Height	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)
Contact Shape	Square	Square	Square	Square	Square	Square	Square	Square	Square	Square	Square
Contact Material	Phosphor Bronze	Copper Alloy	Copper Alloy	Copper Alloy	Copper Alloy	Copper Alloy	Brass	Phosphor Bronze	Phosphor Bronze	Phosphor Bronze	Phosphor Bronze
Contact Finish - Mating	Gold or Gold, GXT™	Tin-Lead	Tin-Lead	Gold	Gold	Gold	Gold	Gold	Gold	Gold	Tin
Contact Finish Thickness - Mating	30.0µin (0.76µm)	100.0µin (2.54µm)	100.0µin (2.54µm)	10.0µin (0.25µm)	10.0µin (0.25µm)	10.0µin (0.25µm)	—	30.0µin (0.76µm)	10.0µin (0.25µm)	10.0µin (0.25µm)	—
Contact Finish - Post	—	—	—	Gold	Gold	Gold	—	Tin	Gold	Tin	Tin
Operating Temperature	—	-40°C ~ 105°C	-40°C ~ 105°C	-40°C ~ 105°C	-40°C ~ 105°C	-40°C ~ 105°C	-40°C ~ 105°C	-55°C ~ 125°C	-55°C ~ 125°C	-55°C ~ 125°C	-55°C ~ 105°C
Material Flammability Rating	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0
Insulation Color	Black	Black	Black	Black	Black	Black	Black	Black	Black	Black	Black
Current Rating (Amps)	—	2.5A	2.5A	2.5A	2.5A	2.5A	3A per Contact	—	—	—	—
RoHS Status	RoHS non-compliant	RoHS non-compliant	RoHS non-compliant	RoHS Compliant	RoHS Compliant	RoHS Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant
Product Status	Active	Active	Discontinued at DiGi Electronics	Active	Active	Active	Active	Active	Active	Active	Active

Engineering Selection Recommendations

For RoHS Compliance Requirements: Select from the 3M 929715 series (929715-01-04-I, 929715-03-04-I, 929715-10-04-I) or Samtec TSW-104 series (TSW-104-14-S-D, TSW-104-14-G-D, TSW-104-14-L-D, TSW-104-14-T-D) or Harwin M20-9970445. All are RoHS Compliant or ROHS3 Compliant. The original 78548-608 is RoHS non-compliant.

For Extended Operating Temperature Range (-55°C to 125°C): Select from Samtec TSW-104 series variants (TSW-104-14-S-D, TSW-104-14-G-D, TSW-104-14-L-D). These provide the widest temperature range. TSW-104-14-T-D operates to -55°C ~ 105°C. All 3M and Harwin alternatives are limited to -40°C ~ 105°C.

For Gold Mating Contact Finish: Select from 3M 929715 series (all variants), Samtec TSW-104-14-G-D, TSW-104-14-L-D, or Harwin M20-9970445. The original 78548-608 specifies gold or gold GXT™ finish.

For Tin-Lead Mating Contact Finish: Select from 3M 929710-01-04 or 929710-03-04. These are the only substitutes with tin-lead finish matching legacy specifications.

For Post Length Variations:

Short post (0.110" / 2.79mm): 3M 929710-01-04, 929715-01-04-I, Samtec TSW-104 series, Harwin M20-9970445
Medium post (0.175" / 4.45mm): 3M 929715-10-04-I
Long post (0.410" / 10.41mm): 3M 929710-03-04, 929715-03-04-I

For Active Product Status: Avoid 3M 929710-03-04, which is discontinued at DiGi Electronics. All other substitutes maintain active status.

For Higher Current Rating: Select Harwin M20-9970445 (3A per contact) for applications requiring higher current capacity than the 2.5A rating of 3M alternatives.

Frequently Asked Questions (FAQ)

Q: Can I substitute the 78548-608 with any of these parts directly? A: Direct substitution is possible only when the application requirements align with the substitute part's specifications. Core parameters such as 2.54mm pitch, 8-position 2-row configuration, through-hole mounting, and push-pull fastening are identical across all parts. However, differences in contact post length, contact finish, operating temperature range, and RoHS compliance status must be evaluated against your specific application requirements.

Q: What is the primary difference between the 3M 929710 and 929715 series? A: The 929710 series uses tin-lead mating contact finish with copper alloy contacts, while the 929715 series uses gold mating contact finish with gold post finish and copper alloy contacts. The 929715 series is RoHS Compliant, whereas the 929710 series is RoHS non-compliant. Both series offer identical pitch, position count, and mounting characteristics.

Q: How do I select the correct post length for my application? A: Post length determines the overall connector height and is selected based on PCB stack-up requirements. The 78548-608 specifies 0.120" (3.05mm) post length. Substitutes with 0.110" (2.79mm) post length are suitable for applications with minimal height constraints. The 0.175" (4.45mm) and 0.410" (10.41mm) options accommodate thicker PCB assemblies or stacked configurations. Verify your mechanical design requirements before selecting a substitute with different post length.

Q: Are Samtec TSW-104 variants interchangeable with each other? A: Samtec TSW-104 variants (TSW-104-14-S-D, TSW-104-14-G-D, TSW-104-14-L-D, TSW-104-14-T-D) differ primarily in contact finish specifications. TSW-104-14-S-D features gold mating finish with 30.0µin thickness and tin post finish. TSW-104-14-G-D features 10.0µin gold mating finish with gold post finish. TSW-104-14-L-D features 10.0µin gold mating finish with tin post finish. TSW-104-14-T-D features tin mating finish with tin post finish and operates to -55°C ~ 105°C. All share identical pitch, position count, and mechanical mounting characteristics. Selection depends on contact finish requirements and operating temperature specifications.

Q: What is the significance of the contact finish thickness specification? A: Contact finish thickness affects durability, corrosion resistance, and mating cycle life. The 78548-608 specifies 30.0µin (0.76µm) gold finish thickness. Thicker finishes (100.0µin / 2.54µm as in 3M 929710 series) provide enhanced durability for high-cycle applications. Thinner finishes (10.0µin / 0.25µm as in 3M 929715 and Samtec TSW-104-14-G-D) are suitable for standard applications with lower mating cycle requirements. Select based on your application's expected connector engagement cycles and environmental exposure.

Q: Is the Harwin M20-9970445 cuttable feature relevant for my application? A: The M20-9970445 is designated as a cuttable header, meaning individual positions can be separated if required. This feature is beneficial for applications requiring custom connector configurations or reduced position counts. If your application requires the full 8-position header without modification, this feature is not relevant. The cuttable design does not affect electrical or mechanical compatibility with standard 8-position applications.

Q: Which substitute offers the best compliance for modern applications? A: For modern applications requiring RoHS compliance and extended operating temperature range, the Samtec TSW-104-14-G-D or TSW-104-14-L-D are optimal choices. Both are ROHS3 Compliant and operate across -55°C to 125°C. For applications requiring RoHS compliance with standard temperature range (-40°C to 105°C), the 3M 929715 series provides equivalent performance with active product status and gold contact finish options.

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