Amphenol ICC 78548-650 Equivalent & Substitute Parts

Part Overview

The Amphenol ICC 78548-650 is a rectangular connector header designed for through-hole mounting applications. This BERGSTIK® II series connector features 50 positions arranged in 2 rows with 0.100" (2.54mm) pitch spacing, suitable for board-to-board interconnections. The part is currently active in production with 931 units in stock. Substitute parts are identified to address supply chain requirements, design flexibility, or specific application constraints while maintaining electrical and mechanical compatibility within the defined parameter envelope.

Key Parameters

Parameter	Value
Connector Type	Header
Contact Type	Male Pin
Number of Positions	50
Number of Rows	2
Pitch - Mating	0.100" (2.54mm)
Row Spacing - Mating	0.100" (2.54mm)
Mounting Type	Through Hole
Termination	Solder
Fastening Type	Push-Pull
Contact Shape	Square
Material Flammability Rating	UL94 V-0
Insulation Color	Black
Moisture Sensitivity Level (MSL)	1 (Unlimited)

Substitute Part Grouping Explanation

Substitution eligibility for the 78548-650 is determined by strict alignment with the following critical parameters:

Connector Type & Contact Configuration: Header with male pins, 50 positions in 2-row arrangement
Pitch Specification: 0.100" (2.54mm) mating pitch and row spacing
Mounting & Termination: Through-hole solder termination with push-pull fastening
Physical Compatibility: Overall contact length, insulation height, and board-to-board style
Material & Compliance: UL94 V-0 flammability rating, black insulation, MSL 1

All identified substitutes meet these core electrical and mechanical requirements. Variations in contact finish, insulation material, and operating temperature ranges are secondary parameters that do not preclude substitution within standard application envelopes.

Parameter Comparison

Parameter	78548-650 (Amphenol ICC)	2-87215-5 (TE Connectivity)	7-146252-5 (TE Connectivity)	TSW-125-14-G-D (Samtec)	TSW-125-14-L-D (Samtec)	TSW-125-14-S-D (Samtec)	TSW-125-14-T-D (Samtec)
Manufacturer	Amphenol ICC (FCI)	TE Connectivity AMP	TE Connectivity AMP	Samtec Inc.	Samtec Inc.	Samtec Inc.	Samtec Inc.
Series	BERGSTIK® II	AMPMODU Mod II	AMPMODU Mod II	TSW	TSW	TSW	TSW
Connector Type	Header	Header	Header, Breakaway	Header	Header	Header	Header
Contact Type	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin
Number of Positions	50	50	50	50	50	50	50
Number of Rows	2	2	2	2	2	2	2
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)
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)
Mounting Type	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole
Termination	Kinked Pin, Solder	Solder	Solder	Solder	Solder	Solder	Solder
Fastening Type	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)	0.320" (8.13mm)	0.320" (8.13mm)	0.320" (8.13mm)	0.320" (8.13mm)
Contact Length - Post	0.120" (3.05mm)	0.125" (3.18mm)	0.125" (3.18mm)	0.110" (2.79mm)	0.110" (2.79mm)	0.110" (2.79mm)	0.110" (2.79mm)
Overall Contact Length	0.538" (13.67mm)	0.533" (14.65mm)	0.533" (14.65mm)	0.530" (13.46mm)	0.530" (13.46mm)	0.530" (13.46mm)	0.530" (13.46mm)
Insulation Height	0.100" (2.54mm)	0.090" (2.29mm)	0.090" (2.29mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)
Contact Shape	Square	Circular	Square	Square	Square	Square	Square
Contact Finish - Mating	Gold or Gold, GXT™	Gold	Gold	Gold	Gold	Gold	Tin
Contact Material	Phosphor Bronze	Phosphor Bronze	Copper Alloy	Phosphor Bronze	Phosphor Bronze	Phosphor Bronze	Phosphor Bronze
Insulation Material	Not specified	Thermoplastic	Liquid Crystal Polymer (LCP)	Polybutylene Terephthalate (PBT)	Polybutylene Terephthalate (PBT)	Polybutylene Terephthalate (PBT)	Polybutylene Terephthalate (PBT)
Operating Temperature	Not specified	-65°C ~ 105°C	-65°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
Insulation Color	Black	Black	Black	Black	Black	Black	Black
Moisture Sensitivity Level (MSL)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)
RoHS Status	RoHS non-compliant	RoHS Compliant	RoHS Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant
Product Status	Active	Active	Active	Active	Active	Active	Active
Inventory (Pcs)	931	1314	1630	908	942	837	942

Engineering Selection Recommendations

All substitute parts listed maintain active product status and meet the core electrical and mechanical requirements for direct substitution with the 78548-650. Selection among substitutes should be based on the following considerations:

RoHS Compliance: The 78548-650 is RoHS non-compliant. All substitute options (2-87215-5, 7-146252-5, TSW-125-14-G-D, TSW-125-14-L-D, TSW-125-14-S-D, TSW-125-14-T-D) are RoHS Compliant or ROHS3 Compliant, providing regulatory advantage for new designs or applications with RoHS requirements.

Contact Finish Specifications: The 78548-650 specifies gold or gold GXT™ mating finish. Substitute parts offer gold mating finish (2-87215-5, 7-146252-5, TSW-125-14-G-D, TSW-125-14-L-D, TSW-125-14-S-D) or tin mating finish (TSW-125-14-T-D). Gold-finished options maintain closest alignment with the original specification.

Operating Temperature Range: The 78548-650 does not specify an operating temperature range. TE Connectivity substitutes (2-87215-5, 7-146252-5) operate from -65°C to 105°C. Samtec TSW series parts operate from -55°C to 125°C (TSW-125-14-G-D, TSW-125-14-L-D, TSW-125-14-S-D) or -55°C to 105°C (TSW-125-14-T-D), providing extended temperature capability for demanding applications.

Insulation Material & Height: TE Connectivity 2-87215-5 features 0.090" insulation height with thermoplastic material. TE Connectivity 7-146252-5 features 0.090" insulation height with LCP material. Samtec TSW series maintains 0.100" insulation height matching the original specification. For applications with tight mechanical constraints, insulation height variation should be evaluated.

Contact Shape Variation: The 78548-650 specifies square contact shape. TE Connectivity 2-87215-5 features circular contacts, while all other substitutes maintain square contact geometry. Circular contacts in 2-87215-5 do not preclude substitution but represent a design variation.

Inventory Availability: TE Connectivity 7-146252-5 offers the highest inventory level (1630 units), followed by 2-87215-5 (1314 units), providing supply chain flexibility.

Frequently Asked Questions (FAQ)

Q: Can the 78548-650 be directly replaced with any of the listed substitutes?

A: Yes. All listed substitutes meet the critical electrical and mechanical parameters: 50-position, 2-row header configuration with 0.100" (2.54mm) pitch, through-hole solder termination, push-pull fastening, and UL94 V-0 flammability rating. Physical compatibility is maintained within standard PCB design tolerances.

Q: What is the significance of the contact shape difference in the 2-87215-5?

A: The 2-87215-5 features circular contacts while the 78548-650 specifies square contacts. Both geometries are functionally equivalent for electrical connectivity and mating force characteristics. The circular design in the 2-87215-5 does not affect substitution eligibility but represents a design variation from the original specification.

Q: Why do the substitute parts have different insulation heights?

A: Insulation height variation (0.090" in TE Connectivity parts versus 0.100" in Samtec TSW series and the original 78548-650) reflects different design approaches within the same connector family. These variations remain within acceptable mechanical tolerances for standard board-to-board applications. Applications with specific mechanical constraints should verify clearance requirements.

Q: Are there RoHS compliance implications for substitution?

A: The 78548-650 is RoHS non-compliant. All substitute parts are RoHS Compliant or ROHS3 Compliant. For new designs or applications subject to RoHS regulations, substitution provides regulatory compliance advantage. Existing designs using the 78548-650 may continue without modification if RoHS exemptions apply.

Q: What is the difference between the Samtec TSW variants?

A: The Samtec TSW-125-14 series variants differ primarily in contact finish specifications: TSW-125-14-G-D (gold mating, gold post), TSW-125-14-L-D (gold mating, tin post), TSW-125-14-S-D (gold mating, tin post with 30.0µin thickness), and TSW-125-14-T-D (tin mating, tin post). All variants maintain identical mechanical configuration and pitch specifications. Selection depends on contact finish requirements for specific applications.

Q: Can the 78548-650 be used interchangeably with the 7-146252-5 breakaway variant?

A: Yes. The 7-146252-5 is designated as a Header, Breakaway type, indicating the connector supports individual position separation. This feature does not preclude standard board-to-board use. The breakaway capability provides additional design flexibility without affecting substitution compatibility.

Q: What are the post length variations among substitutes?

A: The 78548-650 specifies 0.120" (3.05mm) contact post length. TE Connectivity substitutes feature 0.125" (3.18mm) post length, while Samtec TSW series features 0.110" (2.79mm) post length. These variations reflect different solder joint depth requirements and PCB thickness accommodations. Standard PCB thicknesses (0.062" typical) accommodate all variants without modification.

Q: Are there REACH compliance considerations?

A: TE Connectivity 2-87215-5 is REACH Affected. TE Connectivity 7-146252-5 status is not specified in provided data. Samtec TSW series parts are REACH Unaffected. For applications subject to REACH regulations, Samtec TSW variants provide regulatory clarity.

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