TE Connectivity AMP Connectors 796644-5 Equivalent & Substitute Parts

Part Overview

The TE Connectivity AMP Connectors 796644-5 is a 5 Position Terminal Block Header with male pins, shrouded on four sides, featuring 0.197" (5.00mm) pitch and 90° right angle orientation for through-hole mounting. This component is classified as discontinued at DiGi Electronics, necessitating identification of functionally equivalent substitute parts for ongoing design requirements and production continuity. The part operates within -40°C to 110°C temperature range and supports 15 A at 300 V per UL specifications.

Key Parameters

Parameter	Value
Manufacturer Part Number	796644-5
Manufacturer	TE Connectivity AMP Connectors
Category	Terminal Blocks
Number of Positions	5
Pitch	0.197" (5.00mm)
Header Orientation	90°, Right Angle
Type	Header, Male Pins, Shrouded (4 Side)
Termination Style	Solder
Mounting Type	Through Hole
Current - UL	15 A
Voltage - UL	300 V
Operating Temperature	-40°C ~ 110°C
Material Flammability Rating	UL94 V-0
Housing Material	Polyamide (PA66), Nylon 6/6
Contact Material	Copper Alloy
RoHS Status	ROHS3 Compliant
Product Status	Discontinued at DiGi Electronics

Substitute Part Grouping Explanation

Substitute parts for the 796644-5 terminal block header are grouped based on strict electrical and mechanical compatibility criteria. The primary substitution logic is determined by the following parameters:

Critical Matching Parameters:

Number of Positions: 5
Header Orientation: 90°, Right Angle
Type: Header, Male Pins, Shrouded (4 Side)
Termination Style: Solder
Mounting Type: Through Hole
Current - UL: 15 A
Voltage - UL: 300 V
Material Flammability Rating: UL94 V-0
Housing Material: Polyamide (PA66), Nylon 6/6

Pitch Variations: Substitute parts are divided into two pitch categories: 0.197" (5.00mm) pitch and 0.200" (5.08mm) pitch. Parts with matching 5.00mm pitch provide direct mechanical and electrical compatibility. Parts with 5.08mm pitch represent near-equivalent alternatives with minor dimensional variance in contact tail length and insulation height.

Contact Material Variance: The main part uses Copper Alloy contacts, while all substitute parts use Brass contacts. Both materials meet the electrical performance requirements and UL specifications for this application.

Operating Temperature Range: The main part operates to 110°C maximum, while substitute parts operate to 105°C maximum. This represents a 5°C reduction in upper temperature limit for substitute parts.

Parameter Comparison

Parameter	796644-5 (Main)	0395221005	0395226005	0395321005	0395326005
Manufacturer	TE Connectivity AMP	Molex	Molex	Molex	Molex
Number of Positions	5	5	5	5	5
Positions Per Level	5	5	5	5	5
Number of Levels	1	1	1	1	1
Pitch	0.197" (5.00mm)	0.197" (5.00mm)	0.197" (5.00mm)	0.200" (5.08mm)	0.200" (5.08mm)
Header Orientation	90°, Right Angle	90°, Right Angle	90°, Right Angle	90°, Right Angle	90°, Right Angle
Type	Header, Male Pins, Shrouded (4 Side)	Header, Male Pins, Shrouded (4 Side)	Header, Male Pins, Shrouded (4 Side)	Header, Male Pins, Shrouded (4 Side)	Header, Male Pins, Shrouded (4 Side)
Termination Style	Solder	Solder	Solder	Solder	Solder
Mounting Type	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole
Current - UL	15 A	15 A	15 A	15 A	15 A
Voltage - UL	300 V	300 V	300 V	300 V	300 V
Color	Green	Black	Green	Black	Green
Operating Temperature	-40°C ~ 110°C	-40°C ~ 105°C	-40°C ~ 105°C	-40°C ~ 105°C	-40°C ~ 105°C
Contact Mating Finish	Tin	Tin	Tin	Tin	Tin
Material Flammability Rating	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0
Contact Material	Copper Alloy	Brass	Brass	Brass	Brass
Housing Material	Polyamide (PA66), Nylon 6/6	Polyamide (PA66), Nylon 6/6	Polyamide (PA66), Nylon 6/6	Polyamide (PA66), Nylon 6/6	Polyamide (PA66), Nylon 6/6
Contact Tail Length	0.138" (3.50mm)	0.150" (3.81mm)	0.150" (3.81mm)	0.150" (3.81mm)	0.150" (3.81mm)
Insulation Height	0.329" (8.36mm)	0.330" (8.38mm)	0.330" (8.38mm)	0.472" (12.00mm)	0.472" (12.00mm)
RoHS Status	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant
Moisture Sensitivity Level (MSL)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)
REACH Status	REACH Unaffected	REACH Unaffected	REACH Unaffected	REACH Unaffected	REACH Unaffected
Product Status	Discontinued at DiGi Electronics	Active	Active	Active	Active

Engineering Selection Recommendations

Direct Substitutes (5.00mm Pitch):

Molex 0395221005 and 0395226005 provide direct pitch-compatible substitution for the 796644-5. Both parts maintain the 0.197" (5.00mm) pitch specification and are currently active products. The 0395226005 is recommended as the primary substitute due to matching green housing color with the original part. The 0395221005 offers identical electrical and mechanical specifications with black housing as an alternative. Both parts are ROHS3 compliant and REACH unaffected, meeting regulatory requirements equivalent to the main part.

Near-Equivalent Substitutes (5.08mm Pitch):

Molex 0395321005 and 0395326005 represent near-equivalent alternatives with 0.200" (5.08mm) pitch specification. These parts are suitable for applications where minor pitch variance is acceptable. The 0395326005 is recommended for color matching with green housing. Both parts feature increased insulation height (0.472" versus 0.329" on the main part) and are currently active products with ROHS3 compliance.

Compliance and Regulatory Status:

All substitute parts maintain UL94 V-0 flammability rating, 15 A current capacity, and 300 V voltage rating. All substitutes are ROHS3 compliant and REACH unaffected. Operating temperature range on substitute parts is -40°C to 105°C, representing a 5°C reduction from the main part's 110°C maximum. This temperature differential should be evaluated against specific application requirements.

Availability and Inventory:

All substitute parts are currently active products with substantial inventory availability: 0395221005 (1474 pcs), 0395226005 (1984 pcs), 0395321005 (3578 pcs), and 0395326005 (5435 pcs). The main part 796644-5 is discontinued at DiGi Electronics with 818 pcs remaining in stock.

Frequently Asked Questions (FAQ)

Q: Can Molex 0395226005 directly replace TE Connectivity 796644-5 in existing designs?

A: Yes. The 0395226005 maintains identical pitch (0.197" / 5.00mm), position count (5), orientation (90° right angle), termination style (solder), mounting type (through hole), electrical ratings (15 A / 300 V), and housing material (PA66 nylon). The primary difference is contact material (brass versus copper alloy) and operating temperature maximum (105°C versus 110°C). Both parts are UL94 V-0 rated and ROHS3 compliant.

Q: What is the difference between the 5.00mm and 5.08mm pitch substitute options?

A: The 0395221005 and 0395226005 maintain the original 0.197" (5.00mm) pitch for direct mechanical compatibility with existing PCB layouts. The 0395321005 and 0395326005 feature 0.200" (5.08mm) pitch, requiring PCB redesign or accommodation for the 0.003" (0.08mm) pitch difference. The 5.08mm pitch variants also feature increased insulation height (0.472" versus 0.330"), affecting board-level clearance requirements.

Q: Are there color considerations for substitution?

A: The original 796644-5 features green housing. For color matching, select Molex 0395226005 (5.00mm pitch, green) or 0395326005 (5.08mm pitch, green). The 0395221005 and 0395321005 are available in black housing if color is not a design constraint.

Q: What is the impact of the contact material change from copper alloy to brass?

A: Both copper alloy and brass contacts meet the electrical performance requirements and UL specifications for this terminal block application. Brass contacts are standard in the Molex Eurostyle ESE series. The change does not affect current capacity (15 A), voltage rating (300 V), or contact mating finish (tin plating).

Q: Does the 5°C reduction in maximum operating temperature affect substitution suitability?

A: The substitute parts operate to 105°C maximum versus 110°C for the original part. This 5°C difference should be evaluated against specific application thermal requirements. For applications operating below 105°C, substitution is suitable. For applications requiring operation above 105°C, the original part specification must be maintained or alternative components evaluated.

Q: Are all substitute parts RoHS and REACH compliant?

A: Yes. All substitute parts (0395221005, 0395226005, 0395321005, 0395326005) are ROHS3 compliant and REACH unaffected, matching the regulatory status of the original 796644-5.

Q: What is the contact tail length difference between the main part and substitutes?

A: The original 796644-5 has a contact tail length of 0.138" (3.50mm). All Molex substitutes feature 0.150" (3.81mm) contact tail length, representing a 0.012" (0.31mm) increase. This difference affects solder joint depth and PCB pad design. Verify PCB layout compatibility before substitution.

Q: Which substitute part offers the best direct replacement option?

A: Molex 0395226005 provides the optimal direct replacement, maintaining 5.00mm pitch, green housing color, and equivalent electrical specifications. This part is currently active with 1984 pcs in stock inventory.

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