Amphenol ICC 94549-204H Equivalent & Substitute Parts

Part Overview

The Amphenol ICC 94549-204H is a through-hole rectangular connector header in the BERGSTIK® II series, designed for board-to-board applications. This 4-position, 0.100" (2.54mm) pitch connector features male pins with gold-plated phosphor bronze contacts and press-fit/solder termination. The part is active in production with 861 units in current inventory. Substitute parts are identified to address application requirements including alternative contact finishes, insulation materials, operating temperature ranges, and RoHS compliance status.

Key Parameters

Parameter	Value
Connector Type	Header
Contact Type	Male Pin
Number of Positions	4
Pitch - Mating	0.100" (2.54mm)
Number of Rows	1
Mounting Type	Through Hole
Termination	Press-Fit, Solder
Contact Material	Phosphor Bronze
Contact Finish - Mating	Gold or Gold, GXT™
Insulation Material	Polycyclohexylenedimethylene Terephthalate (PCT), Glass Filled
Material Flammability Rating	UL94 V-0
RoHS Status	RoHS non-compliant
Moisture Sensitivity Level (MSL)	1 (Unlimited)

Substitute Part Grouping Explanation

Substitution eligibility for the 94549-204H is determined by the following critical parameters: connector type (header), contact type (male pin), number of positions (4), pitch (0.100"/2.54mm), number of rows (1), mounting type (through hole), contact material (phosphor bronze), insulation material compatibility, and material flammability rating (UL94 V-0). Substitute parts must maintain these core electrical and mechanical characteristics. Variations in contact finish (gold vs. tin), contact finish thickness, insulation material (PCT vs. LCP vs. PBT), operating temperature range, and RoHS compliance status are permitted substitution parameters that do not affect basic form, fit, and function for standard board-to-board header applications.

Parameter Comparison

Parameter	94549-204H (Main)	5-146274-4	HTSW-104-07-G-S	HTSW-104-07-L-S	HTSW-104-07-S-S	HTSW-104-07-T-S	TS-104-T-AA	TSW-104-08-F-S	TSW-104-22-G-S	TSW-104-26-T-S
Connector Type	Header	Header, Breakaway	Header	Header	Header	Header	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
Number of Positions	4	4	4	4	4	4	4	4	4	4
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)
Number of Rows	1	1	1	1	1	1	1	1	1	1
Mounting Type	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole
Termination	Press-Fit, Solder	Solder	Solder	Solder	Solder	Solder	Solder	Solder	Solder	Solder
Contact Material	Phosphor Bronze	Copper Alloy	Phosphor Bronze	Phosphor Bronze	Phosphor Bronze	Phosphor Bronze	Phosphor Bronze	Phosphor Bronze	Phosphor Bronze	Phosphor Bronze
Contact Finish - Mating	Gold or Gold, GXT™	Tin	Gold	Gold	Gold	Tin	Tin	Gold	Gold	Tin
Insulation Material	Polycyclohexylenedimethylene Terephthalate (PCT), Glass Filled	Liquid Crystal Polymer (LCP)	Liquid Crystal Polymer (LCP)	Liquid Crystal Polymer (LCP)	Liquid Crystal Polymer (LCP)	Liquid Crystal Polymer (LCP)	Not specified	Polybutylene Terephthalate (PBT)	Polybutylene Terephthalate (PBT)	Polybutylene Terephthalate (PBT)
Material Flammability Rating	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	Not specified	UL94 V-0	UL94 V-0	UL94 V-0
Operating Temperature	Not specified	-65°C ~ 105°C	-55°C ~ 125°C	-55°C ~ 125°C	-55°C ~ 125°C	-55°C ~ 105°C	Not specified	-55°C ~ 125°C	-55°C ~ 125°C	-55°C ~ 105°C
RoHS Status	RoHS non-compliant	RoHS Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant
Moisture Sensitivity Level (MSL)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)

Engineering Selection Recommendations

All substitute parts listed maintain active product status and meet UL94 V-0 flammability requirements, ensuring compatibility with the 94549-204H in standard through-hole header applications. The primary distinction among substitutes is RoHS compliance: the main part (94549-204H) is RoHS non-compliant, while all listed substitutes are RoHS Compliant or ROHS3 Compliant. Selection between substitutes should prioritize RoHS compliance requirements for the target application.

Contact finish variations (gold vs. tin) and insulation material differences (PCT vs. LCP vs. PBT) are secondary selection criteria. Gold-finished contacts (HTSW-104-07-G-S, HTSW-104-07-L-S, HTSW-104-07-S-S, TSW-104-08-F-S, TSW-104-22-G-S) provide enhanced corrosion resistance compared to tin-finished alternatives. Tin-finished options (5-146274-4, HTSW-104-07-T-S, TS-104-T-AA, TSW-104-26-T-S) are suitable for standard soldering applications without additional environmental protection requirements.

Operating temperature range is a tertiary consideration. Parts rated to -55°C ~ 125°C (HTSW-104-07-G-S, HTSW-104-07-L-S, HTSW-104-07-S-S, TSW-104-08-F-S, TSW-104-22-G-S) provide extended thermal performance compared to -55°C ~ 105°C or -65°C ~ 105°C variants. Selection of extended-range parts is appropriate only when application thermal requirements exceed standard operating conditions.

Frequently Asked Questions (FAQ)

Q: Can the 94549-204H be directly replaced with any of the listed substitutes?

A: Yes, all listed parts are direct substitutes for the 94549-204H in board-to-board header applications. They share identical connector type, contact type, position count, pitch, row configuration, mounting type, and flammability rating. Substitution is valid provided the application does not require the specific press-fit termination option of the original part, as most substitutes offer solder termination only.

Q: What is the primary reason to select a substitute part?

A: RoHS compliance is the primary substitution driver. The 94549-204H is RoHS non-compliant, while all substitutes are RoHS Compliant or ROHS3 Compliant. Applications subject to RoHS regulations require selection of a compliant substitute.

Q: How do contact finish options affect substitution?

A: Contact finish (gold vs. tin) does not affect electrical or mechanical compatibility. Gold-finished contacts provide superior corrosion resistance in high-humidity or corrosive environments. Tin-finished contacts are suitable for standard indoor applications with standard soldering processes. Selection depends on environmental exposure and reliability requirements, not form-fit-function compatibility.

Q: Are there differences in insulation material between the main part and substitutes?

A: Yes. The 94549-204H uses glass-filled PCT, while substitutes employ LCP or PBT insulation materials. All materials meet UL94 V-0 flammability requirements. Insulation material differences do not affect connector compatibility in standard applications. Material selection may be relevant for specific thermal or chemical exposure scenarios not addressed in this reference.

Q: What is the significance of operating temperature range variations?

A: Operating temperature range indicates the thermal limits within which the connector maintains specified electrical and mechanical performance. The 94549-204H does not specify an operating temperature range. Substitutes rated to -55°C ~ 125°C provide broader thermal performance than those rated to -55°C ~ 105°C or -65°C ~ 105°C. Selection of extended-range parts is appropriate only when application thermal requirements exceed standard conditions.

Q: Does packaging format (Bulk vs. Bag) affect substitution eligibility?

A: No. Packaging format is a supply chain and handling consideration, not a technical compatibility factor. Parts supplied in Bulk or Bag packaging are functionally equivalent for circuit board assembly applications.

Q: Can the 94549-204H be used interchangeably with 5-146274-4 in all applications?

A: Both parts are functionally equivalent for board-to-board header applications. The 5-146274-4 offers RoHS compliance and a specified operating temperature range (-65°C ~ 105°C) with 3A current rating. The 94549-204H does not specify current rating or operating temperature. Substitution is valid provided RoHS compliance is not a requirement for the original part application.

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