DL4004 Equivalent & Substitute Parts

Part Overview

The DL4004 is a general-purpose rectifier diode rated for 400 V DC reverse voltage and 1 A average rectified current in a surface mount MELF (DO-213AB) package. Manufactured by Micro Commercial Co, this component is classified as obsolete. Due to its obsolete status and limited availability relative to active alternatives, equivalent substitute parts are necessary to maintain design continuity and ensure long-term supply chain reliability for applications requiring 400 V, 1 A rectification.

Key Parameters

Parameter	Value	Unit
Voltage - DC Reverse (Vr) (Max)	400	V
Current - Average Rectified (Io)	1	A
Voltage - Forward (Vf) (Max) @ If	1.1 @ 1 A	V
Speed	Standard Recovery >500ns, > 200mA (Io)	—
Current - Reverse Leakage @ Vr	5	µA @ 400 V
Mounting Type	Surface Mount	—
Package / Case	DO-213AB, MELF	—
Operating Temperature - Junction	-65 to 150	°C
RoHS Status	RoHS non-compliant	—

Substitute Part Grouping Explanation

Substitution of the DL4004 is determined by the following critical electrical and mechanical parameters:

Primary Substitution Criteria:

Voltage - DC Reverse (Vr) (Max): 400 V minimum
Current - Average Rectified (Io): 1 A minimum
Mounting Type: Surface Mount
Package / Case: DO-213AB, MELF or equivalent surface mount MELF package

Secondary Compatibility Factors:

Forward voltage (Vf) characteristics
Recovery speed classification (Standard or Fast Recovery)
Reverse leakage current
Operating temperature range
RoHS and regulatory compliance status

Substitute parts are grouped into two categories:

Category 1: Direct Package Match (DO-213AB, MELF) Parts maintaining identical or functionally equivalent MELF packaging: 1N6481HE3/96, 1N6481HE3/97, BYM10-400HE3/96, BYM10-400HE3/97, BYM12-400-E3/96, BYM12-400-E3/97, EGL41G-E3/96. These parts satisfy the 400 V, 1 A electrical requirements and maintain the same surface mount MELF form factor.

Category 2: Alternative Surface Mount Package (SQ-MELF, D-5A) Parts with different surface mount MELF variants: 1N5616US, 1N5617US. These maintain 400 V, 1 A electrical specifications but use alternative surface mount package designations (D-5A, SQ-MELF).

Category 3: Reduced Current Rating Part 1N6662US operates at 400 V but with 500 mA average rectified current, representing a reduced-current alternative suitable only for applications with lower current requirements.

Parameter Comparison

Part Number	Manufacturer	Vr (Max) [V]	Io [A]	Vf (Max) [V]	Speed	Reverse Leakage [µA @ 400V]	Package	Tj (°C)	Product Status	RoHS
DL4004	Micro Commercial Co	400	1	1.1 @ 1 A	Standard >500ns	5	DO-213AB, MELF	-65 to 150	Obsolete	Non-compliant
1N5616US	Microchip Technology	400	1	1.3 @ 3 A	Standard >500ns	0.5	SQ-MELF, A	-65 to 200	Active	Non-compliant
1N5617US	Microchip Technology	400	1	1.6 @ 3 A	Fast ≤500ns	0.5	SQ-MELF, A	-65 to 175	Active	Non-compliant
1N6481HE3/96	Vishay General Semiconductor	400	1	1.1 @ 1 A	Standard >500ns	10	DO-213AB, MELF	-65 to 175	Active	ROHS3 Compliant
1N6481HE3/97	Vishay General Semiconductor	400	1	1.1 @ 1 A	Standard >500ns	10	DO-213AB, MELF	-65 to 175	Active	ROHS3 Compliant
1N6662US	Microchip Technology	400	0.5	1 @ 0.4 A	Standard >500ns	0.05	SQ-MELF, A	-65 to 175	Active	Non-compliant
BYM10-400HE3/96	Vishay General Semiconductor	400	1	1.1 @ 1 A	Standard >500ns	10	DO-213AB, MELF	-65 to 175	Active	ROHS3 Compliant
BYM10-400HE3/97	Vishay General Semiconductor	400	1	1.1 @ 1 A	Standard >500ns	10	DO-213AB, MELF	-65 to 175	Active	ROHS3 Compliant
BYM12-400-E3/96	Vishay General Semiconductor	400	1	1.25 @ 1 A	Fast ≤500ns	5	DO-213AB, MELF	-65 to 175	Active	ROHS3 Compliant
BYM12-400-E3/97	Vishay General Semiconductor	400	1	1.25 @ 1 A	Fast ≤500ns	5	DO-213AB, MELF	-65 to 175	Active	ROHS3 Compliant
EGL41G-E3/96	Vishay General Semiconductor	400	1	1.25 @ 1 A	Fast ≤500ns	5	DO-213AB, MELF	-65 to 175	Active	ROHS3 Compliant

Engineering Selection Recommendations

For Direct Replacement with Identical Package and Electrical Characteristics:

The 1N6481HE3/96 and 1N6481HE3/97 (Vishay SUPERECTIFIER® series) provide the closest functional equivalence to the DL4004. Both parts maintain 400 V, 1 A ratings, identical forward voltage characteristics (1.1 V @ 1 A), standard recovery speed, and DO-213AB MELF packaging. Both are active products with ROHS3 compliance, addressing the obsolescence and regulatory limitations of the original DL4004. The primary difference between these two variants is packaging format (both are functionally equivalent).

For Fast Recovery Applications:

The BYM12-400-E3/96 and BYM12-400-E3/97 (Vishay SUPERECTIFIER® series) offer fast recovery characteristics (≤500 ns, trr = 50 ns) while maintaining 400 V, 1 A electrical specifications and DO-213AB MELF packaging. These parts are suitable for applications requiring reduced reverse recovery time. Both variants are active products with ROHS3 compliance. The BYM12-400-E3/97 offers higher inventory availability (20,200 pcs) compared to the E3/96 variant (2,100 pcs).

For Alternative Surface Mount Packages:

The 1N5616US and 1N5617US (Microchip Technology) provide 400 V, 1 A rectification in alternative surface mount MELF packages (SQ-MELF, D-5A). The 1N5616US maintains standard recovery speed, while the 1N5617US offers fast recovery (trr = 150 ns). Both are active products. These alternatives are applicable when package footprint compatibility with SQ-MELF or D-5A designations is acceptable.

For Reduced Current Applications:

The 1N6662US (Microchip Technology) operates at 400 V with 500 mA average rectified current. This part is suitable only for applications with current requirements not exceeding 500 mA and should not be used as a direct replacement for 1 A applications.

Compliance Considerations:

The original DL4004 is RoHS non-compliant. All Vishay SUPERECTIFIER® alternatives (1N6481HE3 series, BYM10-400HE3 series, BYM12-400-E3 series, EGL41G-E3/96) are ROHS3 compliant, addressing regulatory requirements for new designs. Microchip alternatives (1N5616US, 1N5617US, 1N6662US) remain RoHS non-compliant.

Frequently Asked Questions (FAQ)

Q: Can the 1N5616US or 1N5617US be used as direct replacements for the DL4004?

A: Both parts meet the 400 V, 1 A electrical requirements and are active products. However, they use alternative surface mount MELF package designations (SQ-MELF, D-5A) rather than the DO-213AB package of the DL4004. Substitution is valid if the PCB footprint and assembly process accommodate the D-5A or SQ-MELF package geometry. Verify mechanical compatibility with your specific application before implementation.

Q: What is the difference between the 1N6481HE3/96 and 1N6481HE3/97 variants?

A: Both parts are electrically and functionally identical, maintaining 400 V, 1 A ratings, 1.1 V forward voltage, standard recovery speed, and DO-213AB MELF packaging. The difference lies in packaging format designation (E3/96 versus E3/97). Both are active products with ROHS3 compliance. Selection between variants depends on supplier availability and internal part numbering conventions.

Q: Why do the BYM12-400-E3 series parts have higher forward voltage (1.25 V) compared to the DL4004 (1.1 V)?

A: The BYM12-400-E3 series incorporates fast recovery technology (trr = 50 ns) compared to the standard recovery of the DL4004 (>500 ns). The increased forward voltage is a characteristic trade-off associated with fast recovery diode design. This difference is acceptable in most applications; however, verify that the additional forward voltage drop does not exceed circuit design margins.

Q: Is the 1N6662US suitable as a replacement for the DL4004?

A: No. The 1N6662US is rated for 500 mA average rectified current, while the DL4004 is rated for 1 A. Using the 1N6662US in a 1 A application would exceed its current rating and result in component failure. The 1N6662US is suitable only for applications with current requirements not exceeding 500 mA.

Q: What are the advantages of selecting a ROHS3-compliant substitute?

A: ROHS3-compliant parts (1N6481HE3 series, BYM10-400HE3 series, BYM12-400-E3 series, EGL41G-E3/96) meet current regulatory requirements for hazardous substance restrictions. These parts are suitable for new designs and applications subject to environmental compliance mandates. The original DL4004 is RoHS non-compliant and may not be acceptable for regulated applications.

Q: Can I use the BYM10-400HE3 series as a substitute for the DL4004?

A: Yes. The BYM10-400HE3/96 and BYM10-400HE3/97 maintain 400 V, 1 A electrical specifications, 1.1 V forward voltage, standard recovery speed, and DO-213AB MELF packaging. Both are active products with ROHS3 compliance. The BYM10 series incorporates avalanche technology, providing additional overvoltage protection. These parts are direct functional equivalents to the DL4004.

Q: What is the difference between standard recovery and fast recovery diodes?

A: Standard recovery diodes (DL4004, 1N6481HE3, BYM10-400HE3) have reverse recovery times exceeding 500 ns. Fast recovery diodes (1N5617US, BYM12-400-E3, EGL41G-E3/96) have reverse recovery times of 50 ns to 150 ns. Fast recovery diodes are preferred in high-frequency switching applications to reduce switching losses and electromagnetic interference. Standard recovery diodes are suitable for lower-frequency rectification applications.

Q: Are there inventory considerations when selecting a substitute?

A: Yes. Inventory availability varies significantly among substitutes. The BYM12-400-E3/97 offers the highest inventory (20,200 pcs), while the BYM10-400HE3/97 provides 924 pcs. The original DL4004 has 7,600 pcs available. Verify supplier inventory status for your procurement timeline and volume requirements.

Q: Can the EGL41G-E3/96 be used interchangeably with the BYM12-400-E3/96?

A: Yes. Both parts are electrically and functionally identical, maintaining 400 V, 1 A ratings, 1.25 V forward voltage, fast recovery speed (trr = 50 ns), and DO-213AB MELF packaging. Both are active products with ROHS3 compliance. Selection between these parts depends on supplier availability and internal part numbering conventions.

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