EM257512HO Terminal Block Header - Equivalent & Substitute Parts

Part Overview

The EM257512HO is a 12-position terminal block header manufactured by Eaton Electronics Division, part of the Euro-Mag EM2575 series. This component is a male pin header with shrouded design (2-side protection), 0.200" (5.08mm) pitch, configured for 90° right-angle through-hole mounting with solder termination. The part is currently active in production with 1040 units in stock inventory.

Terminal block headers serve as connection interfaces in electronic assemblies, providing reliable solder-based termination for wire-to-board connections. Equivalent and substitute parts are identified when design flexibility, inventory availability, or supply chain considerations require alternative components that maintain functional compatibility within specified electrical and mechanical parameters.

Key Parameters

Parameter	Value
Number of Positions	12
Pitch	0.200" (5.08mm)
Header Orientation	90°, Right Angle
Termination Style	Solder
Mounting Type	Through Hole
Current Rating (UL)	16 A
Voltage Rating (UL)	300 V
Operating Temperature Range	-40°C ~ 105°C
Material Flammability Rating	UL94 V-0
RoHS Status	ROHS3 Compliant

Substitute Part Grouping Explanation

Substitution eligibility for the EM257512HO is determined by the following critical parameters:

Primary Compatibility Criteria:

12 positions per level (fixed requirement)
0.200" (5.08mm) pitch spacing (allows 1-796638-2 and ELFH12210; excludes 1-796644-2 due to 0.197" pitch deviation)
90° right-angle orientation (all candidates match)
Solder termination (all candidates match)
Through-hole mounting (all candidates match)
UL voltage rating of 300 V (all candidates match)
UL94 V-0 flammability rating (all candidates match)
ROHS3 compliance (all candidates match)

Secondary Compatibility Considerations:

Current rating tolerance: EM257512HO rated 16 A; substitute parts rated 15 A represent a 6.25% reduction, acceptable for most applications within the same thermal envelope
Operating temperature range: EM257512HO operates -40°C ~ 105°C; 1-796638-2 and 1-796644-2 extend to 110°C; ELFH12210 matches at 105°C
Shroud configuration: EM257512HO features 2-side shrouding; all substitutes provide 4-side shrouding, offering enhanced mechanical protection
Contact material: EM257512HO uses brass; 1-796638-2 and 1-796644-2 use copper alloy; ELFH12210 uses brass
Housing material: EM257512HO uses thermoplastic; substitutes use polyamide (PA66) or polybutylene terephthalate (PBT)

Pitch Deviation Analysis: The 1-796644-2 operates at 0.197" (5.00mm) pitch, representing a 0.6% deviation from the specified 0.200" (5.08mm) pitch. This deviation exceeds standard tolerance for direct substitution in applications requiring precise pitch-dependent mating with complementary connectors or PCB layouts.

Parameter Comparison

Parameter	EM257512HO (Main)	1-796638-2	1-796644-2	ELFH12210
Manufacturer	Eaton Electronics	TE Connectivity AMP	TE Connectivity AMP	Amphenol PCD
Number of Positions	12	12	12	12
Pitch	0.200" (5.08mm)	0.200" (5.08mm)	0.197" (5.00mm)	0.200" (5.08mm)
Header Orientation	90° Right Angle	90° Right Angle	90° Right Angle	90° Right Angle
Shroud Configuration	2-Side	4-Side	4-Side	4-Side
Termination Style	Solder	Solder	Solder	Solder
Mounting Type	Through Hole	Through Hole	Through Hole	Through Hole
Current Rating (UL)	16 A	15 A	15 A	15 A
Voltage Rating (UL)	300 V	300 V	300 V	300 V
Operating Temperature	-40°C ~ 105°C	-40°C ~ 110°C	-40°C ~ 110°C	-40°C ~ 105°C
Contact Mating Finish	Tin	Tin	Tin	Tin
Material Flammability	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0
RoHS Status	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant
Product Status	Active	Active	Active	Active

Engineering Selection Recommendations

Primary Substitutes (Pitch-Compatible):

1-796638-2 and ELFH12210 are functionally equivalent to EM257512HO based on matching 0.200" (5.08mm) pitch, identical position count, and compatible electrical ratings. Both parts maintain UL94 V-0 flammability compliance and ROHS3 certification. The 1 A reduction in current rating (15 A vs. 16 A) is within acceptable tolerance for most applications. Both substitutes provide enhanced 4-side shrouding compared to the 2-side design of the main part, offering improved mechanical robustness.

Secondary Substitute (Pitch-Variant):

1-796644-2 operates at 0.197" (5.00mm) pitch, creating a 0.6% dimensional deviation from the specified 0.200" (5.08mm) standard. This part is suitable only for applications where pitch-dependent mating constraints do not apply or where the receiving connector accommodates the pitch variance. All other electrical and mechanical parameters align with primary substitutes.

Compliance and Certification:

All substitute parts maintain active product status, ROHS3 compliance, and UL94 V-0 flammability certification, meeting regulatory requirements equivalent to the main part. Moisture sensitivity levels vary: EM257512HO and ELFH12210 are not applicable; 1-796638-2 and 1-796644-2 are rated MSL 1 (Unlimited), indicating superior moisture tolerance.

Frequently Asked Questions (FAQ)

Q: Can 1-796644-2 be used as a direct replacement for EM257512HO?

A: 1-796644-2 is not recommended as a direct replacement due to pitch deviation. The 0.197" (5.00mm) pitch differs from the specified 0.200" (5.08mm) pitch of EM257512HO. This 0.6% variance may cause misalignment with mating connectors or PCB layouts designed for 5.08mm spacing. Use only if the receiving connector or PCB design accommodates 5.00mm pitch.

Q: What is the significance of shroud configuration differences?

A: EM257512HO features 2-side shrouding, while all substitutes provide 4-side shrouding. The 4-side design offers enhanced mechanical protection and improved polarization guidance during assembly. Both configurations are mechanically compatible with standard through-hole PCB mounting. The 4-side shroud does not prevent substitution; it represents an improvement in mechanical robustness.

Q: Are the current rating differences critical?

A: EM257512HO is rated 16 A (UL), while substitutes are rated 15 A (UL). This 1 A difference represents a 6.25% reduction. For applications operating below 15 A, substitutes are fully compatible. For applications requiring the full 16 A capacity, verify that the substitute's 15 A rating meets thermal and electrical requirements under actual operating conditions.

Q: Do all parts meet the same regulatory standards?

A: Yes. All parts are ROHS3 compliant and carry UL94 V-0 flammability certification. All operate at 300 V UL voltage rating. Electrical and safety compliance is equivalent across all candidates.

Q: What are the contact material implications?

A: EM257512HO and ELFH12210 use brass contacts; 1-796638-2 and 1-796644-2 use copper alloy contacts. Both materials provide equivalent electrical conductivity and corrosion resistance when finished with tin plating. Contact material selection does not affect substitution eligibility.

Q: How do operating temperature ranges compare?

A: EM257512HO and ELFH12210 operate -40°C ~ 105°C. TE Connectivity parts (1-796638-2 and 1-796644-2) extend to 110°C. For applications within the -40°C ~ 105°C envelope, all parts are compatible. For applications requiring operation above 105°C, only TE Connectivity substitutes are suitable.

Q: What inventory considerations apply?

A: EM257512HO has 1040 units in stock. 1-796638-2 has 1530 units, 1-796644-2 has 1280 units, and ELFH12210 has 1632 units available. Substitute selection may be influenced by inventory availability and supply chain lead times.

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