Molex 0010897803 Rectangular Connector Header - Equivalent & Substitute Parts

Part Overview

The Molex 0010897803 is an 80-position vertical rectangular connector header with 2.54mm pitch, designed for through-hole board-to-board or cable applications. This unshrouded header features male pins with gold-plated mating contacts and tin-plated posts, constructed from copper alloy with liquid crystal polymer insulation. The part is active in production and RoHS3 compliant, making it suitable for automotive, general purpose, lighting, medical, and telecommunications applications.

Substitute parts are identified when equivalent electrical and mechanical parameters align with the main part's specifications, enabling direct replacement in compatible designs.

Key Parameters

Parameter	Value
Connector Type	Header, Breakaway
Contact Type	Male Pin
Number of Positions	80
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
Insulation Material	Liquid Crystal Polymer (LCP), Glass Filled
Material Flammability Rating	UL94 V-0
Insulation Color	Black
RoHS Status	ROHS3 Compliant
Moisture Sensitivity Level	1 (Unlimited)

Substitute Part Grouping Explanation

Substitution eligibility for the Molex 0010897803 is determined by strict alignment of the following critical parameters:

80-position connector with 2-row configuration
0.100" (2.54mm) mating pitch and row spacing
Male pin contact type with square contact shape
Through-hole solder termination
Push-pull fastening mechanism
Unshrouded header design
Board-to-board or cable style
UL94 V-0 flammability rating
Black insulation color

The four substitute parts listed below meet these core electrical and mechanical requirements. Variations in contact finish materials, insulation polymers, contact post lengths, and operating temperature ranges are secondary parameters that do not prevent substitution when the primary criteria are satisfied.

Parameter Comparison

Parameter	Molex 0010897803	3M 2380-6221-TG	Sullins PREC040DFAN-RC	Sullins PRPC040DFAN-RC	Sullins PRPC040DFBN-RC
Manufacturer	Molex	3M	Sullins Connector Solutions	Sullins Connector Solutions	Sullins Connector Solutions
Number of Positions	80	80	80	80	80
Number of Rows	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)
Row Spacing - Mating	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)
Contact Type	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin
Connector Type	Header, Breakaway	Header	Header, Breakaway	Header, Breakaway	Header, Breakaway
Mounting Type	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole
Termination	Solder	Solder	Solder	Solder	Solder
Fastening Type	Push-Pull	Push-Pull	Push-Pull	Push-Pull	Push-Pull
Contact Shape	Square	Square	Square	Square	Square
Contact Finish - Mating	Gold	Gold	Tin	Gold	Gold
Contact Finish - Post	Tin	Tin-Lead	Tin	Gold	Gold
Contact Material	Copper Alloy	Copper Alloy	Brass	Brass	Brass
Insulation Material	Liquid Crystal Polymer (LCP), Glass Filled	Thermoplastic, Glass Filled	Polybutylene Terephthalate (PBT)	Polybutylene Terephthalate (PBT)	Polybutylene Terephthalate (PBT)
Insulation Height	0.090" (2.29mm)	0.100" (2.54mm)	0.098" (2.50mm)	0.098" (2.50mm)	0.098" (2.50mm)
Contact Length - Mating	0.320" (8.13mm)	0.318" (8.08mm)	0.318" (8.08mm)	0.318" (8.08mm)	0.318" (8.08mm)
Contact Length - Post	0.110" (2.79mm)	0.120" (3.05mm)	0.120" (3.05mm)	0.120" (3.05mm)	0.220" (5.58mm)
Overall Contact Length	0.520" (13.21mm)	0.538" (13.67mm)	0.537" (13.63mm)	0.537" (13.63mm)	0.637" (16.17mm)
Material Flammability Rating	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0
Insulation Color	Black	Black	Black	Black	Black
Operating Temperature	Not specified	-55°C ~ 105°C	-40°C ~ 105°C	-40°C ~ 105°C	-40°C ~ 105°C
Current Rating	Not specified	3A	3A per Contact	3A per Contact	3A per Contact
RoHS Status	ROHS3 Compliant	RoHS non-compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant
Moisture Sensitivity Level	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)
Product Status	Active	Active	Active	Active	Active

Engineering Selection Recommendations

All four substitute parts maintain active production status and satisfy the core mechanical and electrical requirements for direct substitution with the Molex 0010897803.

RoHS Compliance Consideration: The Molex 0010897803 and three Sullins alternatives (PREC040DFAN-RC, PRPC040DFAN-RC, PRPC040DFBN-RC) are ROHS3 compliant. The 3M 2380-6221-TG is RoHS non-compliant and should be selected only when legacy or non-regulated applications explicitly permit non-compliant materials.

Contact Post Length Variation: The Sullins PRPC040DFBN-RC features an extended contact post length of 0.220" (5.58mm) compared to 0.110" (2.79mm) on the main part. This longer post accommodates deeper PCB mounting or thicker substrate applications. The other three substitutes maintain post lengths within 0.120" (3.05mm), closer to the original specification.

Insulation Material Differences: The Molex part uses liquid crystal polymer insulation, while 3M uses thermoplastic, and Sullins alternatives use polybutylene terephthalate. All materials meet UL94 V-0 flammability requirements and are suitable for the specified applications.

Contact Finish Variations: The Molex part features gold-plated mating contacts with tin-plated posts. Substitute options include tin mating contacts (PREC040DFAN-RC) and gold mating contacts with gold posts (PRPC040DFAN-RC, PRPC040DFBN-RC). Contact finish selection depends on application-specific corrosion resistance and signal integrity requirements.

Frequently Asked Questions (FAQ)

Q: Can the Sullins PRPC040DFBN-RC with extended post length replace the Molex 0010897803 in standard applications?

A: The PRPC040DFBN-RC meets all core substitution criteria but features a 0.220" contact post length versus the original 0.110". This extended post is suitable for applications requiring deeper PCB penetration or thicker substrate mounting. Verify PCB thickness and mounting depth compatibility before selection.

Q: What is the difference between the Sullins PREC040DFAN-RC and PRPC040DFAN-RC?

A: Both parts are identical except for contact finish. The PREC040DFAN-RC has tin-plated mating contacts, while the PRPC040DFAN-RC has gold-plated mating contacts. Gold plating provides enhanced corrosion resistance and is preferred for high-reliability applications.

Q: Why is the 3M 2380-6221-TG listed as a substitute if it is RoHS non-compliant?

A: The 3M part meets all core electrical and mechanical substitution parameters. However, RoHS compliance status must be verified against application requirements. Use this part only in applications where non-compliant materials are explicitly permitted or where legacy component compatibility is required.

Q: Are there differences in operating temperature ranges between the main part and substitutes?

A: The Molex 0010897803 does not specify an operating temperature range. The 3M 2380-6221-TG operates from -55°C to 105°C, while all Sullins alternatives operate from -40°C to 105°C. Verify application temperature requirements to ensure substitute compatibility.

Q: Can I use the Sullins PRPC040DFAN-RC with gold-plated posts instead of the original tin-plated posts?

A: Yes. The PRPC040DFAN-RC meets all core substitution criteria and provides enhanced contact durability through gold plating on both mating and post surfaces. This is a direct mechanical and electrical substitute suitable for applications where improved contact reliability is beneficial.

Q: What inventory levels are available for each substitute part?

A: Current inventory includes Molex 0010897803 (865 pcs), 3M 2380-6221-TG (1565 pcs), Sullins PREC040DFAN-RC (8014 pcs), Sullins PRPC040DFAN-RC (4802 pcs), and Sullins PRPC040DFBN-RC (2254 pcs). Verify current stock status with your supplier before finalizing procurement decisions.

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