54202-S0803ALF Equivalent & Substitute Parts

Part Overview

The Amphenol ICC 54202-S0803ALF is a surface mount rectangular connector header with 6 positions arranged in 2 rows at 0.100" (2.54mm) pitch. This BERGSTIK® series connector features male pins with gold-plated mating contacts and tin-plated posts, rated for 3A continuous current and operating temperatures from -65°C to 130°C. The part is actively manufactured and RoHS compliant with UL94 V-0 flammability rating.

Equivalent and substitute parts are necessary when the original part number becomes unavailable, when alternative packaging formats are required for manufacturing processes, or when design flexibility permits selection from multiple qualified suppliers while maintaining electrical and mechanical compatibility.

Key Parameters

Parameter	54202-S0803ALF
Connector Type	Header
Contact Type	Male Pin
Number of Positions	6
Number of Rows	2
Pitch - Mating	0.100" (2.54mm)
Row Spacing - Mating	0.100" (2.54mm)
Mounting Type	Surface Mount
Termination	Solder
Contact Length - Mating	0.230" (5.84mm)
Insulation Height	0.100" (2.54mm)
Contact Shape	Square
Contact Material	Phosphor Bronze
Contact Finish - Mating	Gold or Gold, GXT™
Current Rating	3A
Operating Temperature	-65°C ~ 130°C
Material Flammability Rating	UL94 V-0
RoHS Status	RoHS Compliant
Moisture Sensitivity Level	1 (Unlimited)

Substitute Part Grouping Explanation

Substitution eligibility is determined by strict equivalence across the following critical parameters:

Mandatory Matching Parameters:

Number of Positions: 6
Number of Rows: 2
Pitch - Mating: 0.100" (2.54mm)
Row Spacing - Mating: 0.100" (2.54mm)
Contact Type: Male Pin
Mounting Type: Surface Mount
Termination: Solder
Contact Length - Mating: 0.230" (5.84mm)
Contact Shape: Square
Material Flammability Rating: UL94 V-0
RoHS Status: RoHS Compliant
Moisture Sensitivity Level: 1 (Unlimited)

Allowable Variations:

Connector Type: Header variants (Header, Header Breakaway, Header Cuttable) are functionally equivalent
Contact Material: Phosphor Bronze and Copper Alloy are both acceptable
Insulation Material: Variations permitted (not specified in main part)
Contact Finish Thickness: Minor variations acceptable within industry standards
Operating Temperature Range: Substitute must meet or exceed the minimum and maximum of the main part
Packaging Format: Tube, Tape & Reel (TR), and Cut Tape (CT) & Digi-Reel® are interchangeable for component selection purposes
Features: Pick and Place, Board Guide, Board Lock, and Cuttable features do not affect electrical compatibility

Parameter Comparison

Parameter	54202-S0803ALF (Amphenol ICC)	5-146130-2 (TE Connectivity)	814-22-006-30-007101 (Mill-Max)	TSM-103-01-L-DV (Samtec)	TSM-103-01-L-DV-A (Samtec)	TSM-103-01-L-DV-LC (Samtec)	TSM-103-01-L-DV-P-TR (Samtec)	TSM-103-01-L-DV-TR (Samtec)	TSM-103-01-S-DV-A (Samtec)	TSM-103-01-S-DV-P-TR (Samtec)	TSM-103-01-S-DV-TR (Samtec)
Connector Type	Header	Header, Breakaway	Piston	Header, Cuttable	Header, Cuttable	Header, Cuttable	Header, Cuttable	Header, Cuttable	Header, Cuttable	Header, Cuttable	Header, Cuttable
Contact Type	Male Pin	Male Pin	Piston	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin
Number of Positions	6	6	6	6	6	6	6	6	6	6	6
Number of Rows	2	2	2	2	2	2	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)	0.100" (2.54mm)	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)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)
Mounting Type	Surface Mount	Surface Mount	Surface Mount	Surface Mount	Surface Mount	Surface Mount	Surface Mount	Surface Mount	Surface Mount	Surface Mount	Surface Mount
Termination	Solder	Solder	Solder	Solder	Solder	Solder	Solder	Solder	Solder	Solder	Solder
Contact Length - Mating	0.230" (5.84mm)	0.230" (5.84mm)	—	0.230" (5.84mm)	0.230" (5.84mm)	0.230" (5.84mm)	0.230" (5.84mm)	0.230" (5.84mm)	0.230" (5.84mm)	0.230" (5.84mm)	0.230" (5.84mm)
Insulation Height	0.100" (2.54mm)	0.090" (2.29mm)	—	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)
Contact Shape	Square	Square	—	Square	Square	Square	Square	Square	Square	Square	Square
Contact Material	Phosphor Bronze	Copper Alloy	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™	Gold	Gold	Gold	Gold	Gold	Gold	Gold	Gold	Gold	Gold
Current Rating	3A	3A	—	—	—	—	—	—	—	—	—
Operating Temperature	-65°C ~ 130°C	-65°C ~ 125°C	—	-55°C ~ 125°C	-55°C ~ 125°C	-55°C ~ 125°C	-55°C ~ 125°C	-55°C ~ 125°C	-55°C ~ 125°C	-55°C ~ 125°C	-55°C ~ 125°C
Material Flammability Rating	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0
RoHS Status	RoHS Compliant	RoHS Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant
Moisture Sensitivity Level	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)

Engineering Selection Recommendations

Primary Substitute - TE Connectivity 5-146130-2: This part is manufacturer-recommended and maintains full electrical compatibility with the 54202-S0803ALF. The AMPMODU Mod II series shares identical pitch, position count, and contact geometry. The insulation height variance of 0.010" (0.25mm) is within acceptable mechanical tolerance for standard board-to-board applications. Operating temperature range of -65°C to 125°C covers the critical lower temperature limit of the original specification. RoHS compliance and MSL 1 rating are equivalent. This part is actively manufactured with 13,464 units in stock.

Samtec TSM Series Substitutes (TSM-103-01-L-DV, TSM-103-01-L-DV-A, TSM-103-01-L-DV-LC, TSM-103-01-L-DV-P-TR, TSM-103-01-L-DV-TR, TSM-103-01-S-DV-A, TSM-103-01-S-DV-P-TR, TSM-103-01-S-DV-TR): All Samtec TSM-103 variants meet the mandatory electrical and mechanical parameters. These parts feature cuttable header design with optional board guide or board lock features. Contact finish thickness on mating surfaces is 10.0µin (0.25µm) for L-series and 30.0µin (0.76µm) for S-series variants, both acceptable for 3A current applications. Operating temperature range of -55°C to 125°C does not extend to the -65°C minimum of the original part; applications requiring operation below -55°C must use the original 54202-S0803ALF or TE Connectivity 5-146130-2. All TSM variants are actively manufactured with ROHS3 compliance. Packaging options include Tube, Tape & Reel (TR), and Cut Tape (CT) & Digi-Reel® formats to accommodate different manufacturing processes.

Mill-Max 814-22-006-30-007101: This part features a piston contact design rather than male pins, representing a different connector architecture. While it maintains the 6-position, 2-row, 0.100" pitch configuration, the piston contact type is not electrically equivalent to the male pin design of the 54202-S0803ALF. This part is discontinued at DiGi Electronics and should not be selected for new designs requiring direct substitution.

Frequently Asked Questions (FAQ)

Q: Can I use Samtec TSM-103 parts in applications requiring -65°C operation? A: No. Samtec TSM-103 variants are rated for -55°C to 125°C operation. The 54202-S0803ALF and TE Connectivity 5-146130-2 both support -65°C minimum temperature. For applications requiring -65°C operation, use only these two parts.

Q: What is the difference between TSM-103-01-L-DV and TSM-103-01-S-DV variants? A: The primary difference is contact finish thickness on the mating surface. L-series parts have 10.0µin (0.25µm) gold plating, while S-series parts have 30.0µin (0.76µm) gold plating. Both are electrically equivalent for standard 3A applications. S-series provides enhanced contact durability for high-cycle mating applications.

Q: Does the insulation height difference between 54202-S0803ALF (0.100") and 5-146130-2 (0.090") affect compatibility? A: The 0.010" (0.25mm) difference is within standard mechanical tolerance for board-to-board connector applications. Both parts maintain the same pitch and contact geometry, ensuring proper mating with standard 0.100" pitch receptacles. This variance does not affect electrical performance.

Q: What packaging formats are available for the substitute parts? A: The 54202-S0803ALF is supplied in Tape & Reel (TR) format. Samtec TSM-103 variants are available in Tube, Tape & Reel (TR), and Cut Tape (CT) & Digi-Reel® formats. TE Connectivity 5-146130-2 is supplied in Tube format. Select packaging based on manufacturing process requirements.

Q: Are all substitute parts RoHS compliant? A: Yes. The 54202-S0803ALF is RoHS Compliant. TE Connectivity 5-146130-2 is RoHS Compliant. All Samtec TSM-103 variants are ROHS3 Compliant. All parts meet RoHS requirements for new designs.

Q: What is the difference between cuttable and non-cuttable header designs? A: Samtec TSM-103 parts feature cuttable header design, allowing individual positions to be separated after assembly if required. The 54202-S0803ALF and 5-146130-2 are standard headers without this feature. Cuttability does not affect electrical performance and is an optional design feature for applications requiring modular connector configurations.

Q: Can I substitute the Mill-Max 814-22-006-30-007101 for the 54202-S0803ALF? A: No. The Mill-Max part uses piston contacts instead of male pins, representing a different connector type. Piston connectors are not electrically equivalent to male pin headers and require different mating receptacles. Additionally, this part is discontinued and should not be used for new designs.

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