Equivalent & Substitute Parts for 54202-S08-04

Part Overview

The Amphenol ICC 54202-S08-04 is a rectangular connector header, surface mount type, with 8 positions arranged in 2 rows at 0.100" (2.54mm) pitch. This component is classified as obsolete, making equivalent substitute parts necessary for new designs and ongoing production requirements. The BERGSTIK® series connector provides board-to-board connectivity with solder termination and push-pull fastening.

Key Parameters

Parameter	Value
Connector Type	Header
Contact Type	Male Pin
Pitch - Mating	0.100" (2.54mm)
Number of Positions	8
Number of Rows	2
Row Spacing - Mating	0.100" (2.54mm)
Mounting Type	Surface Mount
Termination	Solder
Fastening Type	Push-Pull
Contact Shape	Square
Material Flammability Rating	UL94 V-0
Current Rating	3A
Operating Temperature	-65°C ~ 130°C
Moisture Sensitivity Level	1 (Unlimited)

Substitute Part Grouping Explanation

Substitute parts for the 54202-S08-04 are qualified based on the following critical parameters that determine functional compatibility:

Pitch and Position Configuration: All substitutes maintain 0.100" (2.54mm) mating pitch with 8 positions in 2 rows at 0.100" row spacing
Connector Type and Contact Type: All substitutes are male pin headers suitable for board-to-board or cable connections
Mounting and Termination: All substitutes use surface mount technology with solder termination and push-pull fastening
Contact Geometry: All substitutes feature square contact shapes with mating contact lengths within 0.228" to 0.240" (5.80mm to 6.10mm)
Electrical and Environmental Ratings: All substitutes meet UL94 V-0 flammability requirements and operate within overlapping temperature ranges
Compliance Status: Substitute parts are selected from active product status manufacturers with RoHS3 compliance

The following four manufacturers provide qualified substitutes: Molex (0015911088), TE Connectivity (5-147292-6), Sullins Connector Solutions (GBC04DABN-M30), and Harwin Inc. (M20-8760442).

Parameter Comparison

Parameter	54202-S08-04 (Amphenol ICC)	0015911088 (Molex)	5-147292-6 (TE Connectivity)	GBC04DABN-M30 (Sullins)	M20-8760442 (Harwin)
Connector Type	Header	Header, Breakaway	Header, Breakaway	Header, Breakaway	Header, Cuttable
Contact Type	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin
Pitch - Mating	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)
Number of Positions	8	8	8	8	8
Number of Rows	2	2	2	2	2
Row Spacing - Mating	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
Termination	Solder	Solder	Solder	Solder	Solder
Fastening Type	Push-Pull	Push-Pull	Push-Pull	Push-Pull	Push-Pull
Contact Length - Mating	0.230" (5.84mm)	0.240" (6.10mm)	0.230" (5.84mm)	0.230" (5.84mm)	0.228" (5.80mm)
Insulation Height	0.100" (2.54mm)	0.090" (2.29mm)	0.090" (2.29mm)	0.100" (2.54mm)	0.100" (2.54mm)
Contact Shape	Square	Square	Square	Square	Square
Contact Finish - Mating	Gold or Gold, GXT™	Gold	Tin	Gold	Gold
Contact Material	Phosphor Bronze	Copper Alloy	Copper Alloy	Phosphor Bronze	Brass
Material Flammability Rating	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0
Current Rating	3A	Not specified	Not specified	3A	3A per Contact
Operating Temperature	-65°C ~ 130°C	Not specified	-65°C ~ 105°C	-65°C ~ 150°C	-40°C ~ 105°C
Voltage Rating	Not specified	Not specified	30VAC	Not specified	250V
RoHS Status	RoHS non-compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant
Product Status	Obsolete	Active	Active	Active	Active
Moisture Sensitivity Level	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)

Engineering Selection Recommendations

All four substitute parts meet the core functional requirements for replacing the obsolete 54202-S08-04. Selection should be based on the following criteria:

Molex 0015911088: Active product status with ROHS3 compliance. Insulation height of 0.090" (2.29mm) differs from the original 0.100" (2.54mm). Suitable for applications where reduced profile is acceptable. Packaged in tube format.

TE Connectivity 5-147292-6: Active product status with ROHS3 compliance. Operating temperature range limited to -65°C ~ 105°C, which is narrower than the original -65°C ~ 130°C. Rated for 30VAC. Packaged in tape and reel format. Contact finish is tin rather than gold.

Sullins Connector Solutions GBC04DABN-M30: Active product status with ROHS3 compliance. Operating temperature range extends to -65°C ~ 150°C, exceeding the original specification. Maintains 0.100" (2.54mm) insulation height matching the original. Current rating of 3A matches the original. Packaged in bulk format.

Harwin Inc. M20-8760442: Active product status with ROHS3 compliance. Operating temperature range of -40°C ~ 105°C is narrower than the original. Rated for 250V. Current rating of 3A per contact matches the original. Cuttable connector type provides design flexibility. Packaged in bulk format.

Frequently Asked Questions (FAQ)

Q: Can I use any of these substitutes as a direct replacement for the 54202-S08-04?

A: All four substitutes share the critical parameters that determine functional compatibility: 0.100" (2.54mm) pitch, 8 positions in 2 rows, surface mount solder termination, and push-pull fastening. However, verify that your application's specific requirements for operating temperature, voltage rating, and insulation height are met by the selected substitute.

Q: What is the difference between the insulation heights of 0.090" and 0.100"?

A: Insulation height affects the overall profile of the connector when mounted. The Molex 0015911088 and TE Connectivity 5-147292-6 have reduced insulation height at 0.090" (2.29mm), while the original, Sullins, and Harwin parts maintain 0.100" (2.54mm). This difference may impact PCB layout and mating connector compatibility.

Q: Why do some substitutes have different contact finish materials?

A: Contact finish affects electrical performance and corrosion resistance. The original uses gold or gold GXT™ finish. The TE Connectivity 5-147292-6 uses tin finish, which is suitable for general applications but may differ in long-term reliability characteristics. Gold-finished substitutes (Molex, Sullins, Harwin) provide closer performance alignment with the original.

Q: What does "breakaway" or "cuttable" connector type mean?

A: Breakaway connectors allow individual positions to be separated after assembly, providing design flexibility. Cuttable connectors (Harwin M20-8760442) can be cut to reduce the number of positions. The original 54202-S08-04 is a standard header without these features.

Q: Are all substitutes RoHS3 compliant?

A: Yes. All four substitute parts are ROHS3 compliant, whereas the original 54202-S08-04 is RoHS non-compliant. This is a significant advantage for new designs subject to RoHS regulations.

Q: Which substitute has the widest operating temperature range?

A: The Sullins Connector Solutions GBC04DABN-M30 operates from -65°C to 150°C, exceeding the original specification of -65°C to 130°C. The Harwin M20-8760442 has the narrowest range at -40°C to 105°C.

Q: What packaging formats are available?

A: Molex 0015911088 is supplied in tube format. TE Connectivity 5-147292-6 is supplied in tape and reel format. Sullins GBC04DABN-M30 and Harwin M20-8760442 are supplied in bulk format. Select based on your assembly process requirements.

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