TE Connectivity 641202-5 Equivalent & Substitute Parts

Part Overview

The TE Connectivity AMP Connectors 641202-5 is a rectangular connector header designed for through-hole mounting applications. This connector features a 5-position configuration with 0.156" (3.96mm) pitch spacing, suitable for board-to-cable and board-to-board interconnections in general purpose and industrial applications. The part operates across a temperature range of -55°C to 105°C with a 600VAC voltage rating.

The 641202-5 is classified as obsolete. Equivalent and substitute parts are available from TE Connectivity and Samtec Inc. that maintain electrical and mechanical compatibility while offering active product status and improved compliance certifications.

Key Parameters

Parameter	Specification
Connector Type	Header
Contact Type	Male Pin
Number of Positions	5
Pitch - Mating	0.156" (3.96mm)
Mounting Type	Through Hole
Termination	Solder
Operating Temperature Range	-55°C ~ 105°C
Voltage Rating	600VAC
Material Flammability Rating	UL94 V-0
Moisture Sensitivity Level	1 (Unlimited)

Substitute Part Grouping Explanation

Substitution of the 641202-5 is determined by the following critical parameters:

Primary Compatibility Criteria:

Number of Positions: 5
Pitch - Mating: 0.156" (3.96mm)
Connector Type: Header
Contact Type: Male Pin
Mounting Type: Through Hole
Termination: Solder
Operating Temperature Range: -55°C ~ 105°C
Material Flammability Rating: UL94 V-0

Substitute parts are grouped into two categories:

Category 1: Direct TE Connectivity Equivalent The part 3-641202-5 is a direct equivalent from TE Connectivity AMP Connectors, maintaining identical electrical and mechanical specifications while offering active product status and RoHS compliance.

Category 2: Samtec Inc. Alternatives Samtec Inc. provides multiple substitute options across three product series (FWJ, HFWJ, and JW). These parts maintain the core compatibility parameters (5 positions, 0.156" pitch, through-hole solder termination, UL94 V-0 rating, and -55°C to 105°C operating temperature). Variations exist in contact length, insulation material, fastening type, and contact finish specifications.

Parameter Comparison

Parameter	641202-5	3-641202-5	FWJ-05-01-T-S	FWJ-05-02-T-S	HFWJ-05-01-T-S	HFWJ-05-02-T-S
Manufacturer	TE Connectivity	TE Connectivity	Samtec Inc.	Samtec Inc.	Samtec Inc.	Samtec Inc.
Product Status	Obsolete	Active	Active	Active	Active	Active
Number of Positions	5	5	5	5	5	5
Pitch - Mating	0.156" (3.96mm)	0.156" (3.96mm)	0.156" (3.96mm)	0.156" (3.96mm)	0.156" (3.96mm)	0.156" (3.96mm)
Connector Type	Header	Header	Header	Header	Header	Header
Contact Type	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin
Mounting Type	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole
Termination	Solder	Solder	Solder	Solder	Solder	Solder
Operating Temperature	-55°C ~ 105°C	-55°C ~ 105°C	-55°C ~ 105°C	-55°C ~ 105°C	-55°C ~ 105°C	-55°C ~ 105°C
Material Flammability Rating	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0
Contact Length - Mating	0.400" (10.16mm)	0.400" (10.16mm)	0.450" (11.43mm)	0.500" (12.70mm)	0.450" (11.43mm)	0.500" (12.70mm)
Contact Length - Post	0.125" (3.18mm)	0.125" (3.18mm)	0.175" (4.45mm)	0.175" (4.45mm)	0.175" (4.45mm)	0.175" (4.45mm)
Overall Contact Length	0.650" (16.51mm)	0.650" (16.51mm)	0.750" (19.05mm)	0.800" (20.32mm)	0.750" (19.05mm)	0.800" (20.32mm)
Insulation Height	0.125" (3.18mm)	0.125" (3.18mm)	0.125" (3.18mm)	0.125" (3.18mm)	0.125" (3.18mm)	0.125" (3.18mm)
Contact Shape	Square	Square	Square	Square	Square	Square
Contact Finish - Mating	Gold	Gold	Tin	Tin	Tin	Tin
Contact Material	Copper Alloy	Copper Alloy	Phosphor Bronze	Phosphor Bronze	Phosphor Bronze	Phosphor Bronze
Insulation Material	Thermoplastic	Thermoplastic	Polybutylene Terephthalate (PBT)	Polybutylene Terephthalate (PBT)	Liquid Crystal Polymer (LCP)	Liquid Crystal Polymer (LCP)
RoHS Status	Non-compliant	Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant
Voltage Rating	600VAC	600VAC	600VAC, 845VDC	600VAC, 845VDC	Not specified	Not specified

Engineering Selection Recommendations

Direct Replacement - TE Connectivity 3-641202-5

The 3-641202-5 is the recommended direct substitute for the obsolete 641202-5. This part maintains identical electrical and mechanical specifications, including contact dimensions, pitch, number of positions, and operating temperature range. The 3-641202-5 offers active product status and RoHS compliance, addressing supply chain continuity and regulatory requirements. Inventory availability is confirmed at 1025 pieces.

Alternative Substitutes - Samtec Inc. Series

Samtec Inc. provides multiple substitute options that maintain core compatibility parameters. Selection among these alternatives depends on specific application requirements:

FWJ Series (FWJ-05-01-T-S, FWJ-05-02-T-S): These parts feature increased contact length (0.450" to 0.500" mating length) compared to the original 641202-5 (0.400" mating length). The FWJ series uses Phosphor Bronze contacts with tin finish and PBT insulation material. Both parts are ROHS3 compliant and rated for 600VAC and 845VDC operation. The FWJ-05-01-T-S and FWJ-05-02-T-S differ in mating contact length and overall contact length.

HFWJ Series (HFWJ-05-01-T-S, HFWJ-05-02-T-S): These high-temperature variants feature Liquid Crystal Polymer (LCP) insulation material and are rated at 6.7A per contact. Contact dimensions match the FWJ series. HFWJ parts are ROHS3 compliant. Voltage rating is not specified for this series.

JW Series (JW-05-04-T-S variants): These flexible stack connectors are available in multiple stack height configurations (0.390", 0.430", 0.440", 0.450"). The JW series is designed for applications requiring flexible stacking and features tin contact finish. All JW variants are ROHS3 compliant.

Compliance Considerations:

The original 641202-5 is RoHS non-compliant. All substitute parts listed (3-641202-5, FWJ series, HFWJ series, and JW series) are RoHS compliant or ROHS3 compliant, supporting regulatory compliance requirements for new designs and procurement.

Frequently Asked Questions (FAQ)

Q: Can the 3-641202-5 be used as a direct replacement for the 641202-5?

A: Yes. The 3-641202-5 maintains identical electrical and mechanical specifications to the 641202-5, including 5-position configuration, 0.156" pitch, contact dimensions, operating temperature range, and voltage rating. The primary differences are active product status and RoHS compliance.

Q: What are the key differences between TE Connectivity and Samtec substitute options?

A: The TE Connectivity 3-641202-5 provides a direct equivalent with identical contact dimensions and specifications. Samtec alternatives (FWJ, HFWJ, and JW series) maintain the core compatibility parameters (5 positions, 0.156" pitch, through-hole solder termination) but feature variations in contact length, insulation material, and fastening type. Samtec parts generally have longer overall contact lengths and different contact materials (Phosphor Bronze vs. Copper Alloy).

Q: Are Samtec FWJ and HFWJ parts interchangeable with the 641202-5?

A: FWJ and HFWJ parts share the same 5-position, 0.156" pitch configuration and are mechanically compatible for through-hole mounting. However, they feature increased contact lengths (0.450" to 0.500" mating length versus 0.400" for the original). This difference may affect board layout and mating depth. Electrical compatibility is maintained across the operating temperature range and voltage specifications.

Q: What is the difference between FWJ-05-01-T-S and FWJ-05-02-T-S?

A: Both parts are identical except for contact length. FWJ-05-01-T-S features 0.450" mating contact length and 0.750" overall contact length. FWJ-05-02-T-S features 0.500" mating contact length and 0.800" overall contact length. Selection depends on application-specific mating depth requirements.

Q: What is the difference between FWJ and HFWJ series?

A: The primary difference is insulation material. FWJ series uses Polybutylene Terephthalate (PBT), while HFWJ series uses Liquid Crystal Polymer (LCP). HFWJ parts are rated at 6.7A per contact. Both series maintain the same pitch, number of positions, and operating temperature range. HFWJ is designated as high-temperature variant based on insulation material properties.

Q: What are JW series connectors used for?

A: JW series connectors are flexible stack headers available in multiple stack height configurations. These parts are designed for applications requiring flexible stacking arrangements. The JW variants differ in stack height (0.390", 0.430", 0.440", 0.450") while maintaining the same 5-position, 0.156" pitch configuration.

Q: Are all substitute parts RoHS compliant?

A: The original 641202-5 is RoHS non-compliant. The TE Connectivity 3-641202-5 is RoHS compliant. All Samtec alternatives (FWJ, HFWJ, and JW series) are ROHS3 compliant, meeting current regulatory requirements.

Q: What is the voltage rating difference between substitute parts?

A: The original 641202-5 is rated for 600VAC. The TE Connectivity 3-641202-5 maintains this 600VAC rating. Samtec FWJ and HFWJ series are rated for both 600VAC and 845VDC. HFWJ series voltage rating is not specified in available documentation. JW series voltage rating is not specified.

Q: Can contact finish differences affect compatibility?

A: Contact finish differences (gold versus tin) do not affect electrical compatibility within the specified operating parameters. The original 641202-5 features gold-plated mating contacts with tin-lead post finish. Samtec alternatives feature tin finish on both mating and post contacts. Material selection should be based on application-specific corrosion resistance and environmental requirements.

Q: What packaging options are available?

A: The original 641202-5 packaging is not specified. The TE Connectivity 3-641202-5 is available in bulk packaging. All Samtec alternatives (FWJ, HFWJ, and JW series) are available in bulk packaging.

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