Equivalent & Substitute Parts for 68016-204HTLF

Part Overview

The 68016-204HTLF is a rectangular connector header manufactured by Amphenol ICC (FCI) in the BERGSTIK® II series. This through-hole, right-angle connector features 4 positions at 0.100" (2.54mm) pitch with male pin contacts and push-pull fastening. The part is Active status and RoHS Compliant with MSL 1 rating, suitable for board-to-board applications requiring solder termination. Equivalent substitute parts are identified for applications where supply constraints, packaging preferences, or specific contact finish requirements necessitate alternative sourcing.

Key Parameters

Parameter	Value
Connector Type	Header
Contact Type	Male Pin
Pitch - Mating	0.100" (2.54mm)
Number of Positions	4
Number of Rows	1
Mounting Type	Through Hole, Right Angle
Termination	Solder
Fastening Type	Push-Pull
Contact Shape	Square
Shrouding	Unshrouded
Material Flammability Rating	UL94 V-0
Insulation Color	Black
Current Rating	3A
Operating Temperature	-65°C ~ 130°C
RoHS Status	RoHS Compliant
MSL Rating	1 (Unlimited)

Substitute Part Grouping Explanation

Substitution eligibility for the 68016-204HTLF is determined by strict equivalence across the following critical parameters:

Mandatory Matching Parameters:

Pitch - Mating: 0.100" (2.54mm)
Number of Positions: 4
Number of Rows: 1
Connector Type: Header
Contact Type: Male Pin
Mounting Type: Through Hole, Right Angle
Termination: Solder
Fastening Type: Push-Pull
Contact Shape: Square
Shrouding: Unshrouded
Material Flammability Rating: UL94 V-0
Insulation Color: Black
Current Rating: 3A (per contact or overall)
MSL Rating: 1 (Unlimited)

All three substitute parts (0022288040, M20-9750446, M20-9960445) meet these mandatory criteria. Variations in contact finish (Gold vs. Tin), contact material (Phosphor Bronze vs. Brass), insulation material composition, and operating temperature ranges represent allowable substitution parameters within the rectangular connector category for this pitch and position configuration.

Parameter Comparison

Parameter	68016-204HTLF (Main)	0022288040 (Molex)	M20-9750446 (Harwin)	M20-9960445 (Harwin)
Manufacturer	Amphenol ICC (FCI)	Molex	Harwin Inc.	Harwin Inc.
Series	BERGSTIK® II	KK254, 42377	M20	M20
Connector Type	Header	Header, Breakaway	Header, Cuttable	Header, Cuttable
Contact Type	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)
Number of Positions	4	4	4	4
Number of Rows	1	1	1	1
Mounting Type	Through Hole, Right Angle	Through Hole, Right Angle	Through Hole, Right Angle	Through Hole, Right Angle
Termination	Solder	Solder	Solder	Solder
Fastening Type	Push-Pull	Push-Pull	Push-Pull	Push-Pull
Contact Shape	Square	Square	Square	Square
Shrouding	Unshrouded	Unshrouded	Unshrouded	Unshrouded
Contact Length - Mating	0.230" (5.84mm)	0.244" (6.20mm)	0.228" (5.80mm)	0.240" (6.10mm)
Contact Length - Post	0.120" (3.05mm)	0.120" (3.05mm)	0.118" (3.00mm)	0.118" (3.00mm)
Insulation Height	0.095" (2.41mm)	0.098" (2.50mm)	0.100" (2.54mm)	0.100" (2.54mm)
Contact Finish - Mating	Gold or Gold, GXT™	Tin	Tin	Gold
Contact Material	Phosphor Bronze	Not specified	Brass	Brass
Insulation Material	Not specified	Polyamide (PA), Nylon, Glass Filled	Polyamide (PA6T), Nylon 6T	Polyamide (PA6T), Nylon 6T
Material Flammability Rating	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0
Insulation Color	Black	Black	Black	Black
Current Rating	3A	Not specified	3A per Contact	3A per Contact
Operating Temperature	-65°C ~ 130°C	Not specified	-40°C ~ 105°C	-40°C ~ 105°C
RoHS Status	RoHS Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant
MSL Rating	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)
Packaging	Tube	Bulk	Bulk	Bulk
Inventory Status	745 Pcs New Original In Stock	1897 Pcs New Original In Stock	11898 Pcs New Original In Stock	10729 Pcs New Original In Stock

Engineering Selection Recommendations

All three substitute parts are Active status components with full RoHS3 compliance and MSL 1 rating, meeting the regulatory and environmental requirements of the 68016-204HTLF.

0022288040 (Molex KK254, 42377 Series): This substitute features tin contact finish with glass-filled polyamide insulation. Contact length dimensions vary slightly (0.244" mating vs. 0.230" on main part). Suitable for applications where tin finish is acceptable and breakaway connector functionality is beneficial. Current rating not specified in available data.

M20-9750446 (Harwin M20 Series, Tin Finish): This substitute provides tin-plated brass contacts with PA6T nylon insulation. Operating temperature range is -40°C ~ 105°C, which is narrower than the main part's -65°C ~ 130°C range. Contact dimensions are within 0.002" of the main part. Explicitly rated at 3A per contact. Suitable for standard industrial temperature applications.

M20-9960445 (Harwin M20 Series, Gold Finish): This substitute features gold-plated brass contacts with PA6T nylon insulation, matching the gold finish specification of the main part. Operating temperature range is -40°C ~ 105°C. Contact length is 0.240" (mating), closest to the main part's 0.230". Explicitly rated at 3A per contact. Recommended for applications requiring gold contact finish compatibility with the original specification.

Selection between substitutes depends on contact finish requirements, operating temperature range, and packaging format. The Harwin M20-9960445 provides the closest electrical and material alignment with the original 68016-204HTLF specification.

Frequently Asked Questions (FAQ)

Q: Can 0022288040 be used as a direct replacement for 68016-204HTLF?

A: The 0022288040 meets all mandatory substitution criteria: 4-position, 2.54mm pitch, through-hole right-angle header with solder termination and push-pull fastening. Differences include tin contact finish (vs. gold on main part), glass-filled polyamide insulation, and slightly longer mating contact length (0.244" vs. 0.230"). Current rating is not specified. Substitution is valid where tin finish is acceptable and current requirements are confirmed.

Q: What is the difference between M20-9750446 and M20-9960445?

A: Both are Harwin M20 series headers with identical mechanical and electrical specifications except for contact finish. M20-9750446 features tin plating; M20-9960445 features gold plating. Both are rated 3A per contact and operate from -40°C to 105°C. Selection depends on whether gold or tin contact finish is required for your application.

Q: Does the operating temperature range difference affect substitution?

A: The main part 68016-204HTLF operates from -65°C to 130°C. Both Harwin substitutes (M20-9750446 and M20-9960445) operate from -40°C to 105°C. If your application requires operation below -40°C or above 105°C, these Harwin parts are not suitable. The Molex 0022288040 operating temperature is not specified in available data.

Q: Are all substitutes RoHS compliant?

A: Yes. The main part is RoHS Compliant. All three substitutes are ROHS3 Compliant, meeting current RoHS Directive requirements. All parts carry MSL 1 (Unlimited) moisture sensitivity rating.

Q: What packaging formats are available?

A: The main part 68016-204HTLF is supplied in Tube packaging. All three substitutes are supplied in Bulk packaging. If tube packaging is required for your assembly process, confirm packaging availability with your supplier.

Q: Can contact length variations affect board layout?

A: Contact length variations are minor (0.228" to 0.244" mating length vs. 0.230" on main part). These differences are within typical PCB design tolerances for through-hole connectors. Verify mating depth requirements in your specific application. Insulation height also varies slightly (0.095" to 0.100"), which may affect clearance in confined spaces.

Q: Which substitute offers the best inventory availability?

A: Harwin M20-9960445 has the highest inventory (10,729 pcs), followed by M20-9750446 (11,898 pcs) and Molex 0022288040 (1,897 pcs). The main part 68016-204HTLF has 745 pcs available. Inventory levels should be confirmed with your supplier for current availability.

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