Amphenol ICC 68494-436 Equivalent & Substitute Parts

Part Overview

The Amphenol ICC 68494-436 is a rectangular connector header, right-angle configuration, with 36 positions at 0.100" (2.54mm) pitch. This through-hole, board-to-board connector features male pins with tin contact finish and is part of the BERGSTIK® II series. The part is currently obsolete, making equivalent substitutes necessary for new designs and ongoing production support. Molex KK254 series connectors provide direct functional equivalents with active product status and improved compliance certifications.

Key Parameters

Parameter	Value
Connector Type	Header
Contact Type	Male Pin
Pitch - Mating	0.100" (2.54mm)
Number of Positions	36
Number of Rows	1
Mounting Type	Through Hole, Right Angle
Termination	Solder
Fastening Type	Push-Pull
Contact Shape	Square
Contact Finish - Mating	Tin or Gold
Insulation Material	Polyamide (PA), Nylon, Glass Filled
Material Flammability Rating	UL94 V-0
Insulation Color	Black
RoHS Status	ROHS3 Compliant (substitutes)
Moisture Sensitivity Level (MSL)	1 (Unlimited)

Substitute Part Grouping Explanation

Substitution eligibility for the 68494-436 is determined by strict alignment with the following core parameters:

Connector type: Header with male pins
Pitch: 0.100" (2.54mm)
Position count: 36 positions, single row
Mounting: Through hole, right angle
Termination: Solder
Fastening: Push-pull mechanism
Contact shape: Square
Flammability: UL94 V-0
Insulation color: Black

All qualified substitutes maintain these parameters. Variations in contact finish (tin vs. gold), contact length dimensions, and post length are permitted within the connector family. The Molex KK254 series (part numbers 0022288361, 0022288363, 0022288365, 0022289361, 0022289363, 0423770962) meets all substitution criteria and offers active product status with ROHS3 compliance.

Parameter Comparison

Parameter	68494-436 (Main)	0022288361	0022288363	0022288365	0022289361	0022289363	0423770962
Manufacturer	Amphenol ICC	Molex	Molex	Molex	Molex	Molex	Molex
Series	BERGSTIK® II	KK254, 42377	KK254, 42377	KK254, 42377	KK254, 42377	KK254, 42377	KK254, 42377
Product Status	Obsolete	Active	Active	Active	Active	Active	Active
Connector Type	Header	Header, Breakaway	Header, Breakaway	Header, Breakaway	Header, Breakaway	Header, Breakaway	Header, Breakaway
Contact Type	Male Pin	Male Pin	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)	0.100" (2.54mm)	0.100" (2.54mm)
Number of Positions	36	36	36	36	36	36	36
Number of Rows	1	1	1	1	1	1	1
Mounting Type	Through Hole, Right Angle	Through Hole, Right Angle	Through Hole, Right Angle	Through Hole, Right Angle	Through Hole, Right Angle	Through Hole, Right Angle	Through Hole, Right Angle
Termination	Solder	Solder	Solder	Solder	Kinked Pin, Solder	Kinked Pin, Solder	Solder
Fastening Type	Push-Pull	Push-Pull	Push-Pull	Push-Pull	Push-Pull	Push-Pull	Push-Pull
Contact Length - Mating	0.400" (10.16mm)	0.324" (8.23mm)	0.324" (8.23mm)	0.324" (8.23mm)	0.324" (8.23mm)	0.324" (8.23mm)	0.317" (8.05mm)
Contact Length - Post	0.110" (2.79mm)	0.120" (3.05mm)	0.120" (3.05mm)	0.120" (3.05mm)	0.135" (3.43mm)	0.135" (3.43mm)	0.290" (7.37mm)
Insulation Height	0.095" (2.41mm)	0.098" (2.50mm)	0.098" (2.50mm)	0.098" (2.50mm)	0.098" (2.50mm)	0.098" (2.50mm)	0.098" (2.50mm)
Contact Shape	Square	Square	Square	Square	Square	Square	Square
Contact Finish - Mating	Tin	Tin	Gold	Gold	Tin	Gold	Gold
Contact Finish Thickness - Mating	100.0µin (2.54µm)	100.0µin (2.54µm)	15.0µin (0.38µm)	30.0µin (0.76µm)	100.0µin (2.54µm)	15.0µin (0.38µm)	15.0µin (0.38µm)
Contact Finish - Post	Not specified	Tin	Tin	Tin	Tin	Tin	Tin
Insulation Material	Not specified	Polyamide (PA), Nylon, Glass Filled	Polyamide (PA), Nylon, Glass Filled	Polyamide (PA), Nylon, Glass Filled	Polyamide (PA), Nylon, Glass Filled	Polyamide (PA), Nylon, Glass Filled	Polyamide (PA), Nylon, Glass Filled
Material Flammability Rating	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0
Insulation Color	Black	Black	Black	Black	Black	Black	Black
RoHS Status	RoHS non-compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant
Moisture Sensitivity Level (MSL)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)

Engineering Selection Recommendations

All Molex KK254 series substitutes (0022288361, 0022288363, 0022288365, 0022289361, 0022289363, 0423770962) are qualified replacements for the obsolete 68494-436. Selection among these substitutes depends on specific application requirements:

For tin contact finish applications: Select 0022288361 or 0022289361. Part 0022289361 features kinked pin termination and extended post length (0.135"), suitable for applications requiring additional mechanical support during soldering.

For gold contact finish applications: Select 0022288363, 0022288365, 0022289363, or 0423770962. Parts 0022288363 and 0022288365 differ only in gold plating thickness (15.0µin vs. 30.0µin). Part 0022289363 combines gold finish with kinked pin termination and extended post length. Part 0423770962 features the longest post length (0.290") and thinnest gold plating (15.0µin).

All substitutes carry ROHS3 compliance, addressing the non-compliant status of the original part. All maintain UL94 V-0 flammability rating, MSL 1 classification, and push-pull fastening. Contact length variations are within acceptable ranges for standard PCB applications.

Frequently Asked Questions (FAQ)

Q: Can I use any of these Molex substitutes interchangeably with the 68494-436?

A: All seven Molex KK254 series parts meet the core substitution criteria: 36-position, 0.100" pitch, right-angle through-hole header with male pins and push-pull fastening. However, contact finish and post length differ. Verify your application's contact finish requirement (tin or gold) and PCB thickness tolerance before selection.

Q: What is the difference between parts with kinked pin termination (0022289361, 0022289363) and standard solder termination?

A: Kinked pin termination provides additional mechanical retention during soldering and is suitable for applications with thicker PCBs or where enhanced mechanical support is required. Standard solder termination is appropriate for standard PCB thicknesses. Both termination types are functionally equivalent for electrical performance.

Q: Why do some substitutes have different contact lengths?

A: Contact length variations accommodate different PCB thicknesses and application geometries. The original 68494-436 specifies 0.400" mating contact length, while Molex substitutes range from 0.317" to 0.324". These variations remain within acceptable tolerance for standard board-to-board applications. Confirm your PCB thickness and mating connector depth before final selection.

Q: What is the significance of gold plating thickness differences (15.0µin vs. 30.0µin)?

A: Gold plating thickness affects contact durability and corrosion resistance. Thicker plating (30.0µin, part 0022288365) provides enhanced protection in harsh environments or high-cycle mating applications. Standard plating (15.0µin) is suitable for general-purpose applications with moderate environmental exposure.

Q: Are all substitutes RoHS compliant?

A: Yes. All Molex KK254 series substitutes are ROHS3 compliant, addressing the non-compliant status of the original 68494-436. This compliance is mandatory for new designs and production in regulated markets.

Q: What inventory levels are available for these substitutes?

A: Current stock levels range from 785 to 2,828 pieces across the substitute parts. Part 0022288363 maintains the highest inventory (2,828 pcs), followed by 0022289363 (984 pcs) and 0022289361 (891 pcs). Verify current availability with your supplier for production requirements.

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