Amphenol ICC 69192-540 Equivalent & Substitute Parts

Part Overview

The Amphenol ICC 69192-540 is a rectangular connector header featuring 40 positions arranged in 2 rows with 0.100" (2.54mm) pitch spacing. This through-hole component is part of the BERGSTIK® II series and is designed for board-to-board applications. The part is currently active in production with 1015 units in stock. Equivalent and substitute parts are necessary when the original part becomes unavailable, when alternative compliance certifications are required, or when design modifications necessitate different contact finishes or insulation materials.

Key Parameters

Parameter	Value
Connector Type	Header
Contact Type	Male Pin
Number of Positions	40
Number of Rows	2
Pitch - Mating	0.100" (2.54mm)
Row Spacing - Mating	0.100" (2.54mm)
Mounting Type	Through Hole
Termination	Kinked Pin, Solder
Contact Length - Mating	0.230" (5.84mm)
Contact Length - Post	0.120" (3.05mm)
Overall Contact Length	0.450" (11.43mm)
Insulation Height	0.100" (2.54mm)
Contact Shape	Square
Contact Material	Phosphor Bronze
Material Flammability Rating	UL94 V-0
Insulation Color	Black
RoHS Status	RoHS non-compliant
Moisture Sensitivity Level (MSL)	1 (Unlimited)

Substitute Part Grouping Explanation

Substitution eligibility for the 69192-540 is determined by strict alignment with the following critical parameters:

Primary Matching Criteria:

40 positions in 2-row configuration
0.100" (2.54mm) mating pitch and row spacing
Male pin contact type
Through-hole mounting
Solder termination
Square contact shape
UL94 V-0 flammability rating
Black insulation color
MSL 1 rating

Secondary Compatibility Factors:

Contact length specifications (mating and post dimensions)
Overall contact length tolerance
Insulation height
Contact material composition
Contact finish type and thickness

Substitute parts are grouped based on whether they maintain these core electrical and mechanical parameters. Variations in contact finish (gold vs. tin), contact material (phosphor bronze vs. copper alloy vs. brass), insulation material (thermoplastic vs. LCP vs. PBT), and product status (active vs. obsolete) are documented but do not disqualify substitution when other parameters align.

Parameter Comparison

Parameter	69192-540 (Main)	1-104350-7	7-146256-0	7-146261-0	M20-9762046	TD-120-G-AA	TSW-120-07-G-D	TSW-120-07-S-D	TSW-120-07-T-D	TSW-120-08-G-D	TSW-120-08-L-D
Manufacturer	Amphenol ICC	TE Connectivity	TE Connectivity	TE Connectivity	Harwin Inc.	Samtec Inc.	Samtec Inc.	Samtec Inc.	Samtec Inc.	Samtec Inc.	Samtec Inc.
Number of Positions	40	40	40	40	40	40	40	40	40	40	40
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)
Contact Type	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin	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	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole
Termination	Kinked Pin, Solder	Press-Fit, 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)	0.228" (5.80mm)	—	0.230" (5.84mm)	0.230" (5.84mm)	0.230" (5.84mm)	0.230" (5.84mm)	0.230" (5.84mm)
Contact Length - Post	0.120" (3.05mm)	0.120" (3.05mm)	0.120" (3.05mm)	0.090" (2.29mm)	0.122" (3.10mm)	—	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.200" (5.08mm)	0.200" (5.08mm)
Overall Contact Length	0.450" (11.43mm)	0.440" (11.18mm)	0.440" (11.18mm)	0.410" (10.41mm)	0.452" (11.48mm)	—	0.430" (10.92mm)	0.430" (10.92mm)	0.430" (10.92mm)	0.530" (13.46mm)	0.530" (13.46mm)
Insulation Height	0.100" (2.54mm)	0.090" (2.29mm)	0.090" (2.29mm)	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)
Contact Shape	Square	Square	Square	Square	Square	—	Square	Square	Square	Square	Square
Contact Material	Phosphor Bronze	Copper Alloy	Copper Alloy	Copper Alloy	Brass	—	Phosphor Bronze	Phosphor Bronze	Phosphor Bronze	Phosphor Bronze	Phosphor Bronze
Contact Finish - Mating	Gold or Gold, GXT™	Gold	Gold	Gold	Tin	Gold	Gold	Gold	Tin	Gold	Gold
Contact Finish Thickness - Mating	15.0µin (0.38µm)	30.0µin (0.76µm)	15.0µin (0.38µm)	30.0µin (0.76µm)	—	20.0µin (0.51µm)	10.0µin (0.25µm)	30.0µin (0.76µm)	—	10.0µin (0.25µm)	10.0µin (0.25µm)
Contact Finish - Post	—	Tin-Lead	Tin	Tin	Tin	—	Gold	Tin	Tin	Gold	Tin
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
Insulation Color	Black	Black	Black	Black	Black	Black	Black	Black	Black	Black	Black
Product Status	Active	Obsolete	Active	Active	Active	Active	Active	Active	Active	Active	Active
RoHS Status	RoHS non-compliant	RoHS non-compliant	RoHS Compliant	ROHS3 Compliant	ROHS3 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)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)

Engineering Selection Recommendations

Primary Substitutes (Active Status, RoHS3 Compliant):

The TE Connectivity 7-146256-0 and 7-146261-0, along with Samtec TSW series parts (TSW-120-07-G-D, TSW-120-07-S-D, TSW-120-07-T-D, TSW-120-08-G-D, TSW-120-08-L-D), and Harwin M20-9762046 are all active production parts with ROHS3 compliance. These represent the most current alternatives when RoHS3 certification is required for new designs or when the original 69192-540 becomes unavailable.

Secondary Substitute (Active Status, RoHS Compliant):

The TE Connectivity 7-146256-0 offers RoHS compliance (non-ROHS3) and maintains active production status, making it suitable for applications where RoHS compliance is necessary but ROHS3 is not mandated.

Legacy Substitute (Obsolete Status):

The TE Connectivity 1-104350-7 is obsolete and should only be selected if existing inventory is available and design constraints prevent use of active alternatives. This part carries RoHS non-compliant status.

Contact Length Considerations:

Parts with differing contact post lengths (TSW-120-08-G-D and TSW-120-08-L-D at 0.200" versus the main part at 0.120") and TE Connectivity 7-146261-0 at 0.090" require PCB design verification to ensure proper mating depth and mechanical clearance.

Compliance Path:

For designs requiring RoHS3 compliance, select from the Samtec TSW series or Harwin M20-9762046. For RoHS compliance without ROHS3 requirement, TE Connectivity 7-146256-0 is suitable. The original 69192-540 remains the specification for non-compliant applications.

Frequently Asked Questions (FAQ)

Q: Can I substitute the 69192-540 with any of the listed parts without PCB modification?

A: Direct substitution without PCB modification is possible with parts maintaining identical contact post length (0.120" / 3.05mm): TE Connectivity 1-104350-7 and 7-146256-0. Parts with different post lengths (TSW-120-08 series at 0.200", 7-146261-0 at 0.090", M20-9762046 at 0.122") require verification of PCB hole depth and mating clearance.

Q: What is the difference between the Samtec TSW-120-07 variants?

A: The TSW-120-07 series differs in contact finish specifications. TSW-120-07-G-D features gold mating and gold post finish. TSW-120-07-S-D features gold mating with tin post finish. TSW-120-07-T-D features tin mating with tin post finish. All three maintain identical mechanical dimensions and electrical performance.

Q: Is the obsolete TE Connectivity 1-104350-7 still a valid substitute?

A: The 1-104350-7 is obsolete and should only be used if existing inventory is available. For new designs or long-term production, select from active alternatives such as 7-146256-0, 7-146261-0, or Samtec TSW series parts.

Q: Which substitute offers the best RoHS compliance for new designs?

A: All active substitutes except the original 69192-540 and obsolete 1-104350-7 offer RoHS compliance. Samtec TSW series, TE Connectivity 7-146256-0 and 7-146261-0, and Harwin M20-9762046 all carry ROHS3 compliance, meeting current regulatory requirements.

Q: Are there differences in contact material between the main part and substitutes?

A: Yes. The 69192-540 uses phosphor bronze contacts. TE Connectivity parts use copper alloy, Harwin M20-9762046 uses brass, and Samtec TSW series uses phosphor bronze. These material differences do not affect electrical performance for standard applications but may influence corrosion resistance in specific environments.

Q: What packaging options are available?

A: The 69192-540 is supplied in bulk packaging. TE Connectivity 1-104350-7, 7-146256-0, and 7-146261-0 are bulk packaged. Samtec TD-120-G-AA is supplied in tube packaging. Samtec TSW series and Harwin M20-9762046 are bulk packaged. Verify packaging requirements for your procurement process.

Q: Can I use the Samtec TD-120-G-AA as a direct substitute?

A: The TD-120-G-AA is functionally equivalent but detailed specifications for contact length and insulation height are not provided in the data. Confirm mechanical compatibility with your PCB design before selection.

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