Amphenol ICC 78511-405 Equivalent & Substitute Parts

Part Overview

The Amphenol ICC 78511-405 is a vertical through-hole rectangular connector header with 5 positions at 0.100" (2.54mm) pitch, designed for board-to-board applications. This connector is part of the BERGSTIK® II series and features unshrouded male pin contacts with solder termination and push-pull fastening. The part is currently obsolete, making equivalent substitutes necessary for new designs and ongoing production support.

Key Parameters

Parameter	Value
Connector Type	Header
Contact Type	Male Pin
Number of Positions	5
Pitch - Mating	0.100" (2.54mm)
Mounting Type	Through Hole
Termination	Solder
Fastening Type	Push-Pull
Contact Shape	Square
Insulation Height	0.100" (2.54mm)
Material Flammability Rating	UL94 V-0
Insulation Color	Black
Moisture Sensitivity Level	1 (Unlimited)

Substitute Part Grouping Explanation

Substitution for the 78511-405 is based on strict electrical and mechanical compatibility. The critical parameters that determine substitutability are:

Connector Type & Contact Type: Must be Header with Male Pin contacts
Number of Positions: Exactly 5 positions
Pitch - Mating: Exactly 0.100" (2.54mm)
Mounting Type: Through Hole
Termination: Solder
Fastening Type: Push-Pull
Contact Shape: Square
Insulation Height: 0.100" (2.54mm)
Material Flammability Rating: UL94 V-0

Substitute parts are grouped into two categories:

Category A - Direct Mechanical & Electrical Equivalents (5-Position Headers) These parts maintain identical position count, pitch, and core mechanical specifications:

3M 2305-6211-TB
3M 2305-6211-TG
TE Connectivity 5-87348-5
3M 929700-01-05
3M 929700-01-05-RK
3M 929700-06-05
3M 929705-01-05-EU
3M 929705-01-05-I
3M 929705-06-05-EU

Category B - Functional Equivalent (40-Position Header) This part shares the same pitch and core specifications but differs in position count:

TE Connectivity 4-103321-0 (40 positions)

Parameter Comparison

Parameter	78511-405	2305-6211-TB	2305-6211-TG	5-87348-5	929700-01-05	929700-01-05-RK	929700-06-05	929705-01-05-EU	929705-01-05-I	929705-06-05-EU	4-103321-0
Manufacturer	Amphenol ICC	3M	3M	TE Connectivity	3M	3M	3M	3M	3M	3M	TE Connectivity
Connector Type	Header	Header	Header	Header	Header, Breakaway	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	Male Pin	Male Pin	Male Pin	Male Pin
Number of Positions	5	5	5	5	5	5	5	5	5	5	40
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)
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	Solder	Solder	Solder	Solder	Solder	Solder	Solder	Solder	Solder	Solder	Solder
Fastening Type	Push-Pull	Push-Pull	Push-Pull	Push-Pull	Push-Pull	Push-Pull	Push-Pull	Push-Pull	Push-Pull	Push-Pull	Push-Pull
Contact Shape	Square	Square	Square	Square	Square	Square	Square	Square	Square	Square	Square
Insulation Height	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	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)	0.090" (2.29mm)
Contact Length - Mating	0.318" (8.08mm)	0.318" (8.08mm)	0.318" (8.08mm)	0.318" (8.08mm)	0.318" (8.08mm)	0.318" (8.08mm)	0.318" (8.08mm)	0.318" (8.08mm)	0.318" (8.08mm)	0.318" (8.08mm)	0.318" (8.08mm)
Contact Length - Post	0.120" (3.05mm)	0.120" (3.05mm)	0.120" (3.05mm)	0.125" (3.18mm)	0.110" (2.79mm)	0.110" (2.79mm)	0.710" (18.03mm)	0.110" (2.79mm)	0.110" (2.79mm)	0.710" (18.03mm)	0.125" (3.18mm)
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	UL94 V-0
Insulation Color	Black	Black	Black	Black	Black	Black	Black	Black	Black	Black	Black
Product Status	Obsolete	Active	Active	Active	Active	Active	Active	Active	Active	Active	Obsolete
RoHS Status	Non-compliant	Non-compliant	Non-compliant	Compliant	Non-compliant	Compliant	Non-compliant	Compliant	Compliant	Compliant	Not applicable
Moisture Sensitivity Level	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 (5-Position, Active Status)

For new designs and production requiring RoHS compliance, select from:

3M 929705-01-05-I (RoHS Compliant, Gold finish mating contacts, 2.5A rating)
3M 929705-01-05-EU (RoHS Compliant, Gold finish mating contacts, 2.5A rating)
TE Connectivity 5-87348-5 (RoHS Compliant, Tin finish, Phosphor Bronze contacts)

For applications where RoHS compliance is not required:

3M 2305-6211-TB (Active status, Gold finish, 3A rating, Copper Alloy contacts)
3M 2305-6211-TG (Active status, Gold finish, 3A rating, higher inventory availability)
3M 929700-01-05 (Active status, Tin-Lead finish, 2.5A rating)
3M 929700-01-05-RK (Active status, Tin finish, RoHS Compliant, 2.5A rating)

Extended Post Length Variants

For applications requiring longer solder posts:

3M 929700-06-05 (0.710" post length, Tin-Lead finish)
3M 929705-06-05-EU (0.710" post length, Gold finish, RoHS Compliant)

Functional Equivalent (40-Position)

TE Connectivity 4-103321-0 shares identical pitch and core specifications but provides 40 positions. This part is obsolete and suitable only for legacy system maintenance.

Frequently Asked Questions (FAQ)

Q: Can I use a 40-position connector as a substitute for the 5-position 78511-405?

A: The TE Connectivity 4-103321-0 shares the same 0.100" (2.54mm) pitch and core mechanical specifications. However, the position count difference (40 vs. 5) makes this suitable only for applications where the additional positions are utilized or can be left unconnected. For direct mechanical replacement in existing designs, use 5-position equivalents.

Q: What is the difference between the 3M 929700 and 929705 series?

A: Both series are 5-position headers with 0.100" (2.54mm) pitch and identical mechanical dimensions. The primary differences are contact finish (Tin-Lead vs. Gold) and insulation material composition. The 929705 series offers gold-plated mating contacts and improved corrosion resistance. Select based on environmental requirements and contact finish specifications.

Q: Are the 3M 2305-6211-TB and 2305-6211-TG interchangeable?

A: Both are 5-position, 0.100" (2.54mm) pitch headers from the 3M 2300 series with identical mechanical specifications. The primary difference is packaging (Tape & Reel vs. Bulk). They are electrically and mechanically interchangeable; selection depends on packaging requirements and inventory availability.

Q: What is the significance of the "-RK" suffix on the 929700-01-05-RK?

A: The "-RK" designation indicates RoHS compliance and Tin finish on both mating and post contacts. This variant is suitable for applications requiring RoHS compliance while maintaining the same 5-position, 0.100" (2.54mm) pitch configuration.

Q: How do contact post lengths affect substitution?

A: Contact post length determines solder joint depth and PCB hole engagement. The 78511-405 has a 0.120" (3.05mm) post. Most direct substitutes maintain this specification. Variants with 0.710" posts (929700-06-05, 929705-06-05-EU) are for applications requiring extended engagement and are not interchangeable with standard-length designs without PCB modification.

Q: Which substitute offers the best compliance profile?

A: The 3M 929705-01-05-I and 929705-01-05-EU both offer RoHS compliance, REACH Unaffected status, and active product status. These are recommended for new designs requiring modern compliance certifications.

Q: Can I substitute based on current rating alone?

A: No. While current rating is important, substitution requires matching all critical parameters: position count, pitch, mounting type, termination, fastening type, contact shape, and insulation height. The 78511-405 does not specify a current rating, so substitute selection should prioritize mechanical and electrical compatibility over current specifications.

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