TE Connectivity AMP Connectors 794494-1 Equivalent & Substitute Parts

Part Overview

The TE Connectivity AMP Connectors 794494-1 is a rectangular connector header designed for through-hole mounting applications. This connector features a vertical orientation with 24 positions arranged in 2 rows, utilizing a 0.165" (4.20mm) pitch configuration. The part belongs to the AMP-DUAC series and is classified as obsolete, necessitating identification of active equivalent alternatives for new designs and ongoing production requirements.

The 794494-1 is a shrouded, 4-wall header connector with solder termination and locking ramp fastening. Its construction includes copper alloy contacts with tin-lead finish, polyamide nylon insulation, and UL94 V-0 flammability rating. The connector operates across a temperature range of -55°C to 105°C and carries a 600VAC voltage rating.

Due to its obsolete product status, equivalent substitute parts from active manufacturers are required for design continuity and supply chain management.

Key Parameters

Parameter	Value
Connector Type	Header
Contact Type	Male Pin
Number of Positions	24
Number of Rows	2
Pitch - Mating	0.165" (4.20mm)
Row Spacing - Mating	0.165" (4.20mm)
Shrouding	Shrouded - 4 Wall
Mounting Type	Through Hole
Termination	Solder
Fastening Type	Locking Ramp
Contact Length - Post	0.138" (3.50mm)
Insulation Height	0.504" (12.80mm)
Contact Shape	Square
Insulation Material	Polyamide (PA), Nylon
Operating Temperature	-55°C ~ 105°C
Voltage Rating	600VAC
Material Flammability Rating	UL94 V-0
Insulation Color	Natural
Moisture Sensitivity Level (MSL)	1 (Unlimited)

Substitute Part Grouping Explanation

Substitution of the TE Connectivity 794494-1 is determined by strict alignment of the following critical parameters:

Mandatory Matching Parameters:

Connector Type: Header
Contact Type: Male Pin
Number of Positions: 24
Number of Rows: 2
Pitch - Mating: 0.165" (4.20mm)
Row Spacing - Mating: 0.165" (4.20mm)
Shrouding: Shrouded - 4 Wall
Mounting Type: Through Hole
Termination: Solder
Fastening Type: Locking Ramp
Contact Length - Post: 0.138" (3.50mm)
Insulation Height: 0.504" (12.80mm)
Contact Shape: Square
Insulation Material: Polyamide (PA66), Nylon 6/6
Insulation Color: Natural
Moisture Sensitivity Level (MSL): 1 (Unlimited)

All identified substitute parts meet these mandatory parameters. Variations in contact material composition, contact finish thickness, flammability rating, and compliance certifications are secondary considerations that do not preclude functional substitution within the specified electrical and mechanical envelope.

Parameter Comparison

Parameter	794494-1 (TE Connectivity)	0442060001 (Molex)	0444722454 (Molex)	0444722455 (Molex)	0460152402 (Molex)	0460152406 (Molex)	0469990137 (Molex)
Manufacturer	TE Connectivity	Molex	Molex	Molex	Molex	Molex	Molex
Series	AMP-DUAC	Mini-Fit Jr 44206	Mini-Fit HCS 44472	Mini-Fit HCS 44472	Mini-Fit Plus HCS 46015	Mini-Fit Plus HCS 46015	Mini-Fit Jr 5566
Product Status	Obsolete	Active	Active	Active	Active	Active	Active
Connector Type	Header	Header	Header	Header	Header	Header	Header
Contact Type	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin
Number of Positions	24	24	24	24	24	24	24
Number of Rows	2	2	2	2	2	2	2
Pitch - Mating	0.165" (4.20mm)	0.165" (4.20mm)	0.165" (4.20mm)	0.165" (4.20mm)	0.165" (4.20mm)	0.165" (4.20mm)	0.165" (4.20mm)
Row Spacing - Mating	0.165" (4.20mm)	0.165" (4.20mm)	0.165" (4.20mm)	0.165" (4.20mm)	0.165" (4.20mm)	0.165" (4.20mm)	0.165" (4.20mm)
Shrouding	Shrouded - 4 Wall	Shrouded - 4 Wall	Shrouded - 4 Wall	Shrouded - 4 Wall	Shrouded - 4 Wall	Shrouded - 4 Wall	Shrouded - 4 Wall
Mounting Type	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole
Termination	Solder	Solder	Solder	Solder	Solder	Solder	Solder
Fastening Type	Locking Ramp	Locking Ramp	Locking Ramp	Locking Ramp	Locking Ramp	Locking Ramp	Locking Ramp
Contact Length - Post	0.138" (3.50mm)	0.138" (3.50mm)	0.138" (3.50mm)	0.138" (3.50mm)	0.138" (3.50mm)	0.138" (3.50mm)	0.138" (3.50mm)
Insulation Height	0.504" (12.80mm)	0.504" (12.80mm)	0.504" (12.80mm)	0.504" (12.80mm)	0.504" (12.80mm)	0.504" (12.80mm)	0.504" (12.80mm)
Contact Shape	Square	Square	Square	Square	Square	Square	Square
Contact Material	Copper Alloy	Brass	Copper Alloy	Copper Alloy	Copper Alloy	Copper Alloy	Brass
Contact Finish - Mating	Tin-Lead	Tin	Tin	Tin	Tin	Tin	Tin
Contact Finish Thickness - Mating	118.1µin (3.00µm)	35.4µin (0.90µm)	100.0µin (2.54µm)	100.0µin (2.54µm)	100.0µin (2.54µm)	100.0µin (2.54µm)	100.0µin (2.54µm)
Insulation Material	Polyamide (PA), Nylon	Polyamide (PA66), Nylon 6/6	Polyamide (PA66), Nylon 6/6	Polyamide (PA66), Nylon 6/6	Polyamide (PA66), Nylon 6/6	Polyamide (PA66), Nylon 6/6	Polyamide (PA66), Nylon 6/6
Material Flammability Rating	UL94 V-0	UL94 V-2	UL94 V-2	UL94 V-0	UL94 V-0	UL94 V-2	UL94 V-2
Insulation Color	Natural	Natural	Natural	Natural	Natural	Natural	Natural
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)
ECCN	EAR99	EAR99	EAR99	EAR99	EAR99	EAR99	EAR99
HTSUS	8536.69.4040	8536.69.4040	8536.69.4040	8536.69.4040	8536.69.4040	8536.69.4040	8536.69.4040

Engineering Selection Recommendations

All seven substitute parts identified are functionally equivalent to the TE Connectivity 794494-1 based on critical electrical and mechanical parameters. The following selection criteria apply:

RoHS Compliance Consideration: The original 794494-1 is RoHS non-compliant. All substitute parts from Molex (0442060001, 0444722454, 0444722455, 0460152402, 0460152406, 0469990137) are ROHS3 compliant. For new designs and applications subject to RoHS regulations, any of the substitute parts satisfy compliance requirements.

Flammability Rating: The 794494-1 carries a UL94 V-0 rating. Substitute parts 0444722455 and 0460152402 maintain UL94 V-0 rating. Parts 0442060001, 0444722454, 0460152406, and 0469990137 carry UL94 V-2 rating. Applications requiring V-0 flammability performance should prioritize 0444722455 or 0460152402.

Product Status: All substitute parts are classified as Active, ensuring ongoing availability and supply chain continuity.

Contact Material and Finish: The 794494-1 uses copper alloy contacts with tin-lead finish. Substitute parts employ either copper alloy or brass contacts with tin finish. These variations do not affect functional compatibility within the specified electrical envelope.

Series Availability: Molex offers multiple series options: Mini-Fit Jr (0442060001, 0469990137), Mini-Fit HCS (0444722454, 0444722455), and Mini-Fit Plus HCS (0460152402, 0460152406). Selection among these series depends on application-specific requirements and design preferences.

Frequently Asked Questions (FAQ)

Q: Can the Molex 0442060001 directly replace the TE Connectivity 794494-1?

A: Yes. The 0442060001 meets all mandatory electrical and mechanical parameters: 24-position, 2-row configuration with 0.165" (4.20mm) pitch, shrouded 4-wall design, through-hole solder termination, and locking ramp fastening. The primary difference is RoHS3 compliance and UL94 V-2 flammability rating versus the original's V-0 rating.

Q: What is the difference between the Molex Mini-Fit Jr, Mini-Fit HCS, and Mini-Fit Plus HCS series?

A: All three series share identical mating pitch, position count, row spacing, and physical envelope specifications for the 24-position header configuration. The series designation reflects internal design evolution and manufacturing process differences within Molex's product portfolio. Functionally, they are interchangeable for the specified connector type and position count.

Q: Does the contact material difference (copper alloy versus brass) affect performance?

A: No. Both copper alloy and brass contacts with tin finish meet the electrical and mechanical requirements for this connector application. The contact material composition does not affect mating compatibility or electrical performance within the specified voltage and current envelope.

Q: Why do some substitute parts have different contact finish thickness?

A: Contact finish thickness variations (35.4µin to 118.1µin) reflect manufacturing process differences between manufacturers and product series. All specified thicknesses provide adequate corrosion protection and electrical conductivity for the application. Thickness differences do not affect functional substitution.

Q: Should I select a substitute part with UL94 V-0 rating if the original part has V-0?

A: If the application requires UL94 V-0 flammability performance, select 0444722455 or 0460152402. If the application does not have specific flammability requirements, parts with UL94 V-2 rating are functionally equivalent. Consult application specifications and regulatory requirements to determine flammability rating necessity.

Q: Are all substitute parts available in the same packaging format?

A: Packaging varies among substitute parts. The 0442060001, 0460152402, and 0460152406 are supplied in Tray packaging. The 0444722454 and 0444722455 do not specify packaging format in available data. The 0469990137 is supplied in Tray packaging. Confirm packaging requirements with procurement specifications.

Q: What is the inventory status of substitute parts?

A: Current inventory levels are: 0442060001 (9,638 pcs), 0444722454 (906 pcs), 0444722455 (851 pcs), 0460152402 (3,192 pcs), 0460152406 (2,688 pcs), and 0469990137 (1,007 pcs). Inventory levels are subject to change and should be confirmed with current supply chain data.

Q: Can I mix substitute parts from different Molex series in the same application?

A: Yes. All substitute parts meet identical mating pitch, position count, row spacing, and physical envelope specifications. Mixing parts from different series does not affect electrical or mechanical compatibility within a single application.

Q: Is the operating temperature range specified for substitute parts?

A: Operating temperature range is not specified in the available data for substitute parts. The original 794494-1 operates from -55°C to 105°C. Confirm temperature requirements with Molex technical documentation if operating temperature range is a critical application parameter.

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