Equivalent & Substitute Parts for 800-80-040-20-004101

Part Overview

The Preci-Dip 800-80-040-20-004101 is an unshrouded rectangular connector header featuring 40 positions at 0.100" (2.54mm) pitch with right-angle through-hole mounting and solder termination. This connector is designed for board-to-board applications requiring male pin contact configuration. The part maintains Active product status and is RoHS3 compliant with unlimited moisture sensitivity rating.

Substitute parts are identified when equivalent rectangular connectors share the same core functional specifications: 40-position configuration, 2.54mm pitch, right-angle through-hole mounting, solder termination, male pin contacts, and board-to-board or board-to-cable compatibility. Substitution becomes necessary due to inventory availability, specific contact finish requirements, or extended post length requirements for particular PCB stack-up configurations.

Key Parameters

Parameter	Specification
Connector Type	Header
Contact Type	Male Pin
Number of Positions	40
Pitch - Mating	0.100" (2.54mm)
Number of Rows	1
Mounting Type	Through Hole, Right Angle
Termination	Solder
Shrouding	Unshrouded
Current Rating	3A
Operating Temperature Range	-55°C ~ 125°C
Material Flammability Rating	UL94 V-0
RoHS Status	ROHS3 Compliant
Moisture Sensitivity Level	1 (Unlimited)

Substitute Part Grouping Explanation

Substitution eligibility for the 800-80-040-20-004101 is determined by the following mandatory parameters:

Core Compatibility Parameters:

40-position connector configuration
0.100" (2.54mm) mating pitch
Single-row layout
Right-angle through-hole mounting
Solder termination
Male pin contact type
Unshrouded design
3A current rating per contact
UL94 V-0 flammability rating
RoHS3 compliance

Variable Parameters Permitting Substitution:

Contact finish material (Tin or Gold)
Contact finish thickness (standard or flash)
Contact length specifications (mating and post lengths)
Insulation material composition (PCT or PBT)
Insulation height tolerance
Operating temperature range (provided minimum -40°C is maintained)
Connector style designation (Header or Header Breakaway)

All four identified substitute parts from Sullins Connector Solutions meet the core compatibility parameters. Differences exist in contact finish specifications, post length configurations, and insulation material composition, enabling selection based on specific application requirements.

Parameter Comparison

Parameter	800-80-040-20-004101 (Preci-Dip)	PREC040SBAN-M71RC (Sullins)	PRPC040SBAN-M71RC (Sullins)	PRPC040SBBN-M71RC (Sullins)	PRPC040SBCN-M71RC (Sullins)
Manufacturer	Preci-Dip	Sullins Connector Solutions	Sullins Connector Solutions	Sullins Connector Solutions	Sullins Connector Solutions
Number of Positions	40	40	40	40	40
Pitch - Mating	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)
Number of Rows	1	1	1	1	1
Connector Type	Header	Header, Breakaway	Header, Breakaway	Header, Breakaway	Header, Breakaway
Contact Type	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin
Mounting Type	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	Solder
Shrouding	Unshrouded	Unshrouded	Unshrouded	Unshrouded	Unshrouded
Contact Length - Mating	0.195" (4.95mm)	0.230" (5.84mm)	0.230" (5.84mm)	0.230" (5.84mm)	0.230" (5.84mm)
Contact Length - Post	0.126" (3.20mm)	0.120" (3.05mm)	0.120" (3.05mm)	0.220" (5.58mm)	0.320" (8.13mm)
Insulation Height	0.100" (2.54mm)	0.098" (2.50mm)	0.098" (2.50mm)	0.098" (2.50mm)	0.098" (2.50mm)
Contact Shape	Circular	Square	Square	Square	Square
Contact Finish - Mating	Tin	Tin	Gold (Flash)	Gold (Flash)	Gold (Flash)
Contact Finish - Post	Tin	Tin	Gold (Flash)	Gold (Flash)	Gold (Flash)
Contact Material	Brass	Brass	Brass	Brass	Brass
Insulation Material	PCT, Polyester, Glass Filled	PBT	PBT	PBT	PBT
Current Rating	3A	3A per Contact	3A per Contact	3A per Contact	3A per Contact
Operating Temperature	-55°C ~ 125°C	-40°C ~ 105°C	-40°C ~ 105°C	-40°C ~ 105°C	-40°C ~ 105°C
Material Flammability Rating	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0
Insulation Color	Black	Black	Black	Black	Black
RoHS Status	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant
Moisture Sensitivity Level	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)
ECCN	EAR99	EAR99	EAR99	EAR99	EAR99

Engineering Selection Recommendations

Primary Selection Criteria:

All four substitute parts maintain Active product status and full RoHS3 compliance, establishing baseline compatibility with the 800-80-040-20-004101. Selection among substitutes is determined by specific application requirements:

PREC040SBAN-M71RC Selection: This substitute maintains tin contact finish matching the original part specification. The 0.120" (3.05mm) post length accommodates standard PCB thicknesses. Insulation material composition differs (PBT versus PCT), but both materials satisfy UL94 V-0 flammability requirements. This part is suitable for applications requiring tin-plated contacts with standard post penetration depth.

PRPC040SBAN-M71RC Selection: This substitute introduces gold flash contact finish on both mating and post surfaces. Gold plating enhances corrosion resistance and contact reliability in environments with potential oxidation exposure. The 0.120" (3.05mm) post length matches standard through-hole requirements. Selection is appropriate for applications demanding superior contact durability and environmental resistance.

PRPC040SBBN-M71RC Selection: This substitute provides gold flash contact finish with extended post length of 0.220" (5.58mm). The increased post length accommodates thicker PCB assemblies or applications requiring deeper solder joint penetration. This configuration is selected when PCB stack-up depth exceeds standard specifications while maintaining gold contact protection.

PRPC040SBCN-M71RC Selection: This substitute offers gold flash contact finish with maximum post length of 0.320" (8.13mm). This extended post configuration addresses applications with substantial PCB thickness or multi-layer board assemblies requiring maximum solder joint engagement. Selection is appropriate for high-reliability applications combining gold contact protection with extended post penetration.

Temperature Operating Range Consideration: The original part operates across -55°C to 125°C. All substitute parts operate within -40°C to 105°C range. Applications requiring operation below -40°C or above 105°C necessitate retention of the original 800-80-040-20-004101 specification.

Frequently Asked Questions (FAQ)

Q: Can PREC040SBAN-M71RC directly replace 800-80-040-20-004101 in existing designs?

A: PREC040SBAN-M71RC is functionally compatible for applications operating within -40°C to 105°C temperature range. The tin contact finish matches the original specification. Insulation material differs (PBT versus PCT), but both satisfy UL94 V-0 requirements. Post length is 0.120" (3.05mm) versus original 0.126" (3.20mm), a 0.006" difference within typical PCB tolerance. Mating contact length increases from 0.195" to 0.230", which does not affect mating interface compatibility. This part is suitable for direct substitution in standard applications.

Q: What is the functional difference between tin and gold contact finishes?

A: Tin contact finish provides standard electrical conductivity and cost efficiency for general applications. Gold flash contact finish provides enhanced corrosion resistance, improved contact reliability in oxidizing environments, and superior long-term contact stability. Gold-plated contacts (PRPC040SBAN-M71RC, PRPC040SBBN-M71RC, PRPC040SBCN-M71RC) are selected for applications requiring extended shelf life, high-reliability requirements, or exposure to corrosive environments.

Q: How do post length variations affect connector selection?

A: Post length determines solder joint penetration depth through the PCB. Standard post length of 0.120" (3.05mm) accommodates typical single and double-layer PCB assemblies. Extended post length of 0.220" (5.58mm) (PRPC040SBBN-M71RC) addresses thicker PCB stacks or multi-layer assemblies. Maximum post length of 0.320" (8.13mm) (PRPC040SBCN-M71RC) is selected for applications with substantial PCB thickness or when maximum solder joint engagement is required. Selection is based on actual PCB thickness and solder joint design requirements.

Q: Are all substitute parts RoHS3 compliant?

A: All four substitute parts maintain ROHS3 compliance status identical to the original 800-80-040-20-004101. All parts are EAR99 classified and carry identical HTSUS coding (8536.69.4040), confirming regulatory equivalence.

Q: What is the significance of the breakaway connector designation?

A: The Sullins substitute parts are designated as "Header, Breakaway" connectors, indicating the connector housing is designed to allow individual pin removal or partial connector separation. The original Preci-Dip part is designated as "Header" without breakaway capability. This functional difference does not affect mating compatibility or electrical performance in applications where breakaway functionality is not required. Applications requiring non-breakaway design should retain the original 800-80-040-20-004101 specification.

Q: What is the impact of insulation material differences between PCT and PBT?

A: Both Polycyclohexylenedimethylene Terephthalate (PCT) and Polybutylene Terephthalate (PBT) are thermoplastic polyester materials meeting UL94 V-0 flammability requirements. PBT offers slightly lower moisture absorption and improved dimensional stability. PCT provides enhanced chemical resistance. Both materials are suitable for standard connector applications. Material selection does not affect electrical performance or mating compatibility.

Q: Can substitute parts be used in applications requiring -55°C operation?

A: No. The original 800-80-040-20-004101 operates from -55°C to 125°C. All substitute parts operate from -40°C to 105°C. Applications requiring operation below -40°C must retain the original Preci-Dip specification. The 15°C difference in minimum operating temperature may be critical for aerospace, military, or extreme environment applications.

Q: What inventory considerations apply to these substitute parts?

A: The original 800-80-040-20-004101 maintains 944 pieces in stock. Substitute parts maintain higher inventory levels: PREC040SBAN-M71RC (10,138 pcs), PRPC040SBAN-M71RC (7,034 pcs), PRPC040SBBN-M71RC (9,010 pcs), and PRPC040SBCN-M71RC (4,339 pcs). Substitute selection may be driven by inventory availability for time-sensitive production requirements.

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