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3M 960238-6202-AR: Equivalent & Substitute Parts Reference
Part Overview
The 3M 960238-6202-AR is a 38-position rectangular receptacle connector with 0.100" (2.54mm) pitch, designed for board-to-board applications with through-hole solder termination. This connector features gold-plated mating contacts and is rated for 2A at 1000VDC. The product is classified as obsolete, making equivalent and substitute parts necessary for ongoing design support and procurement.
Substiute Parts
Key Parameters
| Parameter | Value |
|---|---|
| Connector Type | Receptacle |
| Number of Positions | 38 |
| Pitch - Mating | 0.100" (2.54mm) |
| Number of Rows | 2 |
| Row Spacing - Mating | 0.100" (2.54mm) |
| Mounting Type | Through Hole |
| Termination | Solder |
| Fastening Type | Push-Pull |
| Contact Finish - Mating | Gold |
| Voltage Rating | 1000VDC |
| Current Rating | 2A |
| Operating Temperature | -25°C ~ 105°C |
| Material Flammability Rating | UL94 V-0 |
Substitute Part Grouping Explanation
Substitution for the 3M 960238-6202-AR is determined by the following critical parameters:
- Connector configuration: 38-position receptacle, 2-row layout
- Pitch and spacing: 0.100" (2.54mm) mating pitch with 0.100" row spacing
- Mounting and termination: Through-hole solder attachment with push-pull fastening
- Contact system: Female socket contacts with gold mating finish
- Electrical ratings: Minimum 1000V voltage rating and 2A current capacity
- Environmental compliance: UL94 V-0 flammability rating
Substitute parts are grouped into two categories based on contact material and design approach:
Category 1 - Amphenol ICC (FCI) Dubox™ Series (68683, 76342): Square contact geometry with phosphor bronze material, offering enhanced temperature range (-65°C to 125°C) and improved contact finish specifications. Available in both gold and tin mating finishes with RoHS compliance options.
Category 2 - Mill-Max Manufacturing 803 Series (803-41, 803-43, 803-91, 803-93): Circular contact geometry with beryllium copper material, providing higher current ratings (4.5A) and extended temperature range (-55°C to 125°C). ROHS3 compliant with tin or tin-lead post finishes.
Category 3 - Preci-Dip 803 Series (803-83-038-10-001101): Socket connector variant with beryllium copper contacts, 3A current rating, and ROHS3 compliance.
Parameter Comparison
| Parameter | 3M 960238-6202-AR | 68683-219 | 68683-619 | 76342-319LF | 76342-419LF | 803-41-038-10-001000 | 803-41-038-10-004000 | 803-43-038-10-001000 | 803-83-038-10-001101 | 803-91-038-10-001000 | 803-93-038-10-001000 |
|---|---|---|---|---|---|---|---|---|---|---|---|
| Manufacturer | 3M | Amphenol ICC (FCI) | Amphenol ICC (FCI) | Amphenol ICC (FCI) | Amphenol ICC (FCI) | Mill-Max | Mill-Max | Mill-Max | Preci-Dip | Mill-Max | Mill-Max |
| Connector Type | Receptacle | Receptacle | Receptacle | Receptacle | Receptacle | Receptacle | Receptacle | Receptacle | Socket | Receptacle | Receptacle |
| Number of Positions | 38 | 38 | 38 | 38 | 38 | 38 | 38 | 38 | 38 | 38 | 38 |
| Pitch - Mating | 0.100" | 0.100" | 0.100" | 0.100" | 0.100" | 0.100" | 0.100" | 0.100" | 0.100" | 0.100" | 0.100" |
| Number of Rows | 2 | 2 | 2 | 2 | 2 | 2 | 2 | 2 | 2 | 2 | 2 |
| Row Spacing - Mating | 0.100" | 0.100" | 0.100" | 0.100" | 0.100" | 0.100" | 0.100" | 0.100" | 0.100" | 0.100" | 0.100" |
| 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 Finish - Mating | Gold | Gold | Gold | Gold | Tin | Gold | Gold | Gold | Gold | Gold | Gold |
| Voltage Rating | 1000VDC | 1000V | 1000V | — | — | — | — | — | — | — | — |
| Current Rating | 2A | — | — | — | — | 4.5A | 4.5A | 4.5A | 3A | 4.5A | 4.5A |
| Operating Temperature | -25°C ~ 105°C | -65°C ~ 125°C | -65°C ~ 125°C | — | — | -55°C ~ 125°C | -55°C ~ 125°C | -55°C ~ 125°C | -55°C ~ 125°C | -55°C ~ 125°C | -55°C ~ 125°C |
| 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 |
| Product Status | Obsolete | Active | Active | Active | Active | Active | Active | Active | Active | Active | Active |
| RoHS Status | — | Non-compliant | Non-compliant | Compliant | Compliant | ROHS3 Compliant | ROHS3 Compliant | ROHS3 Compliant | ROHS3 Compliant | ROHS3 Compliant | ROHS3 Compliant |
Engineering Selection Recommendations
For direct functional replacement with extended environmental performance:
The Amphenol ICC (FCI) Dubox™ series (68683-219, 68683-619, 76342-319LF) provides pin-compatible substitution with identical 38-position, 0.100" pitch configuration. The 76342-319LF and 76342-419LF variants offer RoHS compliance and REACH compliance status, suitable for applications requiring modern regulatory adherence. Operating temperature range extends to -65°C to 125°C, exceeding the original specification.
For applications requiring higher current capacity:
The Mill-Max 803 series (803-41-038-10-001000, 803-41-038-10-004000, 803-43-038-10-001000, 803-91-038-10-001000, 803-93-038-10-001000) delivers 4.5A current rating with beryllium copper contacts and ROHS3 compliance. These connectors maintain the 38-position, 0.100" pitch standard with extended temperature range (-55°C to 125°C). Contact geometry differs (circular vs. square), but electrical and mechanical compatibility is maintained for board-to-board applications.
For socket connector applications:
The Preci-Dip 803-83-038-10-001101 provides a socket variant with 3A current rating and ROHS3 compliance, maintaining the same pitch and position count.
Compliance considerations:
All substitute parts meet UL94 V-0 flammability requirements. For new designs, 76342-319LF, 76342-419LF, and Mill-Max 803 series variants provide ROHS3 and REACH compliance. Amphenol ICC 68683 series parts are RoHS non-compliant and should be evaluated against specific regulatory requirements.
Frequently Asked Questions (FAQ)
Q: Can 68683-219 and 68683-619 be used interchangeably with the 3M 960238-6202-AR?
A: Yes. Both parts maintain the 38-position, 0.100" pitch configuration with identical row spacing, through-hole solder termination, and push-pull fastening. Contact finish thickness differs (15.0µin vs. 30.0µin), but both meet the 1000V rating. Insulation height is 0.276" compared to the original 0.280", a 0.004" difference within typical PCB tolerance.
Q: What is the difference between 76342-319LF and 76342-419LF?
A: The primary difference is mating contact finish. 76342-319LF features gold plating (30.0µin), while 76342-419LF uses tin plating (78.7µin). Both maintain identical position count, pitch, and row spacing. Selection depends on application requirements for contact material compatibility and corrosion resistance.
Q: Are Mill-Max 803 series connectors compatible with the original 3M connector?
A: Electrical and mechanical compatibility is maintained for board-to-board applications. Key differences include circular contact geometry (vs. square), higher current rating (4.5A vs. 2A), and extended temperature range (-55°C to 125°C vs. -25°C to 105°C). Beryllium copper contacts provide enhanced performance characteristics. PCB footprint compatibility should be verified due to minor dimensional variations in insulation height and contact post length.
Q: Which substitute part offers the best regulatory compliance?
A: 76342-319LF and 76342-419LF provide RoHS compliance and REACH compliance status. Mill-Max 803 series variants offer ROHS3 compliance. Amphenol ICC 68683 series parts are RoHS non-compliant and should not be used in applications requiring modern environmental regulations.
Q: Can I use 803-83-038-10-001101 (socket connector) as a substitute?
A: No. The 803-83-038-10-001101 is a socket connector type, while the 3M 960238-6202-AR is a receptacle connector. These are distinct connector types with different mating interfaces and cannot be directly substituted without corresponding changes to the mating connector.
Q: What is the significance of the contact finish thickness specifications?
A: Contact finish thickness affects durability and corrosion resistance. The original 3M part specifies flash gold plating. Substitute parts offer varying thicknesses: 15.0µin to 30.0µin for gold finishes, and 78.7µin for tin finishes. Thicker finishes provide extended service life in corrosive environments. Selection should align with application environmental conditions and expected connector mating cycles.
Q: Are there packaging differences between substitute parts?
A: Yes. The 3M original is packaged in standard format. Amphenol ICC parts are supplied in tubes. Mill-Max 803 series parts are supplied in bulk packaging. Preci-Dip 803-83 is supplied in bulk. Packaging affects handling, storage, and procurement logistics but does not affect electrical or mechanical performance.
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