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3M 960240-6202-AR: Equivalent & Substitute Parts Reference
Part Overview
The 3M 960240-6202-AR is a 40-position rectangular receptacle connector with 0.100" (2.54mm) pitch, designed for board-to-board through-hole applications. This connector features gold-plated mating contacts, solder termination, and push-pull fastening. The part is classified as obsolete, making equivalent and substitute parts necessary for ongoing design support and procurement.
Substiute Parts
Key Parameters
| Parameter | Value |
|---|---|
| Manufacturer Part Number | 960240-6202-AR |
| Manufacturer | 3M |
| Connector Type | Receptacle |
| Number of Positions | 40 |
| Pitch - Mating | 0.100" (2.54mm) |
| Number of Rows | 2 |
| Row Spacing - Mating | 0.100" (2.54mm) |
| Mounting Type | Through Hole |
| Contact Finish - Mating | Gold |
| Fastening Type | Push-Pull |
| Operating Temperature | -25°C ~ 105°C |
| Voltage Rating | 1000VDC |
| Current Rating | 2A |
| Material Flammability Rating | UL94 V-0 |
Substitute Part Grouping Explanation
Substitution for the 3M 960240-6202-AR is determined by the following critical parameters:
- Connector Type & Style: Receptacle, board-to-board configuration
- Position Count & Pitch: 40 positions at 0.100" (2.54mm) mating pitch with 2 rows at 0.100" row spacing
- Mounting & Termination: Through-hole solder termination with push-pull fastening
- Contact Finish: Gold-plated mating contacts
- Electrical Ratings: 1000VDC voltage rating; current capacity of 2A or higher
- Environmental Compliance: UL94 V-0 flammability rating
Substitute parts are grouped into two categories based on contact material and finish specifications:
Category A - Amphenol ICC (FCI) Dubox™ Series: Parts 68682-320LF, 68683-220LF, 68683-320LF, 68683-420, 68683-620, 76342-320LF, and 76342-420LF feature phosphor bronze contacts with thermoplastic or polyphenylene sulfide insulation. These connectors maintain the 40-position, 0.100" pitch configuration with through-hole solder termination and push-pull fastening.
Category B - TE Connectivity AMPMODU HV-100 Series: Part 2-215307-0 uses phosphor bronze contacts with polyester glass-filled insulation and kinked pin or solder termination options.
Category C - Mill-Max Manufacturing 803 Series: Parts 803-41-040-10-001000 and 803-41-040-10-004000 feature beryllium copper contacts with higher current ratings (4.5A) and extended operating temperature range (-55°C ~ 125°C).
Parameter Comparison
| Parameter | 3M 960240-6202-AR | 2-215307-0 | 68682-320LF | 68683-220LF | 68683-320LF | 68683-420 | 68683-620 | 76342-320LF | 76342-420LF | 803-41-040-10-001000 | 803-41-040-10-004000 |
|---|---|---|---|---|---|---|---|---|---|---|---|
| Connector Type | Receptacle | Receptacle | Receptacle, Bottom or Top Entry | Receptacle | Receptacle | Receptacle | Receptacle | Receptacle | Receptacle | Receptacle | Receptacle |
| Number of Positions | 40 | 40 | 40 | 40 | 40 | 40 | 40 | 40 | 40 | 40 | 40 |
| 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 | Kinked Pin, Solder | Solder | Solder | Solder | Solder | Solder | Solder | Solder | Solder | Solder |
| Fastening Type | Push-Pull | Push-Pull | Not specified | Push-Pull | Push-Pull | Push-Pull | Push-Pull | Push-Pull | Push-Pull | Push-Pull | Push-Pull |
| Contact Finish - Mating | Gold | Gold | Gold or Gold, GXT™ | Gold | Gold | Tin | Gold | Gold | Tin | Gold | Gold |
| Insulation Color | Black | Black or Green | Black | Black | Black | Black | Black | Blue | Blue | Black | Black |
| Insulation Height | 0.280" | 0.276" | 0.276" | 0.276" | 0.276" | 0.276" | 0.276" | 0.275" | 0.275" | 0.276" | 0.272" |
| Operating Temperature | -25°C ~ 105°C | Not specified | Not specified | -65°C ~ 125°C | -65°C ~ 125°C | -65°C ~ 125°C | -65°C ~ 125°C | Not specified | Not specified | -55°C ~ 125°C | -55°C ~ 125°C |
| Voltage Rating | 1000VDC | Not specified | Not specified | 1000V | 1000V | 1000V | 1000V | Not specified | Not specified | Not specified | Not specified |
| Current Rating | 2A | Not specified | Not specified | Not specified | Not specified | Not specified | Not specified | Not specified | Not specified | 4.5A | 4.5A |
| 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 | Not specified | ROHS3 Compliant | RoHS Compliant | RoHS Compliant | RoHS Compliant | RoHS non-compliant | RoHS non-compliant | RoHS Compliant | RoHS Compliant | ROHS3 Compliant | ROHS3 Compliant |
Engineering Selection Recommendations
For RoHS3 Compliant Applications: Select 2-215307-0 (TE Connectivity AMPMODU HV-100) or 803-41-040-10-001000 and 803-41-040-10-004000 (Mill-Max 803 Series). These parts carry ROHS3 Compliant certification, meeting stringent environmental regulations for new product designs.
For RoHS Compliant Applications: Amphenol ICC (FCI) Dubox™ Series parts 68682-320LF, 68683-220LF, 68683-320LF, 76342-320LF, and 76342-420LF are RoHS Compliant and suitable for applications requiring RoHS certification without ROHS3 requirements.
For Extended Temperature Range: Mill-Max 803-41-040-10-001000 and 803-41-040-10-004000 provide -55°C ~ 125°C operating range, exceeding the original 3M part specification of -25°C ~ 105°C. Amphenol ICC (FCI) Dubox™ Series parts 68683-220LF, 68683-320LF, 68683-420, and 68683-620 also offer -65°C ~ 125°C range.
For Higher Current Capacity: Mill-Max 803 Series parts (803-41-040-10-001000 and 803-41-040-10-004000) deliver 4.5A current rating, compared to the original 2A specification, with beryllium copper contacts providing enhanced electrical performance.
For Gold Mating Contact Finish: All substitute parts except 68683-420 and 76342-420LF maintain gold-plated mating contacts matching the original specification. Parts 68683-420 and 76342-420LF feature tin mating contacts for cost-optimized applications.
For REACH Compliance: Amphenol ICC (FCI) Dubox™ Series parts 68683-220LF, 68683-320LF, 76342-320LF, and 76342-420LF carry REACH Affected status. TE Connectivity 2-215307-0 shows Vendor Undefined REACH status. Mill-Max 803 Series parts are REACH Unaffected.
Frequently Asked Questions (FAQ)
Q: Can I directly replace the 3M 960240-6202-AR with any of these substitute parts?
A: Direct replacement is possible for parts matching the core mechanical and electrical parameters: 40 positions, 0.100" pitch, 2-row configuration, through-hole solder termination, and push-pull fastening. All listed substitutes meet these criteria. However, verify contact finish (gold vs. tin), insulation color, and compliance certifications against your application requirements before implementation.
Q: What is the difference between gold and tin mating contact finishes?
A: The original 3M 960240-6202-AR and most substitutes feature gold-plated mating contacts, which provide superior corrosion resistance and lower contact resistance. Parts 68683-420 and 76342-420LF use tin mating contacts, which are cost-effective alternatives suitable for applications without stringent corrosion or contact resistance requirements.
Q: Are there differences in insulation material between the original and substitutes?
A: Yes. The 3M 960240-6202-AR uses thermoplastic insulation. Amphenol ICC (FCI) Dubox™ Series parts use polyphenylene sulfide (PPS) glass-filled or thermoplastic glass-filled insulation. TE Connectivity 2-215307-0 uses polyester glass-filled insulation. Mill-Max 803 Series uses polycyclohexylenedimethylene terephthalate (PCT) polyester insulation. All materials meet UL94 V-0 flammability requirements.
Q: Which substitute offers the best performance upgrade?
A: Mill-Max 803-41-040-10-001000 and 803-41-040-10-004000 provide the most significant performance improvements: 4.5A current rating (vs. 2A original), extended operating temperature range (-55°C ~ 125°C vs. -25°C ~ 105°C original), and beryllium copper contacts for enhanced electrical properties. These parts are suitable for demanding industrial and telecommunications applications.
Q: What packaging options are available?
A: Packaging varies by manufacturer. TE Connectivity 2-215307-0 is supplied in Tray packaging. Amphenol ICC (FCI) Dubox™ Series parts are supplied in Tube packaging. Mill-Max 803 Series parts are supplied in Bulk packaging. Verify packaging compatibility with your procurement and assembly processes.
Q: Are all substitutes RoHS compliant?
A: No. Parts 68683-420 and 68683-620 are RoHS non-compliant. All other substitutes are either RoHS Compliant or ROHS3 Compliant. For new designs requiring environmental compliance, select from RoHS Compliant or ROHS3 Compliant options.
Q: Can I use parts with different insulation colors interchangeably?
A: Insulation color is a visual identifier and does not affect electrical or mechanical function. The original 3M part uses black insulation. Amphenol ICC (FCI) Dubox™ Series parts 76342-320LF and 76342-420LF use blue insulation. TE Connectivity 2-215307-0 is available in black or green. Color selection is application-dependent and does not impact compatibility.
Q: What is the difference between 803-41-040-10-001000 and 803-41-040-10-004000?
A: Both Mill-Max parts share identical electrical and mechanical specifications. The difference lies in insulation height: 803-41-040-10-001000 has 0.276" height, while 803-41-040-10-004000 has 0.272" height. Select based on PCB layout and stacking height requirements.
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