HTSW-120-08-G-D Equivalent & Substitute Parts

Part Overview

The HTSW-120-08-G-D is a rectangular connector header manufactured by Samtec Inc., designed for through-hole mounting applications. This unshrouded, vertically-oriented header accommodates 40 positions across 2 rows with 0.100" (2.54mm) pitch spacing. The connector features gold-plated phosphor bronze contacts with solder termination and push-pull fastening, suitable for board-to-board or cable interconnection in industrial and commercial electronics.

The part maintains Active product status with full RoHS3 compliance and ROHS Unaffected REACH status. Equivalent and substitute parts are identified based on matching core electrical and mechanical parameters: 40-position configuration, 2.54mm pitch, 2-row layout, through-hole mounting, push-pull fastening, and operating temperature range compatibility.

Key Parameters

Parameter	HTSW-120-08-G-D Specification
Manufacturer	Samtec Inc.
Connector Type	Header
Number of Positions	40
Number of Rows	2
Pitch - Mating	0.100" (2.54mm)
Row Spacing - Mating	0.100" (2.54mm)
Contact Type	Male Pin
Mounting Type	Through Hole
Termination	Solder
Fastening Type	Push-Pull
Shrouding	Unshrouded
Contact Finish - Mating	Gold
Contact Material	Phosphor Bronze
Operating Temperature	-55°C ~ 125°C
Insulation Material	Liquid Crystal Polymer (LCP)
Material Flammability Rating	UL94 V-0
RoHS Status	ROHS3 Compliant
Moisture Sensitivity Level	1 (Unlimited)

Substitute Part Grouping Explanation

Substitute parts for the HTSW-120-08-G-D are classified based on strict adherence to the following core parameters:

Primary Matching Criteria:

40-position connector configuration
2-row layout with 0.100" (2.54mm) pitch spacing
Male pin contact type
Through-hole mounting
Push-pull fastening mechanism
Unshrouded design
Solder termination capability
UL94 V-0 flammability rating

Secondary Compatibility Parameters:

Contact finish (gold-plated mating surface preferred for signal integrity)
Contact material (phosphor bronze or copper alloy)
Operating temperature range (minimum -55°C to 125°C overlap required)
Insulation material (LCP or thermoplastic acceptable)
RoHS compliance status

Substitutes are grouped into two categories: direct equivalents from alternative manufacturers (Amphenol ICC/FCI, TE Connectivity) maintaining identical electrical and mechanical specifications, and functional equivalents with minor variations in contact post length, contact finish thickness, or insulation material that do not affect primary circuit performance.

Parameter Comparison

Parameter	HTSW-120-08-G-D	1-104350-7	67997-140HLF	67997-240HLF	68602-140HLF	68602-440HLF	69192-140HLF	7-146256-0	7-146261-0	77313-101-40LF	77313-102-40LF
Manufacturer	Samtec Inc.	TE Connectivity	Amphenol ICC (FCI)	Amphenol ICC (FCI)	Amphenol ICC (FCI)	Amphenol ICC (FCI)	Amphenol ICC (FCI)	TE Connectivity	TE Connectivity	Amphenol ICC (FCI)	Amphenol ICC (FCI)
Number of Positions	40	40	40	40	40	40	40	40	40	40	40
Number of Rows	2	2	2	2	2	2	2	2	2	2	2
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)
Row Spacing - 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)
Contact Type	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin
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	Press-Fit, Solder	Solder	Solder	Solder	Solder	Kinked Pin, 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
Shrouding	Unshrouded	Unshrouded	Unshrouded	Unshrouded	Unshrouded	Unshrouded	Unshrouded	Unshrouded	Unshrouded	Unshrouded	Unshrouded
Contact Finish - Mating	Gold	Gold	Gold or Gold, GXT™	Gold or Gold, GXT™	Gold or Gold, GXT™	Tin	Gold or Gold, GXT™	Gold	Gold	Gold or Gold, GXT™	Gold or Gold, GXT™
Contact Material	Phosphor Bronze	Copper Alloy	Phosphor Bronze	Phosphor Bronze	Phosphor Bronze	Phosphor Bronze	Phosphor Bronze	Copper Alloy	Copper Alloy	Phosphor Bronze	Phosphor Bronze
Operating Temperature	-55°C ~ 125°C	-65°C ~ 105°C	-65°C ~ 130°C	-65°C ~ 130°C	-65°C ~ 130°C	-65°C ~ 130°C	-65°C ~ 130°C	-65°C ~ 105°C	-65°C ~ 105°C	-65°C ~ 130°C	-65°C ~ 130°C
Insulation Material	Liquid Crystal Polymer (LCP)	Thermoplastic	Not specified	Not specified	Not specified	Not specified	Not specified	Liquid Crystal Polymer (LCP)	Liquid Crystal Polymer (LCP)	Thermoplastic	Thermoplastic
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
RoHS Status	ROHS3 Compliant	RoHS non-compliant	RoHS Compliant	RoHS Compliant	RoHS Compliant	RoHS Compliant	RoHS Compliant	RoHS Compliant	ROHS3 Compliant	RoHS Compliant	RoHS Compliant
Product Status	Active	Obsolete	Active	Active	Active	Active	Active	Active	Active	Active	Active

Engineering Selection Recommendations

Preferred Substitutes (Active Status, RoHS Compliant):

The following parts are recommended as direct substitutes based on Active product status and full RoHS compliance alignment with the HTSW-120-08-G-D:

67997-140HLF (Amphenol ICC BERGSTIK® II): Active status, RoHS Compliant, phosphor bronze contacts with gold finish, operating temperature -65°C ~ 130°C. Contact post length 0.120" (3.05mm) versus 0.200" (5.08mm) on primary part.
67997-240HLF (Amphenol ICC BERGSTIK® II): Active status, RoHS Compliant, phosphor bronze contacts with reduced gold finish thickness (15.0µin), operating temperature -65°C ~ 130°C.
68602-140HLF (Amphenol ICC BERGSTIK® II): Active status, RoHS Compliant, phosphor bronze contacts, extended contact post length 0.150" (3.81mm), operating temperature -65°C ~ 130°C.
68602-440HLF (Amphenol ICC BERGSTIK® II): Active status, RoHS Compliant, tin-plated contacts and posts, extended contact post length 0.150" (3.81mm), operating temperature -65°C ~ 130°C.
69192-140HLF (Amphenol ICC BERGSTIK® II): Active status, RoHS Compliant, kinked pin termination option, phosphor bronze contacts with gold finish, operating temperature -65°C ~ 130°C.
7-146256-0 (TE Connectivity AMPMODU Mod II): Active status, RoHS Compliant, copper alloy contacts with gold finish, LCP insulation material matching primary part, operating temperature -65°C ~ 105°C.
7-146261-0 (TE Connectivity AMPMODU Mod II): Active status, ROHS3 Compliant, copper alloy contacts with gold finish, LCP insulation material, shorter contact post 0.090" (2.29mm), operating temperature -65°C ~ 105°C.
77313-101-40LF (Amphenol ICC BERGSTIK®): Active status, RoHS Compliant, breakaway header option, phosphor bronze contacts with gold finish, operating temperature -65°C ~ 130°C.
77313-102-40LF (Amphenol ICC BERGSTIK®): Active status, RoHS Compliant, breakaway header option, phosphor bronze contacts with gold finish, extended contact post 0.135" (3.43mm), operating temperature -65°C ~ 130°C.

Not Recommended:

1-104350-7 (TE Connectivity AMPMODU Mod II): Obsolete product status and RoHS non-compliant. Use only if legacy system compatibility is mandatory and no alternative exists.

Frequently Asked Questions (FAQ)

Q: Can I substitute the HTSW-120-08-G-D with any of the listed alternatives without PCB redesign?

A: Yes, all listed Active and RoHS-compliant substitutes maintain the same 40-position, 2-row, 0.100" (2.54mm) pitch configuration and through-hole mounting footprint. However, contact post length variations (ranging from 0.090" to 0.200") may affect solder joint depth and PCB trace routing. Verify contact post length compatibility with your PCB design before final selection.

Q: What is the difference between the BERGSTIK® II and BERGSTIK® series from Amphenol ICC?

A: Both series meet the core 40-position, 2.54mm pitch specifications. BERGSTIK® II parts (67997, 68602, 69192 series) are current production lines with Active status. BERGSTIK® parts (77313 series) offer breakaway header options for modular applications. Both maintain identical electrical performance and UL94 V-0 flammability ratings.

Q: Why do some substitutes have tin-plated contacts instead of gold?

A: The 68602-440HLF variant uses tin plating on both mating and post surfaces. Tin provides equivalent electrical conductivity and solderability for standard applications while reducing material cost. Gold plating offers superior corrosion resistance in high-humidity or harsh environments. Select based on application environmental requirements.

Q: Are TE Connectivity AMPMODU Mod II parts compatible with Samtec HTSW headers?

A: Yes. The 7-146256-0 and 7-146261-0 maintain identical 40-position, 2-row, 0.100" (2.54mm) pitch specifications and push-pull fastening. Both use LCP insulation material matching the primary HTSW-120-08-G-D. Operating temperature range is -65°C ~ 105°C, which overlaps the primary part's -55°C ~ 125°C range.

Q: What does "Kinked Pin" termination mean on the 69192-140HLF?

A: Kinked pin termination features a bent contact post design that improves mechanical retention in the PCB hole during soldering. This reduces the risk of contact migration during thermal cycling. Electrical performance is identical to straight-pin designs.

Q: Should I use ROHS3 Compliant parts or RoHS Compliant parts?

A: ROHS3 Compliant parts (HTSW-120-08-G-D, 7-146261-0) meet the most current RoHS 3 directive requirements. RoHS Compliant parts meet earlier RoHS standards. For new designs, ROHS3 Compliant parts are preferred. For legacy system maintenance, either classification is acceptable if the original design specified RoHS compliance.

Q: What is the inventory availability difference between substitute options?

A: Inventory levels vary: 7-146256-0 has 6549 units, 68602-440HLF has 2286 units, 7-146261-0 has 2951 units, and 1-104350-7 has 1366 units. Verify current stock status with your supplier before committing to high-volume orders.

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