GeForce RTX 4090 power connector meltdown analysis paints improper insertion and debris inside the connector as chief culprits

Shortly after the launch of the RTX 4090, Nvidia found itself embroiled in a big controversy: some of the 12VHPWR power connectors that debuted on the Lovelace flagship were melting, damaging the US$1,600 GPUs in the process. Nvidia responded by calling on AIBs to send the affected cards directly to Team Green’s HQ for further investigations.

However, Nvidia wasn’t the only team looking into the matter as third-parties such as igor’s Lab also started testing the 12VHPWR adapters that come bundled with the RTX 4090 boards. Folks at Gamers Nexus (GN), a popular YouTube channel focused on PC hardware, were also testing the cables. GN has now published its findings regarding the failing RTX 4090 power connectors.

According to GN, the failure rate of the 12VHPWR power connectors is quite small as it only lies between 0.05-0.1%. The figure is based on user data, the information provided by AIBs, and data from cable suppliers. GN claims that all 12VHPWR adapters regardless of the supplier and even the native PSU cables can fail depending upon several factors.

Firstly, “Foreign Object Debris (FOD)” is mentioned as a possible cause of cable malfunctions. Per GN, FOD can be the result of manufacturing errors and/or scraping of the connector bumps that can deliver debris inside the connectors. The problem is further exacerbated due to the high levels of current that flows through the thin connectors and less-than-ideal contact.

Remember, that although the RTX 4090 FE has a TDP of 450 W, overclocked models can draw up to 600 W. At such elevated power usage, any debris stuck inside the plastic housing can heat up quite a bit due to bad contact points potentially causing a meltdown.

Secondly, improper connector seating can also be a major cause of melting power connectors especially if the cable is inserted at an angle. GN explains that, because the 12VHPWR cables don’t come with a latch to secure them in place, it is much easier for users to not insert the cables completely.

While the full video goes into much more detail about the root causes of the problem, here is what you need to know if you have an RTX 4090 or are planning to buy one: make sure the connectors are seated properly without any egregious bends in the cable at relatively extreme angles and you'll most probably be fine.

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