Hardware Unboxed Suffers Melted RTX 5090 Power Connector After Cable Hits 175°C

12V-2×6 Connector Meltdown Strikes RTX 5090 Test Bench

Hardware Unboxed has encountered a significant hardware failure involving the 12V-2×6 power connector on an RTX 5090 graphics card during a recent test. The incident occurred while using an ASUS ROG Astral RTX 5090 paired with a be quiet! Dark Power 13 power supply unit (PSU). The issue first became apparent when the host, Steve, noticed the cable was dangerously hot to the touch—hot enough to cause a burn. Subsequent thermal imaging revealed temperatures exceeding 150°C, peaking at approximately 175°C under load.

To diagnose the problem, a Thermal Grizzly WireView Pro was used, which quickly identified a severe current imbalance. While some pins on the connector carried almost no current, a single wire was found to be drawing around 22 amps. Interestingly, the most severe damage was observed on the PSU side of the cable, rather than at the graphics card itself.

The affected cable had fused inside the Dark Power 13’s connector, requiring pliers for removal. In contrast, the graphics card’s connector showed no visible signs of damage. Hardware Unboxed confirmed that the cable was fully seated, ruling out improper installation as the cause.

Ongoing Issues with 12V-2×6 Connectors on High-End GPUs

This is not an isolated incident. The 12V-2×6 connector has developed a reputation for reliability issues, particularly with high-performance GPUs like the RTX 5090. Reports have surfaced of connectors melting even when users apply undervolting and power limits to reduce stress on the hardware. In one documented case, an ASRock PSU’s thermal cutoff feature prevented a similar failure, potentially saving the graphics card from damage.

The persistent risk has led some enthusiasts and modders to take drastic measures, such as soldering power wires directly to the PCB to bypass the problematic connector entirely. These ongoing failures highlight the need for improved connector designs and stricter quality control, especially as graphics cards continue to demand higher power delivery.