Disassembly Report: Intel NUC Mini PC Original 120W Power Adapter

Introduction

The mini PC has emerged in recent years as a new type of compact computer, usually featuring integrated graphics and powered by an external power supply. Compared to traditional desktop cases, mini PCs have a significant size advantage, roughly equivalent to the size of two 12CM fans, making them suitable for placement on desks or behind monitors, saving space and meeting office needs.

The Charging Head Network has purchased an original FSP 120W adapter for the Intel NUC mini PC. This adapter, model FSP120-ABBN3, has an output power of 120W, output voltage of 19V, output current of 6.32A, and comes with a 1.8-meter DC output cable. The adapter supports global wide voltage input and features a C6 plug socket, allowing for the use of power cords of different lengths and plug types. Below is the disassembly of this adapter to examine its internal design and materials.

FSP 120W Power Adapter Appearance

The FSP power adapter is entirely black, with a large flat body. The power cable at the input end is designed to be detachable from the body, making it easy to replace, while the output end comes with a built-in DC cable.

The outer shell is matte and fingerprint-resistant, with no branding or markings on the top or sides, resulting in a very clean design.

The bottom has an adapter nameplate affixed, with four hemispherical protrusions to prevent wear.

Close-up of the adapter nameplate

Model: FSP120-ABBN3

Input: 100-240V~50/60Hz 1.8A

Output: 19V6.32A 120W

Manufacturer: FSP Group Inc.

The adapter has passed multiple safety certifications, including CCC, CE, CP, EAC, PSE, NOM, NYCE, UL, KC, GS, and has also achieved VI energy efficiency certification.

The input end of the adapter uses a plug socket that effectively prevents electric shock.

The output cable features a 90° bend design and is also reinforced against bending, making it convenient for placement in tight corners.

The cable features a common shielding magnetic ring.

Close-up of the DC terminal of the cable.

The measured length of the FSP power adapter is 151.04mm.

The measured width is 75.61mm.

The thickness is 25.79mm.

The cable length is approximately 1.8 meters, and with the power cord, the total length is sufficient to meet various application needs.

The size of the adapter in hand gives an intuitive feel.

Additionally, the measured weight is approximately 374g.

Disassembly of FSP 120W Power Adapter

Open the adapter shell along the side seam; the internal PCBA module is wrapped in aluminum for heat dissipation.

The input socket uses wire soldering connections.

Insulation tape is applied to the aluminum sheet corresponding to the output capacitor position.

The heat sink is fixed via clips.

The heat sink is soldered to the PCBA module.

The AC input wire is cold-pressed and soldered.

The output wire is also cold-pressed and soldered, with heat shrink tubing for insulation.

Open the heat sink wrapped around the PCBA module; the internal PFC inductor and LLC transformer are coated with thermal paste for heat conduction.

The rectifier bridge and PFC switch tube are fixed to the heat sink with screws.

The aluminum heat sink is riveted and soldered to a metal piece.

The length of the PCBA module is measured to be approximately 145.8mm.

The width is approximately 67mm.

The thickness is approximately 18.27mm.

The front view of the PCBA module shows the input fuse at the upper left, followed by the varistor, common mode inductor, rectifier bridge, filter capacitor, and filter inductor, with the PFC boost inductor at the top, and the PFC switch tube at the top. To the right of the PFC boost inductor are the high voltage filter capacitor, resonant capacitor, transformer, and soldered filter capacitor and filter inductor.

The back side is soldered with the PFC controller, PFC rectifier tube, LLC controller, LLC switch tube, feedback optocoupler, synchronous rectification controller, and synchronous rectification tube.

By observing the PCBA module, it is found that this FSP power adapter uses an efficient switching power supply architecture with PFC + LLC + synchronous rectification, with three controllers respectively for PFC boosting, LLC switching power supply, and synchronous rectification, providing fixed voltage output. Now let’s start learning about each component from the input end.

The input fuse specification is 4A 250V.

The varistor model is TVR10681K, used for lightning surge protection.

The safety X2 capacitor specification is 0.33μF.

The common mode inductor is wound with enameled wire, and the internal glue fixes the insulating board.

The rectifier bridge model is KBJ406, with a specification of 600V4A.

One of the film capacitors has a specification of 0.68μF 450V.

The other film capacitor has a specification of 1μF 450V.

The filter inductor is wound with a magnetic ring.

The PFC controller is NXP TEA19162, used to boost the rectified voltage and perform active power factor correction, with an integrated discharge element for the X capacitor, eliminating the need for external components, with integrated soft start and shutdown, supporting high precision voltage boost, and multiple comprehensive protection functions.

The PFC boost inductor is shown in close-up, with the core printed with the FSP brand.

Two switch tubes come from Jilin Huamei, model JCS10N60FT, NMOS, with a voltage rating of 600V and a resistance of 750mΩ, using TO220F insulated packaging, and are connected in parallel.

A close-up of a blue ceramic capacitor.

The 56mΩ sampling resistor is used to detect the current of the PFC switch tube.

The PFC rectifier tube is marked U3J.

The high voltage filter capacitor is from TAICON brand.

Specification: 420V 120μF.

The LLC controller is from NXP, model TEA19161T, which is a fully digital control high-efficiency LLC controller, with integrated high-voltage startup, high-voltage driver, soft start, and a maximum operating frequency of 500kHz, providing high conversion efficiency across the full load range and extremely low standby power consumption.

The LLC switch tube comes from STMicroelectronics, model STD11N50M2, NMOS, with a voltage rating of 550V and a resistance of 530mΩ, using DPAK packaging.

The other switch tube is of the same model.

The LLC resonant capacitor is from TDK, with a specification of 0.015μF, rated at 1KV.

The filter capacitor supplying power to the LLC controller has a specification of 25V 100μF.

The transformer is shown in close-up, with the core reinforced with glue.

The LTV-1008 optocoupler is used for output voltage feedback.

The synchronous rectification controller comes from MPS, model MP6924A, which is an LLC synchronous rectification controller with stronger anti-interference and fast shutdown capabilities, compatible with CCM/DCM modes. The MP6924A integrates two synchronous rectification controllers, used for rectification applications of the two secondary coils of the LLC converter.

The synchronous rectification tube comes from STMicroelectronics, model STL90N6F7, which is an NMOS with a voltage rating of 60V and a resistance of 5.4mΩ.

The other synchronous rectification tube is of the same model.

Two output filter capacitors are from TAICON brand, with specifications of 25V 680μF each.

The output filter inductor is shown in close-up, wound with a magnetic ring.

Additionally, a filter capacitor is soldered at the output end, with a specification of 25V 100μF.

A comprehensive view of all disassembled components.

Charging Head Network Disassembly Summary

The FSP power adapter has an output power of 120W, comes with a 1.8-meter long output cable, and features a 5525 DC plug. The adapter supports global wide voltage input, with an output voltage of 19V and an output current of 6.32A, suitable for powering NUC hosts and some laptops. This adapter features a plug socket that allows for the replacement of different plug types and lengths, making it versatile.

Through disassembly, the Charging Head Network learned that all internal components of this adapter are from well-known brands, using NXP TEA19162 PFC controller paired with TEA19161 LLC controller, and the synchronous rectification controller is MPS MP6924A. The PFC switch tubes come from Jilin Huamei, while the LLC switch tubes and synchronous rectification tubes are from STMicroelectronics.

The internal PCBA module is wrapped in aluminum for heat dissipation, with the rectifier bridge and PFC switch tubes fixed to the heat sink with screws, and the heat-generating components on the back of the PCB are also glued for heat dissipation through the aluminum sheet, ensuring adequate internal heat dissipation measures to meet long-term usage needs.