November 27th, 2024

The capacitor that Apple soldered incorrectly at the factory

Doug Brown's analysis reveals a manufacturing error in Apple's Macintosh LC III involving capacitor C22, which was incorrectly installed, posing risks for future repairs and emphasizing the need for proper documentation.

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The capacitor that Apple soldered incorrectly at the factory

In a recent analysis, Doug Brown discusses a manufacturing error involving a capacitor in Apple's Macintosh LC III model, produced between 1993 and 1994. The issue centers around the incorrect installation of capacitor C22, which was found to have its positive terminal connected to the -5V rail instead of ground, contrary to standard practices. This misplacement could lead to potential failures, especially when replacing the original electrolytic capacitors with tantalum ones, which are less tolerant of reverse polarity. Brown highlights that while the original capacitor may have functioned without catastrophic failure, the design flaw poses risks for future repairs and restorations. He emphasizes the importance of documenting this error, as many recapping guides overlook it, potentially leading to dangerous situations for hobbyists. The analysis also compares the LC III's circuit with that of earlier and later models, confirming that Apple did not maintain consistent design practices. Brown concludes by advising anyone recapping an LC III to install C22 in the opposite orientation from what the PCB indicates, ensuring proper functionality and safety.

- The Macintosh LC III has a known capacitor installation error that could lead to failures.

- The incorrect orientation of capacitor C22 poses risks when using tantalum capacitors for replacements.

- Original capacitors may have tolerated the error, but future repairs could be hazardous.

- Documentation of this error is lacking in many recapping guides.

- Users are advised to install C22 in the opposite orientation from the PCB markings.

Link Icon 32 comments
By @ethbr1 - 6 months
Well, today I learned to install one capacitor in reverse orientation on the PCB on a 34 year old computer...

Definitely starting Wednesday off productively.

By @ethernot - 6 months
There are so many cases of this sort of stuff it's unreal. But it gets even stupider.

I found one a few years back when I repaired a linear power supply. This required me to reverse engineer it first because there was no service manual. I buzzed the whole thing out and found out that one of the electrolytic capacitors had both legs connected to ground. They must have shipped thousands of power supplies with that error in it and no one even noticed.

By @codewiz - 6 months
Commodore had 3 capacitors mounted backwards on the A3640, the CPU board of the Amiga 4000 with 68040 processors: https://youtu.be/zhUpcBpJUzg?si=j6UFmIJzoC-UDS6u&t=945

Also mentioned here: https://amiga.resource.cx/exp/a3640

By @likeabatterycar - 6 months
The author seems to misunderstand PCB design flow. This is neither a "factory component placement issue" nor a silkscreen error. The error is in the schematic.

The layout CAD is often done by a different team that follows the schematic provided by design engineering. Automated workflows are common. The silk screen is predefined in a QA'd library. It is not their job to double check engineering's schematic.

The components are placed per the layout data.

Both those teams did their jobs correctly, to incorrect specifications. In fact, the factory performing assembly often is denied access to the schematic as it is sensitive IP.

If you're going to cast blame on a 30 year old computer, at least direct it at the correct group. It wasn't soldered incorrectly at the factory. They soldered it exactly how they were told to - backwards.

By @PeterStuer - 6 months
In the mid 80's I was the head of the CS student chapter. We ran the computer rooms for the science faculty. We had a room with about 20 Mac 128k. I do not know where Apple sourced their capacitors from, but these were not A-tier. A Mac going up in a puff of white smoke was a weekly occurrence. We had a few in reserve just to cycle them in while they were out to Apple for repair.

P.S. still my favorite Mac of all time was the IIcx. That one coupled with the 'full page display' was a dream.

By @robomartin - 6 months
Brings back memories…

About 30 years ago I designed my first PCB with frequencies in the GHz range. It was full of challenging transmission line paths with frequencies in the hundreds of MHz and above.

I am still proud of the fact that all of the high speed signals worked as designed, with excellent signal and power integrity (the large FPGA was challenging). Emissions passed as well.

I did, however, screw up one thing: DC

I somehow managed to layout the DC input connector backwards!

These boards were very expensive ($2K), so an immediate respin was not possible.

I had to design a set of contacts to be able to flip the connector upside-down and make the electrons go in the right way.

The joke from that point forward was that I was great at multi-GHz designs but should not be trusted with DC circuits.

By @rasz - 6 months
Commodore struggled with same mistakes on negative rail in Audio section, but also somehow on highend expensive CPU board.

https://wiki.console5.com/wiki/Amiga_CD32 C408 C811 "original may be installed backwards! Verify orientation against cap map"

A4000 https://wordpress.hertell.nu/?p=1438 C443 C433 "notice that the 2 capacitors that originally on A4000 have the wrong polarity"

Much worse is Commodore A3640 68040 CPU board aimed at top of the line A3000 and A4000 http://amiga.serveftp.net/A3640_capacitor.html https://forum.amiga.org/index.php?topic=73570.0 C105 C106 C107 silkscreen wrong, early revisions build according to bad silkscreen.

By @alain94040 - 6 months
Sounds like the person who designed the board followed a very simple and wise rule: always connect the negative side to the ground. Can't go wrong with that...

until you have to deal with negative voltage (-5V). Another out of bounds bug.

By @magic_smoke_ee - 6 months
From around 2011-2015, I sometimes talked to an ex-Navy electrical tech who said he was also an early Apple rework tech in the SF Bay Area. He had no shortage of work fixing manufacturing problems, adding rework improvements, and building custom test equipment until they laid him off, outsourced his job to some random country, and then he was homeless until around 2016.
By @johnklos - 6 months
It's a good thing that these machines don't even need -5 volts. With just the positive voltages provided, RS-422 still works, including LocalTalk.

I think the -5 volts is only there in case an expansion card needs it.

By @shiroiushi - 6 months
Apple should be required to do a recall for these motherboards.
By @0xbadcafebee - 6 months
Anyone else a veteran of the Great Capacitor Plague? Seen more than one fire in the server room due to bad capacitors. "Burning-in" your server became literal.
By @foft - 6 months
It is not just Apple that did this, for example here is an equivalent from Atari: https://www.exxosforum.co.uk/forum/viewtopic.php?f=17&t=1698
By @1970-01-01 - 5 months
The best way to remove any aluminum SMD cap is to grab it with needle nose pliers, press it down into the PCB, and begin twisting them a under moderate pressure while alternating direction until they break away from the PCB. Never pull up!
By @chefandy - 6 months
What’s the liquid in the old capacitors? PCBs? (as in polychlorinated biphenyls… that abbreviation collision always annoyed me.)

I think I know exactly enough about electronics to ask more annoying questions than someone who doesn’t know anything at all.

By @yborg - 6 months
I have a Quadra 700 of this vintage that hasn't been powered up in 25+ years. Kind of wanted to fire it up again to experience the glory of A/UX one more time, but sounds like I'd have to replace all the lytics :/
By @sroussey - 6 months
I have an original Mac that no longer turns on. I bet there is a capacitor to replace. This is giving me the energy to go look for it!
By @Waterluvian - 6 months
I spent my mid childhood on an LCIII. One summer my friend brought his Performa over and we tried to play 1v1 Warcraft 2 over the serial port. LocalTalk or something alike?

But it just never quite worked right. I remember how frustrated and confused my older brother was. The computers would sometimes see each other but would drop off so easily.

Was this that?!

By @mikewarot - 6 months
I've found a ground lug in a Kilowatt Grounded Grid amplifier... that didn't ground the grid.

I found a bad solder joint that looked ok, but was intermittent, and had been that way, in a Television built in 1948 and used for decades.

Bad design and assembly goes back forever, as near as I can tell.

By @etrautmann - 6 months
The first board I ever designed and had manufactured had a reversed tantalum capacitor on the power rails and exploded somewhat dramatically when powered up. Lesson learned!
By @Animats - 6 months
Does the -5V rail do anything other than power old RS-232 ports?
By @omoikane - 6 months
I wonder if there were any bootleg boards that copied the silkscreen mistake, but didn't use those 16V capacitors, and ended up catching fire.
By @weinzierl - 5 months
"The capacitor might not have been doing its job properly if it was installed backwards, but it didn’t seem to really be hurting anything."

This is the buried lede! I am of the opinion that half of the capacitors in any modern circuit are useless; the trouble is we don't know which half.

By @mhardcastle - 6 months
Why include that capacitor at all if it doesn't matter whether it works?
By @moring - 5 months
Why is the pool of goo under C21 when it is C22 that is flipped?
By @PcChip - 6 months
Didn’t this also happen on some Asus motherboards a couple years ago?
By @1oooqooq - 6 months
what apple era are those machines? is this before or after Jobs shafted the engineering department on the sale and Woz had to give them bonus to keep them on the factory?
By @lmpdev - 6 months
I have my childhood LC II in storage

I wonder if it has the same defect

By @nsmog767 - 6 months
not the Flux Capacitor?!?!
By @hettygreen - 6 months
They were probably expecting these to fail a few months after the warranty expired.