dolomiah wrote:
However I've just spent 3 evenings scratching my head over random issues which looked like software but I was convinced was hardware. I checked the EEPROM and RAM over and again, but finally this evening decided to swap out the 6502 with a fresh one. It worked! So then I decide to solder a bypass capacitor to this one, plug it back in and find exactly the same weird problems! So I swap that one out for yet another fresh 6502 and my system is working again.
My experience with defective ICs has been extremely limited, despite have worked with them for close to 50 years. Almost always, defects are actually damage caused by ESD (most common) or operation at excessive voltage, not soldering. As Garth pointed out, devices can tolerate some amazingly high temperatures for short periods of time, even under bias. 450 degrees F is a typical reflow temperature in many production environments, so you know the device has to be able to withstand that.
When I built POC V1.1, I used an SOIC-24 version of the MAX238, as well as an SOJ-32 SRAM, both with 50 mil pin centers. I dragged-soldered these parts, which subjected them to considerable heat for about 12-15 seconds per side. Adding insult to injury, I then used desoldering braid to clean up my handiwork, adding more heat to an already hot part. Yet, I have experienced absolutely no problems with the computer, which has exhibited excellent stability. In fact, and as Garth pointed out, POC V1.1 ran 24/7 for over 300 straight days without being rebooted. That's nearly 8000 continuous operating hours.
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There was a time when chip yields were poor and most manufacturers cheerfully admitted that some of what they sold would turn up defective. It is possible your 6502 was defective from the day it was manufactured and only a certain combination of operations uncovered the problems. However, the bad old days of low yields had pretty much subsided by the latter 1970s. So I think it is unlikely you got a device that was defective as produced.
As you admitted that your handling techniques aren't the most cautious, I'm inclined to say you accidentally zapped the 6502 at some point and the "wound" is now "festering." It isn't going to get better, no matter how many bypass capacitors you connect to it. Try to be more careful with the next one.
I'm not obsessive about ESD handling precautions, but I am careful to ground myself before touching anything. I have never zapped anything.