Indy, crackling speaker & strange smell

trembl

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Feb 13, 2025
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After being a SGI user in the mid-90ies, I finally got my hands on a SGI Indy!

The good news: it boots to the PRAM screen, I am planning to use a BlueSCSI has hard disk replacement.

The worrying news: the speaker started to make crackling sounds, which were soon followed by a strange burning smell. The video output kept working, but I pulled the power immediately.

I visually inspected the Sony PSU, no obviously blown caps.

I would be grateful for any advice or suggestions what to do next.

Was anyone in a similar situation?
 
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Check the MOSFETs. These systems are known for needing a full recap. If that's beyond your capabilities, Weblacky has rebuilt two of my power supplies and while I have not yet tested either of them I am fully confident in his capabilities. There will be a review of his service as soon as I have time to fuck with them.
 
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I've seen something like this before. There's an audio amplifier on the board and usually one of the yellow tantalum capacitors has caught on fire on its circuit. Most of the time this is from a power supply that has fed very unclean power, possibly even out of tolerance voltages, to the motherboard. I actually bought a system from somebody that had done this exact thing. Make a little noise and start burning and yet the system kept running just fine (see attached photo) for a minute or so more before it was finally turned off.

Most of the time you can just replace the failed capacitor(s) and get another power supply and you should be fine. There is the off chance of the power supply was fine and the capacitor just went on its own, but I don't normally see that. The tantalum caps are very prone to failure (especially with advanced age) if there is excessive ripple (dirty DC power) coming out of the PSU. It's their one weakness really. They don't have the filtering tolerance of a MLCC or an electrolytic cap. But when fed correct power, that's clean, they are extremely long lived and durable.

Replacing the capacitor is pretty easy, they're all usually the same or similar values and there's lots of pictures online of the Indy motherboard to get the values off of (I've provided a link on this post below): https://bukosek.si/hardware/collection/sgi-indy/img/indy_motherboard_front.jpg

The affected capacitor (for me) was C52, see both photos for comparison. I can't guarantee it's the exact same capacitor for you. But this is what you'd be looking for. I used high-end desoldering tweezers to simply remove this and replace it in two minutes. But if you don't have that kind of equipment you may have to get creative.

The heat should've discolored the capacitor. It may not be as bad as the picture that I provided because the previous owner just let it go as they were wondering what that smell was. That's why I always recommend that people start an Indy with its cover off when they first test start it because this can happen and you'll see where the smoke is coming from.

Be aware that I would recommend you not use hot air in this section as the three silver looking components next to C52 (marked U35, U36, & U38) are an obsolete form of resettable polyfuse that's no longer available. I have a small stash of them but they have a tendency to fail if exposed to heat for desoldering them or soldering them in wrong. So if you heat the whole region those three silver components right next to that cap could be ruined which will disconnect major parts of the motherboard circuit. I recommend you use two soldering irons, one on each end, to try to successfully get the cap off the board or buy a really cheap set of ceramic heating desoldering tweezers for like $20 that you only need to use once.

If you can take pictures and post them we might be able to see something in the pictures to help you out, you'll need really good lighting though to get good pictures.

Good Luck.
 

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Thank you for the very detailed and helpful comments. A closer olfactorial inspection made it clear, that the smell was coming from one of the capacitors on the motherboard! Off to order the replacement capacitors - and trying to get another PSU! I'll make sure to document my journey in getting the Indy to work!
 
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That's the plan! I saw some forum members offering refurbished PSUs, but could not find a list for replacement parts (yet). If anyone has a parts list for the Indy Sony PSU, it would be great. I am also happy to work on the PSU, document and share any info I can find.
 
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That's the plan! I saw some forum members offering refurbished PSUs, but could not find a list for replacement parts (yet). If anyone has a parts list for the Indy Sony PSU, it would be great. I am also happy to work on the PSU, document and share any info I can find.

There might be a listing somewhere, but I purposely do not work on the Sony's as information in this forum has proven that they are prone to allowing the Indy to overheat in several scenarios. Until someone who has electrical engineering talents can alter the fan PWM curve (via circuitry), it's likely going to remain that way. I've never been in a Sony, I exclusively do Nidec for Indys.

However I can easily warn you that assuming the Sony is built like the Nidec, it might use previous generation PCB technology which is essentially gigantic solder tracks coated in a very delicate resist. The tracks are incredibly prone to lifting unless you use professional equipment. This is especially true of the filter capacitors in the Nidec. Those capacitors use vias that have been artificially inserted through the single layer board, those vias very easily come out with the capacitor terminals unless you not only use low melt solder but you dwell enough time to rock them out slowly.

The Sony's do have some positives but until somebody figures out how to even just shift the fan curve properly, it's not worth my time.

Also to be fair, I'm not a big fan of posting material lists because it encourages people that shouldn't be inside these things to try to fix them. Remember they don't make any more of these and they're proprietary. So every unit that somebody chars the board with a heat gun or something is a unit lost permanently to time. If you have the correct tools then obviously making the material list yourself is absolutely no problem. After all most of the issues are going to be dimensional so even if somebody posted capacitor values you can't just go buy any random capacitor. You need to get one that's physically going to fit in the dimension required or it's actually smaller. Part numbers change so frequently that even when I order stuff, six months later one or more of the parts has been retired on DigiKey. That's another reason I don't bother.

I'm not trying to be arrogant about it, I'm simply saying that the barrier to entry stays where it is because these things are so easy to damage and we've already lost a huge amount of inventory already to people throwing away broken parts. It's one of the main reasons prices have radically increased in in the past decade.

Obviously it's personal property and you may do whatever with it, I just warned you that it is a project and you should expect to at least spend 10 hours or so not only removing each of those capacitors and marking where they're supposed to go but also researching their correct replacement and recording that and their dimensions and then finding something that's actually in stock at a reputable part supplier that matches those specifications.

Since your power supply technically works you shouldn't have any semiconductor issues so a simple recap should work. I also recap the logic daughterboard on the Nidecs, as there are a few small electrolytics there.

Also I don't know about the Sonys, but the Nidecs also use a very old form of stabilizer that glues several of the components down as well as holds the daughterboard down to its connectors to prevent accidental separation during shipping. About 25 minutes of my time is spent very carefully disconnecting these with a special low temperature blade on my soldering iron and then attempting to get it removed off some of the components. Some of them are fully coated in this stuff which causes some problems and some of it is just to tack components to each other but all of them need to be separated because several need replacement. So not only will you have to replace components you'll likely have to separate the old stabilizer. I replace the stabilizer with a 3M product design designed for the same purpose but using different chemicals. That radically increase my time and costs but there's a reason the stabilizer was used, as some of the components are incredibly top-heavy, a few coils especially, and so moving the system around or putting it on its side and potentially jarring it could actually cause part damage inside the power supply. So after load testing and then bench testing I batch up about 4 to 5 power supplies at once and open a new tube and start gooping up all the same locations for the same reasons.

Good luck.
 
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I just acquired an Indy, that had exactly the same symptoms, as stated by @trembl. The magic smoked escaped elsewhere: (see attached Image)
The PSU still works, the machine powers on, recommends me to change a "faulty system board" (impressive, that Indy feels its 'pain'!). So I quickly powered it down. Next step: replace the cap on the planar and recap the PSU.
 

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