Factual error: A recurring mechanism in the series is if the power fails the prison cells that are magnetically locked open immediately. No magnetic locks are designed like this. They would fail their initial purpose which is to provide physical security. If a power outage occurs it would take hours before the locks would be released.
Chuck Versus the Fat Lady - S2-E7
Factual error: When Chuck and Jill recover Guy LeFleur's hard drive containing the list of Fulcrum agents, General Beckman says that the flash drive is encrypted with a 512 bit AES cypher. She then goes on to state, "the computer is trying every possible key against the encrypted data, " i.e., a brute force hack. However, it would take the fastest supercomputer in the world longer than the existence of the known universe in order to crack even a 128 bit AES encryption (and a 512 bit AES encryption has the number of possible keys of a 128 bit AES encryption, raised to the fourth power). In a previous episode, Chuck refers to the computer in Castle as having a "30 teraflops" speed, which is far less than the current fastest supercomputer. General Beckman instead says it will take only hours or days. (00:26:10)
Chuck Versus the Fake Name - S3-E8
Factual error: When they first bring Grueber into Castle, Sara states that "he is one of five people who can hit a target from half a mile away." Half a mile is 880 yards. Basically every person who has graduated from (or likely everyone who has been selected for) sniper school in any military in the world should be able to do this. (00:05:20)
Chuck Versus the Anniversary - S4-E1
Factual error: Chuck is supposedly riding a Los Angeles city bus. But the buses pictured are NYC buses. (00:14:05)
Chuck Versus the Suitcase - S4-E2
Factual error: During a fast serie of Milan and runways shots there is one pic of the harbour of Hamburg, Germany. (00:08:05)