I've tried replacing the motherboard, power supply, video output card, and hard drives. As well as, adding case fans. So far nothing has helped.
We haven't bothered with advance replacements for two reasons:
1) We purchased three new units (as i mentioned in my original post) and two were bad out of the box.
2) Tempest has been extremely difficult to deal with. I tried to explain to them that our customers are required by law to keep six months video history so I needed to keep the hard drives out of the bad units for six months. They charged me $155 for each 250 gig hard drive. I've had numerous other problems with Tempest, but there is not enough space here for me to relate all of them.
As far as, loading the OS and drivers separately, this is a linux based unit and the OS is inseparable from the Tempest software. I've had several computer experts look at it and they can't find a way to separate them.
I believe the problem may be in the proprietary Tempest capture cards.
Each card has one BT878 capture chip which should capture 30 frames per second, yet Tempest claims a capture rate of 60 frames per second per card. I've set the capture rate at 5 frames per second yet on playback the capture rate seems closer to 10 frames per second. It seems the BT878 is being overclocked. There is an option in the software that is suppose to disable this feature but it does not seem to work. There is a relatively large IC on the capture card that I beleive modifies the function of the BT878.