SERVICE BULLETIN

NOTICE: The Type of Change and Recommended Compliance specified reflects Solar’s best judgment regarding the
Service Bulletin. All questions should be directed to your Solar Field Service Representative. Solar, Saturn,
Centaur, Taurus, Mercury, Mars, Titan, SoLoNOx, and Turbotronic are trademarks of Solar Turbines Incorporated.
Cat and Caterpillar are trademarks of Caterpillar Inc. Specifications subject to change without notice.

NUMBER: 5.13.1/103
ISSUED: March 2001
REVISED:
PRODUCT: All
MODEL(S): All
Specifics: Applies to all Turbotronic units with TT2000 rack mounted
Industrial Display Computers

SUBJECT: FIELD PROCEDURES USED FOR TROUBLESHOOTING

AND REPLACEMENT OF TT2000 INDUSTRIAL
DISPLAY COMPUTERS

Type of Change: Product Enhancement

Recommended
Compliance: Information

Purpose:
This Service Bulletin describes the troubleshooting procedures, techniques, and kits to use in main-
taining the rack mounted T37/6151 Cathode Ray Tube (CRT) based industrial display computers.
The Solar core part number that includes these industrial display computers is 1014220.

GENERAL INFORMATION:
Solar has supplied industrial display computers since 1989. The heart of the computer is a highly
reliable real time data gathering operating system loaded on an Asynchronous Real-Time Interface
Coprocessor (ARTIC) card. The industrial display computers and ARTIC cards have been loaded
with Solar TT2000 display software package supplied by Solar to monitor engine parameters and
conditions.

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The computer consists of two sections:

1. A ’chassis’ section containing; the CRT, degauss and video circuits

2. A ’drawer’ section containing; the power supply, passive back-plane, CPU card and
ARTIC card.
Solar has supplied three basic rack mounted industrial display computer configurations:

1. T35 industrial display computers between 1989 and 1993

2. T36 industrial display computers from 1993 to 1996
3. T37/6151 industrial display computers from 1996 to the present.
The estimated life of an industrial display computer is around 5 years. The T35 and T36 industrial
display computers have reached or will be reaching the end of their life cycle. It is recommended
that they be replaced with a T37/6151 industrial display computers. The troubleshooting and main-
tenance of the T37/6151 industrial display computers are the main subjects of this Service Bulletin.

ACTION REQUIRED:
The following procedure outlines the processes to maintain and troubleshoot the T37/6151 CRT
based industrial display computers.

When a suspected problem occurs with a T37/6151 CRT based industrial computer the following
steps should be taken:

1. Identify the serial numbers of the chassis and drawer sections to determine the vintage
and compatibility of the sections. Solar Chassis power supply and degauss circuits
have been matched to prevent component failures. Mis-matched Chassis and drawer
sections can lead to failed or reduced component life. See the Troubleshooting Guide
for compatible matches.
2. Identify and describe the symptoms associated with the concern or failure. Some of the
issues/problems can be resolved directly in the field, some can be resolved with the
assistance of a local Solar Field Service Representative (FSR), and some of them may
have to be returned to Solar through normal channels for repair.
3. Review the Troubleshooting Guide to determine possible causes and associated
corrective actions. Issues not contained in the guide should be referred to a local Solar
FSR. They can help determine if the unit needs to be returned for repair or if it can be
resolved in the field.
4. Minor adjustments can be made with the unit in place. It is recommended that these
adjustments be made by a local FSR. Minor adjustments are:
a. Screen size and position

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 b. Pincushion
c. Focus
d. Brightness
5. Floppy drive, hard drives, ARTIC cards and monitor cooling fans can be replaced directly
in the field. The drawer section needs to be removed from the computer to make these
changes. For replacement procedures and the Solar kit part numbers see:
a. The Hard Drive Replacement Procedure
b. The Floppy Drive Replacement Procedure
c. ARTIC Card Replacement Procedure
d. Monitor Cooling Fan Replacement Procedure
6. Video and keyboard cables can be replaced directly in the field in the control console.
The computer will have to be rebooted to enable the keypad. For Solar kit part numbers
see the attached Troubleshooting Guide.
7. For all other issues/problems the industrial computer requires replacement.
a. Prior to replacement compare the software in the existing computer to the software
in the four floppy disks to be used to load software into the replacement computer.
I. Copy the files that are different or have a later date stamp to a floppy for later
installation
II. Copy the following log files from the root directory:
(1.) Snapshot.1
(2.) History.1
(3.) Eventlog.1
(4.) Lookup.1
(5.)Trigger.1
III. The Snapshot file may be very large. It is recommended that this file be
compressed with a Microsoft DOS compression utility that spans floppy
discs. One such program is PKZIP, Version 2.04g. The compression and
its corresponding decompression program should be loaded onto a blank
3 14 inch floppy disc and inserted into the floppy drive of the T37/6151
industrial display computer. PKZIP and PKUNZIP files use about 61KB of
disc space. With typical compression ratios and file sizes two floppy disks
will be needed for a complete set. With PKZIP in the floppy drive:
(1.) Select ’System Manager’ on the TT2000 menu page.
(2.) Enter the password and select ’0’ to ’exit to DOS’

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NUMBER: 5.13.1/103
 (3.) With a keyboard installed into the keyboard connection perform
the following commands
(a.) Copy c:\main\*.inf a:\*.*
(b.) Copy c:\main\history.dat a:\*.*
(c.) Copy c:\main\*.ini a:\*.*
(d.) a:\pkzip -& a:\snapshot c:\snapshot.? c:\History.?
c:\Eventlog.? e:\Trigger?.? c:\Trigger?.?
If help is needed with this process please contact your local field service
office.
b. Remove the computer and install the replacement computer per the Installation
procedure.
c. Load the software into the replacement computer with the four floppy disks per
the OMI instructions.
d. Load in the log files back into the root directory.
e. Load back any modified files identified in item 7.a.i back into the Main directory.
I. If files have been zipped in 7.a.iii.3.d with PKZIP they will need to be
unzipped from the DOS prompt with PKUNZIP. This can be achieved by
entering the command
(1.) a:\pkunzip -d a:\snapshot.zip
f. Prepare the replaced computer for shipment. Return video and keyboard cables
with the computer. Affix the Failure Incident Form to the computer showing the
description/symptom of the failure, serial number of the chassis, serial number of
the drawer and the site location.
Contact your local field service office for shipment instructions.

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ATTACHMENTS

Table 1 Troubleshooting Guide

Problem Possible Causes Corrective Action
Unit will not power up No power to unit 1 Ensure unit is supplied with power.
(Fan does not turn on, Inverted 24VDC supply 2 Check power switch
Hard drive and floppy Spike on 24 VDC supply 3 Verify proper voltage polarity on 24Vdc
drive not accessed Component failure units
during boot & display 4 Check fuse on back of unit
does not turn on) 5 Check for EMI/surge/spike filter
1022716 per Service Bulletin
5.13.1/100
No TT2000 display No power to unit 1 See corrective actions above.
Defective video cable 2 Check power to monitor
Defective video circuit. 3 Check/replace external video cable
Poor circuit board (Solar PN 1014216-55)
connection 4 Remove/inspect and reseat circuit
Defective ARTIC card boards
Incorrect ARTIC card 5 Verify ARTIC card settings correct
settings for version of drawer (ARTIC card
Unit powered up with Replacement Procedure)
condensation 6 Power up only if unit free from
condensation (Installation procedure)
Hard drive will not Missing operating system 1 Install operating system and applications
boot up Defective or loose data from floppy drive.
cables 2 Remove and reseat hard drive data cable
Defective hard drive 3 Replace hard drive (Solar PN
Incorrect BIOS settings 1014216-53 & Hard drive replacement
procedure)
4 Enter setup program on initial boot F2
and verify setup settings (Hard drive
software replacement procedure)
5 CMOS settings lost/changed (Verify
CMOS Settings)
Mismatched drawer Prior field change-outs of 1 Ensure that 1014220-105 and
and chassis leading to only the chassis later drawers get installed only in
failures/ reduced life 1014220-105 and later chassis
of power supply & 2 Only install 1014220-102 drawers in
degauss circuit 1014220-102 chassis
3 Ensure that 1014220-100 and
101 drawers get installed only in
1014220-100 and 101 chassis

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 Table 1 Troubleshooting Guide (Cont’d)
Problem Possible Causes Corrective Action
Monitor out of Component degradation 1 Adjust monitor using field alignment
adjustment (colors Adjustment pots changed procedures (Field adjustment procedure)
off, screen size off, too Power surge damage to 2 Replace Computer
bright, too dim) video circuit
Display is present but Noise generated by other 1 Remove source of noise or relocate
unstable equipment equipment.
Defective video cable 2 Degauss console
3 Check / replace external video cable
(Solar PN 1014216-55)
Floppy drive will not Bad floppy disk 1 Check with known good bootable
boot Dirty floppy drive floppy.
Data cable loose/Data 2 Clean floppy drive
cable routed too near 3 Check data cables on floppy
power supply 4 Replace floppy drive (Solar PN
Defective floppy drive 1014216-54 & floppy drive replacement
Foreign objects in drive procedure)
Keypads not Rear jumper unplugged 1 Check/replace cable on rear of unit
functional Loose internal keypad (Solar PN 1014216-55).
cable 2 Check verify seating of internal keypad
cable
Additional Keyboard Rear cable unplugged 1 Check/replace cable on rear of unit
not functional Defective keyboard (Solar PN 1014216-55).
Wrong Keyboard type 2 Use IBM AT compatible keyboard
3 Check with keyboard connected in rear
of drawer
Data frozen ARTIC card failure 1 Replace ARTIC card.
Incorrect CMOS setting 2 Verify CMOS settings
Unit powers up but fan Fan failure 1 Replace Monitor Cooling Fan (Solar
is not working PN 1014216-64 & Fan Replacement
Procedure)

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Hard Drive Replacement Procedure
PARTS REQUIRED:
1 Hard Drive Replacement (Solar PN 1014216-53)

PROCEDURE:

ENSURE THAT PROPER ELECTROSTATIC DISCHARGE PROCE-

DURES ARE USED

1. Copy all required software and log files from existing drives if possible.
2. Remove power from the industrial display computer.
3. Remove all cables from rear of computer drawer.
4. Loosen 2 thumbscrews securing computer drawer to chassis.
5. Remove computer drawer.
6. Remove 5 screws securing front bezel to chassis. (Figure 1)
7. Carefully move bezel with Light Emitting Diodes, LEDs and wiring to side.
8. From side of drawer, remove data cable to hard drive noting cable orientation. (Figure 2)
9. Remove 4 screws securing hard drive to chassis.
10. Slide hard drive from front of drawer.
11. Remove power connector from hard drive.
12. Install new hard drive reversing above procedure
13. Follow installation process for installing operating system and software and logs to drive.

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NUMBER: 5.13.1/103
 Figure 1

Figure 2

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Floppy Drive Replacement Procedure
PARTS REQUIRED:
1 Floppy Drive Replacement (Solar PN 1014216-54)

PROCEDURE:

ENSURE THAT PROPER ELECTROSTATIC DISCHARGE PROCE-

DURES ARE USED

1. Remove power from the industrial display computer

2. Remove all cables from rear of computer drawer.
3. Loosen 2 thumbscrews securing computer drawer to chassis.
4. Remove computer drawer.
5. Remove hard drive from drawer.
6. Locate and remove 4 screws on bottom of drawer that secure floppy drive to drawer.
(Figure 3)
7. From right side of drawer, remove 34-pin data cable from floppy drive noting orientation
of red wire. (Figure 4)
8. Remove power cable from floppy drive.
9. Slide floppy drive out from front of drawer.
10. Install new floppy drive reversing above procedure.

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 Figure 3

Figure 4

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Installation Procedure
ENVIRONMENTAL CONSIDERATIONS
Ensure the unit is allowed to warm to ambient temperature to reduce the possibility of condensa-
tion forming on critical electronic circuits. Failure to do so may result in catastrophic failure of
equipment.

PANEL MOUNTING
1. Confirm that the shipping carton contains a package of 20 10-32 lock nuts and 20 10-32
flat washers. You will need 14 nuts for installation.
2. Carefully remove the computer from its packaging - avoid damaging the panel gasket.
3. Insert the computer in the panel cutout from the front of the panel.
4. Install the washers and nuts provided on the mounting studs behind the panel.
5. Tighten the nuts evenly to 25 inch-pounds of torque.
Mounting nuts must be tightened to a torque of 25 inch-pounds to provide panel seal and avoid
potential damage to the Industrial Computer. To assure a proper seal, be sure to install a nut and
washer on each of the mounting studs.

POWER SUPPLY CONNECTION

1. Install surge suppression devices as appropriate.
2. Facing the back of the industrial display computer, look for the Power ON/OFF Button.
This is located at the bottom center, below the Keyboard connector. Make sure that this
Button is in the "OFF" or "0" position.
3. On 24v DC powered industrial display computers
a. Facing the back of the unit locate the White DC Power connector at the upper left
corner. Loosen the screws on the connector just enough to insert the wires from
your DC source.
b. Insert the Positive wire from your 24v DC source into the connector Labeled + V
(Red). (Figure 5)
c. Insert the Common wire from your 24v DC source into the connector Labeled - V
(Black).
d. Insert the Chassis Ground wire into the connector Labeled Gnd (Green).
4. Ensure that all connections are tight.

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 5. Continue to connect the other cables to your unit including the following:
a. Connect the 15 pin video connectors
b. Connect the 5 pin DIN keypad/keyboard jumper connector
c. Connect the power cable to the display
6. On 24v DC powered Industrial Computers turn on DC power source first and before
turning on the ON/OFF button on the industrial display computer. Verify the polarity
of the 24v DC signal at the connector. Only press the ON/OFF button on the Industrial
Computer if the polarity is correct.
7. Check for proper display. If no display is present, refer to troubleshooting guide.

Figure 5

CABLE ROUTING
1. Check all cables for tightness and proper routing.

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PERIODIC INSPECTION
1. Clean all air filters monthly.
2. To clean the computer screen, use a 50% solution of alcohol (ethanol or isopropyl) in
water on a soft cloth. Do not use paper products as they may scratch the surface. Apply
the solution only to the cloth, and not directly to the surface to be cleaned.

ARTIC CARD REPLACEMENT PROCEDURE

ARTIC Card Settings for T37/6151’s with the Aaeon 486-DX4-100/DX5-133 Processor Cards

Figure 6

1. Loosen the two thumbscrews on the "drawer" or computer portion of the unit.
2. Remove jumper cables as necessary and Slide the "drawer" out from the chassis.
3. Facing the rear of the computer drawer, remove the small Phillips head screw that
attaches the card retention bar to the side of the drawer.
4. Remove the Phillips head screw that attaches the card retention bar to an extended piece
of metal.
5. Remove the Phillips head screw located at the rear of the drawer that holds the ARTIC
card in place.
6. Pull evenly- rocking gently as necessary to remove the ARTIC card.
7. Verify and re-set as necessary the follow jumper and dip switch settings for the
replacement ARTIC card.

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 Figure 7 (Example: IBM 1036)

8. Re-insert the card in the same slot (Standard is the 4th from left while facing rear).
9. Re-mount all screws for card retention.
10. Slide drawer into the chassis.
11. Re-attach all jumper cables and power, accordingly.

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IRQ switch settings for the various versions of ARTIC cards and Industrial computers

ARTIC card (1036) SW positions 5-10 are as shown in above illustration. ARTIC card (6330) has
four positions they are listed below.

Solar PN 1014220-xxx 6330 ARTIC Card Solar 1036 ARTIC Card Solar
PN: 4-Position SW PN: 10-Position SW
-100 to -102 IRQ 12 JP15 (See Chart) IRQ 12
Units with video board
SW1-1 = ON
SW1-2 = OFF
SW1-3 = OFF
SW1-4 = OFF
-103 to -107 IRQ 12
Units with video board
SW1-1 = ON
SW1-2 = OFF
SW1-3 = OFF
SW1-4 = OFF
-108 to -110 IRQ 10
Units with video on CPU
motherboard SW1-1 = ON
SW1-2 = ON
SW1-3 = OFF
SW1-4 = OFF

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Address Switch SW1 Setting (IBM-6330)

Switch Settings
SW1 SW2 SW3 SW4 Base Address (Hex) Physical Card
Designation
ON ON ON ON 02A0 0

Set Interrupt-Acknowledge Level Jumper JP15 (IBM-6330) IRQ12

Figure 9

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Industrial display computer Complementary Metal Oxide Semiconductor/Basic Input
Output System, CMOS/BIOS Settings

The following CMOS/BIOS settings were set at the factory and can be verified in the following
manner:

1. Boot the computer.

2. Immediately, depress the delete key on the keyboard or keypad.
3. Scroll with the arrow keys or tab as necessary to verify the following

Required CMOS/BIOS Settings for the Industrial Display (-102 to -107):

Standard

Pri Master
Type : User, 1023 cyl, 16 hd, 63 sec
Pri Slave
Type : Not Installed
Sec Slave
Type : Not Installed
Keyboard : Not Installed

Advanced

Above 1 MB Memory Test : Enabled

System Boot Up Numlock : Off
System Boot Up Sequence : A :, C:
Auto Config Option : Disabled
DRAM Speed Option : Faster
DRAM Write Cycle : 0 W/ S
Watch Dog Timer : Disabled

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Required CMOS/BIOS Settings for the Industrial Display (-108 to -110):

Standard

Pri Master
Type : User, 1023 cyl, 16 hd, 63 sec
LBA/Large Mode : Off
Pri Slave
Type : Not Installed
Sec Master
Type : Not Installed
Sec Slave
Type : Not Installed

Advanced

Quick Boot : Disabled

BootUp Sequence : A:, C:, CDROM
BootUp NumLock : Off
TurboSwitch : Disabled
System Keyboard : Absent

Chipset

Auto Config Function : Disabled

DRAM Write Timing : Faster

PCI/PnP

Plug and Play Aware O/S : No

Peripheral

OnBoard FDC : Enabled

OnBoard Serial Port1 : 3F8h
OnBoard Serial Port2 : 2F8h
OnBoard Parallel Port : 3BC

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MONITOR COOLING FAN REPLACEMENT PROCEDURE
The fan assembly located behind the fan filter may be replaced, as needed with Solar PN
1014216-64 Fan Replacement.

1. Remove and clean the filter as needed.

2. Remove 4 Phillips head screws from the metal work (save all screws for later use).
3. Remove the 4 Phillips head screws that attach the fan to the metal work.
4. Trace and unplug the red power connector from position J81 on the analog PCB.
5. Re-attach the power connector for the new part to the same location.
6. Utilizing the original screws, remount the new fan assembly.
7. Re-attach the filter assembly with clean filter.

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 Failure Incident Form

Date of Failure

Date Returned

Field Contact & phone

Number

Solar FSR

Serial # Drawer

Return Authorization #

Failure Description

Site location & unit #

PD of engine

Other

Please attach form to Computer prior to shipment

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