Installations – Page 5 – Engineering Radio

Cellular work on a skirted tower

Cell carriers generally do not like working on AM towers. It is out of their comfort zone and adds a layer of complexity to the project. However, sometimes they don’t have a choice, mainly when there is an existing site and they need to make changes. We have also had mixed results with tower contractors employed by various cell carriers. In one incident, a contractor showed up and re-tensioned the guy wires breaking all of the porcelain insulators. Another time, a contractor showed up to install footings 10 feet away from the tower and ripped up all the ground wires. One tower climber found one of the skirt wires was in his way, so he cut it off with a hack saw.

Those experiences demonstrate that it is far less expensive to have somebody on site while tower contractors are doing installation work on any skirted AM tower. And so it was today.

AT&T 5G sector assembled waiting for lift

This tower has two AM stations diplexed as well as two FM translators combined into one Nicomm antenna. We did before measurements on the AM stations using an OIB-3. Once the installation is done, we will do the after-measurements and then assist the licensee with any FCC 302 filings if the base impedance has changed significantly.

With each lift, I went out to the base of the tower and made sure that the skirt wires were clear of the mounting brackets and not touching anything else. The tower crew was Russian speakers. When they asked if the transmitter was still on, which was kind of comical (he motioned to the skirt wire, made like he was grabbing it, then jerked around like he was being electrocuted). I had to wrack my brain to try and remember: Передатчик выключен. The literal translation is “Not working.” The difference between “working” and “not working” is one consonant at the beginning of the second word which is pronounced soft for off and hard for on.

This site was the subject of a previous post: A tale of five signals.

FLX20KFAX50K+HD

Greetings from the Roxborough tower farm, a place with roots. It is slightly northwest of Philadelphia, PA, and is home to many TV and FM stations. The public road that cuts through the tower farm is called Domino Lane because if one tower falls, they all fall. A comforting thought to those that live in the vicinity I am sure.

View from the residential neighborhood next to the site

The reason for the visit; this rather nice GatesAir FLX20 transmitter:

Newly installed FLX20+HD, WRNB Philadelphia, PA

I must admit, I am growing rather fond of these transmitters. This unit is being installed because the station had to move from its old site, just down the hill. The tower owner is taking down the tower and building due to the age of the tower. Thus, it was moved into the KYW-TV building. If Wikipedia is to be believed, KYW-TV is the oldest TV station in Philadelphia, signing on in 1932.

The site is still being built as we were installing this transmitter. These days, the electricians are having supply chain problems like everyone else. There were delays getting the large electrical panel board and other necessary things for the build-out.

Cooling system high point, sight glass, and air purge valve

Overall, the installation went well. This system is using flexible hoses for the coolant loop. We have installed two of these liquid-cooled transmitters with 1 1/2 copper pipe. These days, copper pipe is expensive, so most are opting for flexible hose installation.

Topping off the pump station after 50/50 fillup. After the initial system fillup, it takes a while for all of the dissolved air to come out of the Heat Transfer Fluid (HTF). The extra steps with a liquid-cooled system are worth it, especially if the station is running HD. With the HD carrier on, the transmitter efficiency is 54% AC to RF. With a TPO of around 15 KW, that is a whole lot of heat that needs to be dissipated during operation. It is much cheaper to pipe the heat outside to a heat exchanger than to use several tons of AC to remove it from the room.

Overall, this was a fun project.

New transmitter building for an old station

UPDATE:

What the site looks like now with the old building removed:

Putting the finishing touches on another transmitter site rebuild, this time in central NY. This station for many years used this rambling white residential-looking structure for both the studio and transmitter site:

Former studio and transmitter site for WDLA, Walton, NY

Unfortunately, over the years, the building has deteriorated beyond economical repair. A few years ago, the studio facility was moved to a new location in town. Now the transmitters are being moved to this repurposed cellular building:

Former NEXTEL building, now WDLA AM/FM transmitter site

This was purchased used from a local crane company, which had dozens of them on their lot after NEXTEL was absorbed by Sprint. During the permitting process with the town, they referred to it as a “Circular Use.”

They are actually nice buildings, coming prewired with a 200 amp single phase service, two working Bard HVAC units, ready-made coax entry ports, etc. My only complaint (so far), is the light switch timer. I like the idea, the lights get switched off automatically and are not left on for months at a time when nobody is at the site. However, the timer only goes up to 2 hours. Thus, when we were doing the installation work, periodically there would be an audible click, then everything would go dark. Not terrible.

There are also two other FM stations that have an STL transmitter here.

STL equipment for two additional stations

All in all, an enjoyable project.

A nice pair

I am reminded of a Pink Floyd compilation album from the very early 70s. The music dates back to the late 60s and Syd Barrett. Poor Syd; shine on you crazy diamond!

I recently finished installing these rather nice GatesAir FLX-40 transmitters:

WXBK-FM New York, GatesAir FLX-40 x 2 installation

Audacy New York decided to move 94.7 from the East Orange, NJ location down to the WOR transmitter site in Rutherford, NJ. Acting as contractors for GatesAir, we installed these two transmitters. I can say, I like the liquid-cooled transmitters for several reasons. First, once installed, they seem to be very stable. I believe that the cooling scheme helps prolong the life of the RF devices by keeping the junctions at a constant temperature. Those semi-conductor junctions are tiny for the amount of current that they need to handle. Second, they cost less in the long run to operate. Anytime a refrigerant cycle can be skipped, that reduces or greatly reduces the electrical use. The Heat Exchangers in this system use VFD’s for fan motor control. That means more constant control over the HTF temperature and reduced electrical use on the fan motors themselves.

The pump stations have backup pumps as well. In the newer transmitter firmware, the pump control needs to be set up to automatically failover to the standby unit. It is a couple of clicks in the GUI to do this.

We didn’t have anything to do with the antenna installation, however, it is a good-looking antenna! ERI 4 bay 3 around mounted on one of the WOR towers.

Overall, this was a good project. Lots of moving parts during the installation, but we were flexible working with the client and other contractors and sub-contractors on site.