Installations – Page 6 – Engineering Radio

A little bit of catching up…

I regret not having enough time for writing these days. There are a number of reasons for this. Firstly, much of what I do running my business is mundane and not worth noting. For example; today I am going over work reports and reconciling the bank account. Necessary, but about as exciting as watching the grass grow or reading about drying paint.

However, the rest of the time I have been working on various projects around the northeast, to wit:

In Boston, I took part in converting an LPTV station to ATSC 3.0. That was interesting and I am enjoying the TV work.

Boris Johnson resigns, also one of the first ATSC 3.0 images transmitted OTA in Boston, MA

In Syracuse, we had to lower a TV transmitter from the 23rd floor to the 22nd floor on the outside of the building. The transmitter itself became marooned because an electrical conduit for an alarm system was installed restricting the size of the stairwell.

Carefully lowering a 2KW UHF TV transmitter, State Tower Building, Syracuse, NY

Fortunately, we hired a moving company to do this. I am pretty sure that our insurance does not cover damages from transmitters falling 22 stories.

In NYC, I installed two FLX-40 transmitters for GatesAir.

WXBK FLX-40 transmitters, Rutherford, NJ

“Do you see over yonder, friend Sancho, thirty or forty hulking giants? I intend to do battle with them and slay them.” *“Take care, sir,* those over there are not giants but buildings on the island of Manhattan.”

In Kingston, NY a used BE AM1A (along with a coax switch and dummy load) was installed at WKNY.

Slightly used BE AM1A installed as backup at WKNY, Kingston, NY

7/8 inch coax switch and 2.5 KW oil cooled test load suspended from the ceiling

It is nice that this station has a decent backup transmitter to buttress the aging, yet very reliable Nautel ND-1.

Even though it is a short drive away, I had never visited the 1969 Woodstock Music and Art Fair site in Bethel, NY. It was interesting and being sort of an audiophile, I enjoyed this exhibit in particular:

Your author, standing in front of a “Woodstock Bin.”

From the display:

This speaker stack sat on scaffolding high in the air… festival sound engineer Bill Hanley custom-built eight speaker cabinets for Woodstock, amplifying music and stage announcements across the large festival site… Afterward, the design would be known in the industry as the “Woodstock Bin.”
Bethal Woods Performing Arts center Museum, August 10, 2022

The high-frequency horns used Electrovoice diaphragm S/A compression drivers. I don’t know which driver was used for the bins.

Site of Woodstock ’69 stage, looking up into the field

Looking down from the field to the stage area. Person(s) for scale.

I am also writing articles for Radio Guide, I hope that you are enjoying them!

The BE STX 10

We just finished installing one of these units on Mount Beacon for WSPK. Mount Beacon is around 1,500 feet high and is accessed by a road that is a little bit rough. After the snow flies, the only way to get there is a snow machine or perhaps a helicopter. Thus, whatever is installed there needs to be reliable.

BE STX 10 mounted in Middle Atlantic Rack, WSPK, Mount Beacon, NY

My first comment, I recall 10 KW FM transmitters being much larger. This unit is pretty compact and we probably could have fit two of them in this Mid-Atlantic rack had we wanted to.

The transmitter itself is pretty simple, four RF modules powered by seven OEM switching power supplies with two fan power supplies, one for each fan unit. This is driven and controlled by an STXe 500-watt exciter.

The back has a 1 5/8 inch EIA flange output, some power connections, remote control interface, etc. Pretty simple overall.

I can also say, there was a noticeable improvement in the audio quality when this was placed in service.

The GatesAir FLX-30

This is the second time I have installed one of these liquid-cooled transmitters. This time, it is for WVPS in Burlington, VT. WVPS is the flagship station for Vermont Public Radio. The station is a full class C, a rarity in the North East. The transmitter is located on Mount Mansfield giving it a HAAT of 2,717 feet (828 Meters), which is a good way up.

This transmitter replaced the previous backup transmitter, a Harris Z16 unit from the early ’00s. There was nothing really wrong with this unit, it just was not a full power backup.

The new transmitter came in two pieces, which is typical for the 30 and 40 KW GatesAir liquid and air-cooled transmitters.

New Transmitter, being placed in Radio Transmitter room

For the cooling part of this installation, 1 1/2 inch type M copper pipe was used. This matches most of the other TV transmitters down the hall. In the same building are the transmitters for WCAX-TV, WPTZ-TV, WFFF-TV, and WVNY-TV.

FLX-30 Heat Exchanger, outside with all the others

Liquid-cooled transmitter piping, WCAX’s left pair, WVPS right pair

Air purge valve, sight glass, cross-connect and distribution manifold, above the transmitter

The highest point in the liquid-cooled system is the air purge valve and distribution manifold just above the transmitter. From here, everything slopes down to a few low points; the heat exchanger outside, the pump station, and the power blocks. This is to make it easier to drain if that ever needs to happen. There is also an air inlet valve to aid in draining.

All of the cooling work is controlled by the pump station. The fans are connected to VFD modules, which control the flow of air through the Heat Exchanger.

All of this plumbing work was greatly sped along with the use of this Pro Press pipe press tool. This thing is great! No more sweating connections. Dry fit a section to make sure that it is all cut correctly, then go to work with this and it is done in a matter of seconds. Of course, there are no re-dos, so the dry fit procedure is a little more important.

Prior to filling with Heat Transfer Fluid (50/50 water/antifreeze mix), the system was first pressure tested with air, then filled with clean water for a 12-hour flush. The water was drained out and the filter screen was cleaned, then it was filled with the appropriate Heat Transfer Fluid.

Testing into dummy load, TPO is 25,995 watts with -14 dBc HD Radio

Final system checks, remote control test, and HTF top off and the transmitter is ready to go pending the HD Radio installation.

WEZF and WVPS four bay three around panel antenna

Doing it with sound AND pictures

AKA: Television!

I am talking about the type of TV you need an antenna for. I have been installing a few of these low-power digital TV transmitters at various places and it is good work.

Anywave MPTV 2.2 KW digital TV transmitter, WCRN Boston

LPTV antenna side mounted on tower in Quincy, MA ERP is 15 KW.

Anywave MPTV unpacking, rolling into the building, Ellenville, NY

This transmitter’s dry weight is about 500 pounds, which was a little bit too much for our appliance hand truck, so we built a ramp. They have a nice set of wheels on the bottom, so they roll into place.

Carrier power after pre-correction files updated

There are a few differences in the way things are done. First of all, there is a different set of acronyms:

ASI- Asynchronous Serial Interface, format for MPEG transport stream, max speed 270 Mbps.
SDI – Serial Digital Interface – Similar to ASI but can run much faster, up to 12 Gbps.
TS – Transport Stream, Encoded video and audio streams into the exciter. Same idea as composite audio input on an FM exciter.
TSID – Transport Stream ID, a unique number assigned to each DTV station and encoded with the transport stream.
PSIP – Program System Information Protocol, carries program and system data about the transport stream.
ATSC 3.0 – recently updated ATSC standard that allows TV stations to do more with their transport streams than before. Will also change the modulation from 8VSB to COFDM.

Then, some things that look familiar are called by different names, BNC cable vs ASI cable… I am a neophyte in the TV world, so there are still many things to learn.

EAS is still EAS, but now there is a locally generated video to go along with the audio.

A while back, some fool wrote their congressman because THE COMMERCIALS ON THE TEE-VEE WERE TOO LOUD, so there is something called CALM Act compliance.

However, at the output connector on the exciter, through the amplifier, filters, directional coupler, etc; it is RF and behaves like RF. Even more interesting; Mr. Doherty’s name is used to describe the RF amp. Doherty amplifier or Doherty modulation was designed by William Doherty for Western Electric in 1936. It was not until Continental Electronics began using it in their AM (317B) and Shortwave (420A) transmitters that it became known broadly. Old things are new again:

Continental Electronics 420A 500 KW Shortwave transmitter, Greenville site B

That picture is from my visit to Greenville, NC in 2017. This is the control console, the transmitter is behind the glass and takes up half the building. It was installed when the site was built in the early 1960s. The new Doherty UHF amplifiers use LDMOS devices, notably the BLF888E in the Anywave units.

Antenna sweep, channel 30 UHF slot antenna, WCRN Boston

Antenna with channel band pass filter, Channel 30 WCRN Boston

The Channel Band Pass Filter is required by the FCC, basically, it ensures that the TV transmitter is staying in its allotted 6 MHz channel. They add phase rotation, as noted above. This is why pre-correction is needed to keep the ATSC signal linear across the entire 6 MHz bandwidth. RF is RF and we like RF.