Tales of disaster – Page 12 – Engineering Radio

The surreal trip to the WICC transmitter site

What could be so bad about going to an AM transmitter site on a peninsula off of the Long Island Sound. Sounds pretty nice, right? It began just so, driving through the town of Stratford Beach parking lot to the construction gate, the towers were visible off in the distance. A nice crushed gravel road across the barrier island, I have certainly been to worse places.

WICC towers pleasure beach island — WICC towers Pleasure Beach Island, CT

And then, things begin to look a little bit different. It is really hard to put into words, seems like some other country.

Pleasure Beach Bungalows — The beginning of the Pleasure Beach Bungalow Colony

It turns out this is not quite a nice trip after all.

Pleasure beach lawless zone — Pleasure Beach Lawless Zone

I’ve been to several so-called “developing areas” like Port Au Prince, Hatti for example. Nothing ever looked this bad.

Pleasure Beach ocean side bungalow — Pleasure Beach Ocean Side Bungalow

I can imagine some family coming here every summer to spend time at the beach.

What anarchy looks like.

Pleasure beach burned out cottage — Pleasure Beach burned out cottage

The back story is this: From the 1920s until 1996, Pleasure Beach was a nice seasonal oceanside bungalow colony, complete with an amusement park. These cottages (but not the land they were on) were owned by people from the surrounding cities and towns and the entire area appeared to be quite nice in its day. Then, in 1996, the wooden bridge that connected Pleasure Beach to Bridgeport burned. There are several theories; crackheads, radical environmentalists, etc. The city of Bridgeport did not rebuild the bridge, which meant the only access was by walking from the Town of Stratford beach parking lot, a trek of at least a mile or longer. In 2007, the town of Stratford decided not to renew these land leases, and the building owners were forced to remove any remaining items they wanted by barge. Soon thereafter vandals began walking down the peninsula from Stratford. Slowly, most of the bungalows were broken into and several were burned. This is mostly the work of “kids,” who, because they are under the age of 18, get a slap on the wrist and returned to their parents. Oh, those wacky kids, what will they do next?

Truth be told, they should be the ones out here cleaning this up, for free.

Finally, this year, the city began tearing down and cleaning up the remaining buildings, trying to put the former bungalow colony “back to nature.”

The transmitter site for WICC moved here in 1932. This building contained a nighttime operating studio, kitchen, bathroom, and bedroom. I can imagine hanging out here some summer night, spinning tunes, and having a good time. The former amusement part is just out of the picture to the left. At the amusement park, there was a carousel, a big snack bar, a dance hall, and an area for portable rides like Ferris Wheels and such.

Now the building is full of disused gear, old carts, transmitter, and tower parts, the water has been shut off and I’d not want to be out here at night under any circumstances.

The antenna array consists of two 300-foot Milliken towers, originally installed at WNAC (Now WRKO) Boston, MA. They were moved to Pleasure Beach Island in 1932. Many people mistakenly think these are Blaw-Knox towers. Milliken preceded Blaw-Knox by several years. They built and designed towers around the world for radio and electric transmission. In the late 1930’s they were bought out by Blaw-Knox, which kept the design. I love these tapered self-supporters, they have survived several major Hurricanes since 1932. The south tower is about 150 yards from the Long Island Sound. Salt air seems to do them no harm, either.

WICC Milliken tower, south looking up — WICC Milliken south Tower, looking up

The station operates at 1 KW day, 500 watts night, DA2. The towers are 60 degrees tall, spaced 149 degrees. That is a little short, however, they are surrounded by salt water, so the signal goes like gangbusters. Because they are short, the impedances are low, about 10 ohms for nighttime and 30 ohms for daytime. Since the towers are so wide, the impedances are flat far beyond 50 kHz on either side of the carrier, which makes it a nice broad-banded antenna system. The 1932 phasors and ATUs were redone in 1972. All of the common point impedance measurements are still posted on the wall.

WICC Harris SX-1A, Phasor and Harris BC1H — WICC Harris SX-1A, Phasor and Harris HC1H

The main transmitter is a 1990 Harris model SX-1A. It seems to be reliable enough, my experience with the SX-1 is it has an overly complicated control system. The backup is a Harris BC1H, a sort of hybrid solid-state tube unit, which is also reliable.

Frequency voltage meter — WICC frequency and voltage meter

This high-tech test and measurement center is attached to the incoming electrical service. Over the years, there have been some quality control issues with the incoming electrical service, mostly due to Osprey building nests on the crossarms. During rain storms, these nests catch on fire and kill the power to the site. The power company is in the process of redoing the electrical service to the building.

This is a video of the former amusement park and cottages shot two years ago when the cottages were more or less intact. It is a bunch of stills set to Pink Floyd music:

Looks like they all just got up and left.

Harris FM25-K

Old blue, I like to call them, the Harris 1980s model transmitters with black faces, white cabinets, and blue trim. I have yet to find one that I really like, the FM 25-K is, well okay. Sort of like that 200,000-mile jeep that works, most of the time, and it’s paid for.
This particular FM-25K transmitter is located at WIZN in Charlotte, VT.

This transmitter was new in 1987. It had a bad day yesterday, deciding to throw a temper tantrum and trip the HV power supply breaker. Fortunately, the station has a backup transmitter. When we arrived, we found the HV power supply feed through the insulator at E1 arced over and broken. Again, fortunately, this station’s management believes in stocking spare parts and a replacement was on hand.

Harris FM25K HV power supply feed through insulator

This is part of the RF filter for the HV power supply. This happened once before, about two months ago. The replacement insulator then was used, so that might be a factor. Two months ago, both capacitors in the Pi filter and the HV power supply cable (RG-8 coax) were replaced all the way back to the rectifier stacks.

The FM25-K can produce spontaneous high-frequency oscillations if not tuned properly. We looked at the transmitter output with a Rode Schwartz spectrum analyzer and found it to be clean. Exactly why it blew out another feed-through insulator is a bit of a mystery. Since the first replacement was a used part, we surmise that it may have been cracked. If this replacement insulator arcs, there needs to be a full investigation.

As I said in the beginning, I have found these transmitters to be okay, not the best, not the worst. Most of the problems I have encountered with the K series FM transmitters had to do with the controller cards. There are two, one analog and one digital. That’s what Harris calls them anyway. Like the SX transmitter, and the MW transmitter to a certain extent, the control circuits are way over complicated and full of +/- 5 volt CMOS logic. Having that type of control logic connected to a radio tower (e.g. lightning rod) is asking for trouble.

The sad story of WCVR

I have been the road warrior lately if you haven’t noticed a certain decline in the blog posts… One place that seems to keep pulling me back is Randolph, VT, which is about as close to the geographical center of Vermont as one can get and still be on a roadway. There resides the silent FM station formerly known as WCVR, to be returned to the air as WXVR by Vermont Public Radio.

WCVR went on the air in 1982 and was a community-oriented country station for 17 years. Then in 1999, it was sold to Clear Channel and things began to go downhill. Over the next decade, the station transferred ownership four times. Finally ending up with absentee landlord Vox Radio. By the time the station was sold to Vermont Public Radio last May, the years of neglect were compounded and the main transmitter was no longer running. The transmitter site was raided before the transfer and things like spare parts, a backup transmitter, and a dummy load were removed. As one engineer from VPR noted, the only thing of any value is the Shively antenna.

This story probably repeats itself a thousand times throughout the country as a small market, formerly community radio stations are left to die on the vine by big-time corporate radio gurus in Atlanta, San Antonio, and Las Vegas.

Said station has a McMartin BF5-K transmitter that is not currently running and by the accumulations of dirt, debris, and other evidence, has not run in quite some time.

The beauty of a McMartin FM transmitter is it is a grounded grid. Can’t get much simpler than that when it comes to FM transmitters. The downside is, of course, McMartin has been out of business for almost thirty years. Thankfully, Goodrich Enterprises is still around and still supports them.

The first order of business was cleaning out the filthy, and I mean absolutely filthy building. Several hours with a broom, dustpan, and shop vac got rid of most of the dirt and made my skin less likely to crawl. Then came the fateful attempt to run the transmitter. Loud arcs, power supply hum, and dimming lights revealed that all was not well. All of the fluorescent lights were out, new bulbs did not fix the problem. So, to the Grainger to pick up new fixtures and install them. Now, at least, we could see what were doing.

Next, step-by-step troubleshooting of the High Voltage power supply. Step one, resistance checks on the HV transformer and filter chokes to the ground. Next forward and reverse resistance checks on the rectifier stacks. All of those looked good. Next, we isolated the HV transformer and the rectifiers and turned the transmitter on; no problems. Next, we added the metering and filtering capacitors and turned the transmitter on; no problem. Finally, we found the problem with the HV power supply RF filter on the side of the PA enclosure. In a McMartin FM transmitter, there is a little box mounted on the outside of the PA enclosure that holds half the parts in this circuit. Taking that box off revealed a bad 200 pf 7.5 KV doorknob capacitor that was shorting to ground. Lots of arc marks, soot, debris, and other stuff make me think that this problem had been going on for a long time. I can kick myself for not taking a picture.

Hopefully, this thing will run for a few months while a replacement is sought.

Compounding that issue is the leaking transmission line connector at the bottom of the antenna, which was fixed, but there appears to be another leak somewhere else as the line still does not hold pressure for very long.

VPR is going to broadcast their Classical Music format on this station, starting as soon as we can make the transmitter run.

UPDATE: Pictures:

300 foot WCVR tower, Randolph Center, VT

Transmitter building:

WCVR Mc Martin BF-5K transmitter:

Arcing power supply filter section, the bad door knob capacitor has been replaced, still evident are the arc marks on the PA cavity:

Mc Martin BF-5K transmitter on the air:

We’ll see how long that lasts.

Delta Current Sample Toroid

Another example from my blown-up shit collection, artifacts division:

Delta TCT-1HV current sample toroid destroyed by lightning

This is a Delta TCT-1HV current sample toroid that was pretty well destroyed during a thunderstorm. I mounted it on a piece of plexiglass because I think it looks cool. This unit was installed at the base of the WGY transmitting tower. One June evening, I received a call from the station operator (back when they had live operators) that the air signal sounded kind of “funny.” So I turned on the radio and sure enough, if one thinks a radio station that sounds like a motorboat is funny, then, why yes indeed, it did sound funny.

Since I only lived a few miles away from the site, I jumped in the trusty truck and headed over. Upon arrival, I found the MW50B on the air at full power, with the carrier power swinging wildly from 20-90 KW with modulation. Hmmmm, bad power supply? Turned the transmitter off and tried to place the backup transmitter on the air. Now the old Gates BC5P had never been super reliable in the first place, but it was odd that it would not even run at all.

Then I had a hunch, let’s walk out to the tower I said to my assistant who had shown up to help. When we got to the ATU building it was filled with blue smoke. Ah ha! Somebody let the magic smoke out of one of the components! I was expecting a capacitor blown in half but was surprised to find the copper tubing that connected the ATU to the tower melted in half. Lightning must have caused an arc between the tubing and the toroid and for some reason, the transmitter kept on running while it was arcing. The copper tubing in the picture with the toroid is only missing about six inches, the way the system was mounted at the tower base, fourteen inches of copper tubing was missing, or rather melted into a puddle on the bottom of the ATU.

I quickly found another piece of 1/2-inch copper, cut it to length, flattened out the ends with a hammer, and drilled mounting holes. Luckily I was able to get everything back in order quickly and the station returned to the air about an hour or so after it went off.

Everything has a cause. Investigation showed that the VSWR circuit on the MW50 had been disconnected from the directional coupler. The lead was un-soldered and taped off, so it was quite intentional. I spoke briefly with two of the three prior engineers that had serviced the MW50 over the years, they both blamed the other one. I surmise this; The WGY tower was prone to lightning strikes because of its height. Even if the tower was not directly struck by lightning, oftentimes the guy wires would arc across the insulators, causing the MW50 to momentarily interrupt the PDM signal and drop the carrier for about a second. Some programming people at the station did not like this, it sounded bad on the air, so one of those guys undid the VSWR circuit, and voila! No more momentary outages during a thunderstorm! Brilliant! Except for the 60-90 minute outage one night…

Sometimes it is better to tell the program directors that their idea is not good, then move on.