Tales of disaster – Page 13 – Engineering Radio

Harmonic Filter for BE FM-30T

Another example from my blown-up shit collection, pictures archive:

Burned out harmonic filter, BE FM-30T transmitter — Burned-out harmonic filter, BE FM-30T transmitter

The harmonic filter from a Broadcast Electronics FM-30T. This actually started in the bullet connector to the 3-inch hardline on the output side of the filter.

Burned out 3 inch hard line section — Burned out 3-inch hard-line section

Again, I did not install this myself, someone else did. Cutting 3-inch hard line is pretty straightforward. When using a field flange, the outer and inner conductors are cut flush. Both conductors should be de-burred and filed smoothly. It only takes a little thing to start an arc with 30 KW of FM power, so once again, attention to detail is key to avoiding these things.

Fortunately, BE sent along replacement parts for the harmonic filter and the line section was replaced.

BE AM5E power supply problem

This is from my burned-out shit collection, pictures section:

It is a power supply from a Broadcast Electronics AM5E transmitter. Here is another view:

Broadcast Electronics AM5E power supply mating connector

As you can see, there was a small fire started in the mating connector for the transmitter wiring harness. I did not install this unit so I have no way to know for sure what happened, but I suspect that the mating connector was not pushed all the way in during installation. In this business, really in all engineering fields, it is the little details that will catch up with you.

I know that one of the stations I used to work at had a fire at their electrical service panel at the FM transmitter site after they installed a new transmitter. This happened after I departed for greener pastures. In any case, it is very important to torque the connections on any service disconnect or circuit breaker to the panel manufacturer’s specifications. I also check the lugs every so often with a Fluke 62 mini IR temperature meter. Any loose connections will show up as hot spots, which can be fixed before the fire breaks out.

All current-carrying electrical connections should be double-checked for solid connections before the transmitter is turned on, then check periodically thereafter for heat buildup and or heat damage.

How stupid do you have to be?

I read through the news coverage of the vandalism at the KRKO transmitter site. Apparently, there is some group of idiots people running around insisting that radio towers are bad for the environment and people’s health. These are the same ones who have torched SUVs and burned high-end housing developments down. Naturally, no pollution is released into the environment during these acts, or else they would be hypocrites.

They make these claims with no merit or scientific basis, instead relying on base fears to make people go crazy, either temporarily or permanently like. It is actually a pretty good motivator as both political parties and all sorts of fringe truthier, birthier, and others have discovered. If enough people insist that it is true, then it must be so.

Unfortunately, there is always some idiot around who thinks it is his or her duty to take action, to protect the rest of us from some terrible fate.

In the meantime, some security cameras at the transmitter site might be a good investment. Chances are, these Earth Liberators that sneak around with bolt cutters and hack saws will likely think twice if there is any chance of themselves going to jail.

By the way, those KRKO towers looked like self-supporters which would have been very difficult to get down. Did they rent that excavator, or was some construction equipment left unattended?

When batteries explode

This is a picture of an exploded battery on a 45 KW backup generator:

850 CCA battery exploded during generator startup

This happened during a thunderstorm. The smoking crew was out on the back porch, during a thunderstorm (you have to have your priorities I suppose) and witnessed the entire incident. What was told to me was lightning stuck the generator. I find that improbable since there are many metal objects scattered around the area that are much taller. What likely happened was lightning stuck something close by, causing the power to drop out momentarily. This caused the generator to turn over. The battery was likely low in electrolyte, so there was an internal arc and the thing exploded in short order.

These events happened in rapid succession, giving the illusion that lightning struck the generator.

I removed the old battery and hosed the inside of the generator with copious amounts of water. There is nothing that can be done about the spilled electrolyte, since it was likely washed into the storm sewer during the storm. After the replacement of the battery, I tested the generator and all is well.