Synchronized FM signals

How effective are they at filling in or expanding coverage for FM stations?  The answer is, it depends.  Most have heard of the quadcast around New York City on 107.1 MHz formed in 1996-98.  It was well documented in Radio World and several other publications as a clever way to overcome the suburban rimshot problem.  Four signals on 107.1 were synchronized using GPS timing data, then fed the same program material.  They were WYNY, Briarcliff Manor, NY; WWXY, Hampton Bays (Long Island), NY; WWYZ, Long Branch, NJ; and WWYY Belvidere, NJ.  These being four separate Class A FM stations, the 60 dBu contours did not overlap.  There was some mutual interference in some areas, but there were few if any reception negative zones where the signal strength is equal between stations.

In early 2003, I was a part of the disassembly of the quadcast.  In the end, it is difficult to point to any one thing that leads to the breakup.  The station’s owners, Big City Radio, had filed for bankruptcy.  I am not sure if the company ever had the correct formula for marketing and sales, given the strong suburban, but weak and lacking building penetration in Manhattan signal.  The station initially had a country format, something that armchair quarterbacks said would not work in New York City.  After a few years, Big City changed the format to Rumba, a Spanish/Caribbean music format, which did worse than Country.  The fact is, that it never lived up to expectations and the station was worth more separately than together.  Given the right circumstances, it could have worked.

The other synchronized FM broadcasts are those where boosters are employed.  These are a good deal more difficult to configure because the booster signal is within the main station’s 60 dBu contour.  Often cases, where there is severe terrain shadowing or other limitations, a well-positioned booster that is in a population center can greatly improve the signal in those areas.  This was formerly the duty of an FM translator, however, those stations seem to be taking on a life of their own, without regard for the intent of the current FCC rules.  Boosters can also be called a single frequency repeaters or single frequency network (SFN).

The disadvantages of an SFN are the aforementioned negative reception areas.  To the receiver, this will create a multipath or picket fencing situation, which is objectionable to most listeners.  The advantages are, of course, better coverage in key areas, spectrum efficiency, and the ability to create a network of common frequency systems.  Think of how easy it would be if all NPR stations were all on the same frequency, for example.

The key to making a booster work is to synchronize several aspects of the RF and Audio signals:

  • RF carrier frequency
  • Stereo pilot frequency and phase
  • Audio amplitude and phase

The RF carrier frequency, stereo pilot frequency, and phase are locked with a GPS. Most transmitters have a 10 MHz or 1 PPS input for this.

The audio amplitude and phase synchronization are slightly more complicated. Basically, all of the audio should be coming from one audio processor and the path to the individual transmitter sites has to be very low latency. RF STLs work for this setup well, if there are suitable paths.

Once that is established, the audio timing is used to move the interference zone away from undesirable areas. There will always be an interference zone where both signals are received at the same relative strength causing dropouts.

WDBY, Patterson, NY 60 dBu contour
WDBY, Patterson, NY 60 dBu contour

This is the situation with WDBY in Patterson, NY.  The main transmitter site is located on a hill in Patterson and has a power level of 900 Watts at 610 feet (186 meters) HAAT. The main population area is Danbury, CT, to the southeast, about 12 miles away.  Between the two, there are several imposing hills, which create reception issues in Danbury.  Therefore, WDBY FM1 was placed in service at the Danbury Medical Center.  The booster has a power output of 1,200 Watts, at 0 feet (0 meters) HAAT (49 meters AGL).

WDBY FM-1 signal, Danbury, CT 60 dBu contour
WDBY FM-1 signal, Danbury, CT 60 dBu contour

Therefore, the southern area of the 60 dBu contour is filled in by the booster.  The interference zone between the two transmitters is determined by the amount of delay in the audio between the two units.  If both are time the same, the interference will occur at precisely 1/2 the distance between the transmitter sites, which in this case is 10.18 KM from the booster.  Looking at the population maps, it might be better to move that more toward the north, away from Danbury.

The formula for computing audio delay time is:

A-B=C where A is the distance between the transmitters and B is the distance to the interference zone from any given transmitter.  The product of that is multiplied by a constant of 3.34 to obtain the time delay in microseconds.  Therefore, if the interference zone is desired to be further outside of Danbury, say 15 KM away, then the equation looks like this:

20.358 kM -15.0 kM = 5.358 KM

5.358 KM x 3.34 = 17.89 μS delay from the main transmitter site will put the interference zone out in the middle of nowhere, away from Danbury.  This is the total delay between the two stations, therefore any difference in STL paths needs to be included in this figure.

Nautel has a good webinar on SFNs which can be found on their website: Single Frequency Networks Webinar

Nautel equipment has most of these features built into it, therefore, the implementation of an SFN using Nautel exciters and transmitters should be relatively straightforward.

Conduit fill

It may be surprising to some, but the number of wires allowed in any given conduit is not “as many as can be jammed in there.” The National Electrical Code, AKA NEC or NFPA 70 gives specific guidance on the number of current-carrying conductors allowed in any specific size and type of conduit.

This is due to the fact that current-carrying conductors generate heat.  Cables enclosed in a conduit need to dissipate that heat so that the insulation on the cable doesn’t melt, which would be a bad outcome.

Conduit fill tables are found in Chapter 9 of the NEC.  There are several tables that give the number of conductors for each size and type of conduit.  Then there is the general rule of thumb that for more than two cables, the maximum conduit fill is 40%.  This comes in handy when several different size conductors are being run in the same conduit.

An example of this is when several circuits are going across the room to the same general location, in this case, a row of transmitters and racks.  Instead of running individual conduits for all those units, one or two conduits from the electrical panel are run to a square wireway, then the individual circuits are broken out and wired from wireway to the individual loads.  In this case, the following equipment is being connected:

  • Harris FM25K: 100 amp 3 phase high voltage power supply (#2 THHN), 30 amp 3 phase transmitter cabinet (#10 THHN)
  • Harris FM3.5K: 70 amp split phase (#6 THHN)
  • Harris MW1A: 30 amp split phase (#10 THHN)
  • Two equipment racks: 20 amp single phase (#12 THHN)
  • Coax switch: 15 amp single phase (#14 THHN)
  • Dummy Load: 15 amp single phase (#14 THHN)
  • Antenna switch/dissipation network for AM station: 15 amp split phase (#14 THHN)
  • Convenience outlets for the back wall: 20 amp single phase (#12 THHN)

Excluding grounding conductors, which will be addressed below, the total current carrying conductor count is thus:

  • #2 THHN: 3 each
  • #6 THHN: 3 each
  • #10 THHN: 7 each
  • #12 THHN: 6 each
  • #14 THHN: 6 each

Ampacities based on NEC table 310.16, THHN insulation in dry locations, maximum temperature rating is 90° C (194° F) based on the ambient temperature of 30° C (86° F)

Grounding conductors for each of those circuits, based on NEC Table 250.122 (all conductors are copper):

  • 100 amp circuit: #8
  • 70 amp circuit: #8
  • 30 amp circuit: #10
  • 20 amp circuit: #12
  • 15 amp circuit: #14

The final conductor count is:

  • #2 THHN: 3 each
  • #6 THHN: 3 each
  • #8 THHN: 2 each
  • #10 THHN: 9 each
  • #12 THHN: 9 each
  • #14 THHN: 9 each

The plan is to use two 1 and 1/2-inch EMT conduits between the electrical service panel and the 4 x 4 square wireway. According to  NEC Chapter 9, Table 4, the 40% cross-sectional size of this conduit is 526 mm2.  It is easier to simply use metric measurements for this.  The cross-sectional wire areas are found in Chapter 9, Table 5.  Chart of various conductor sizes and areas:

ConductorArea (mm2)Total conductorTotal area (mm2)
#2 THHN74.713224.13
#6 THHN32.71398.13
#8 THHN23.61247.22
#10 THHN13.619122.49
#12 THHN8.581977.229
#14 THHN6.258956.322

Thus, in order to break this up into two 1 and 1/2-inch conduits, the #2, #6, and #8 (main transmitter HV power supply, backup transmitter, and grounds) are run in one conduit, the remaining circuits in the other.  The idea is that the main transmitter and backup transmitter will not be running simultaneously for long periods of time.  Those cable areas total 369.48 mm2, well within the 40% limit of 526 mm2 for 1 and 1/2 inch EMT.   The rest of the circuit’s cable areas total 256.041 mm2.  That leaves room for additional circuits in the second conduit if future needs dictate.  The extra conduit area will make pulling the wires through easy.

From the square wireway to the HV power supply, 1 and 1/4 inch conduit will carry the three #2 and one #8 ground.  1 and 1/4 inch EMT has a cross sectional area of 387 mm2, the conductors contained within will be 271 mm2.  Less room here, but still well within the 40% limit.

Pictures will be posted when the project is done.

The Gates BFE-50C Amplifier

Found in a pile of junk in the corner of an older transmitter site, this Gates BFE-50C or otherwise known as an M5675 Amplifier. This was used as an IPA in a Gates FM 1C transmitter installed around 1960 or so.  The rest of the transmitter has long since departed, likely to the scrap yard, however, somebody thought to remove this and set it aside.

Gates BFE-50C 50 watt VHF amplifier
Gates BFE-50C 50 Watt VHF amplifier

This unit is missing it’s grid tune knob.  The grid tune capacitor is still there, however.  There is also some evidence of heating on R403 and R407/408 likely due to a prolonged overdrive condition.  Otherwise, it is in good shape.

Gate BFE-50C 50 Watt VHF amplifier back
Gate BFE-50C 50 Watt VHF amplifier back

The design is pretty simple, a pair of 6146’s in push pull, three watts in nets about 50-60 watts out, according to the manual, which can be found here (.pdf).  The power supply voltages are fairly tame, 500 volts plate, 300 volts screen.  The one thing that this design does not have is any type of harmonic filtering.  When used with a larger transmitter, this makes sense because the transmitter output will have overall harmonic filters.  If this was to be used on it’s own for any reason, a good harmonic filter would need to be designed and installed.

Gates BFE-50C or M5675 50 watt VHF amplifier
Gates BFE-50C or M5675 50 Watt VHF amplifier

The schematic is straight forward.  Gates, the old Gates Radio of Parker Gates, designed good equipment.  Click on image for higher resolution.

Gates BFE50-C input section
Gates BFE50-C input section

It is a bit hard to see in this picture; the input section consists of three turns of #14 gauge wire coupled to two 4 turn sections of 14 gauge wire on either side of it.  This is matched to the grids Screen1 of the 6146s with C401.  L412, C411 and L413 form a low pass filter.  L412 consist of one turn #14 gauge wire, L413 is five turns of #14 gauge wire.  All coils are 3/4 inch in diameter.

Gates BFE-50C output section
Gates BFE-50C output section

The output section is even simpler, using just one loop of small diameter copper tubing.  The plate tuning is accomplished by C407, loading is C406.  Power output is adjusted by varying the screen voltage using R405.

Advantages of this design:

  1. The 6146 tube is fairly rugged, at class AB the 50 to 60 watt output range is well within the plate dissipation for a push pull configuration.
  2. No special parts are needed, everything can be found or fabricated by hand
  3. The 500 volt supply is fairly tame, maximum PA current should be less than 0.2 amps for 50 watt output and 50% PA efficiency.
  4. Output tuning and load allow for tuning into less than ideal loads, if required.
  5. If operated as a stand-alone unit, some type of plate current meter should be used to aid tuning.  A harmonic Filter would need to be designed and built for the output.
All in all, a pretty cool little FM amp.

The BE FM20T transmitter

This is the main transmitter for WYJB in Albany, NY. The backup is the Harris FM20H3 on the right. I haven’t turned that unit on lately, but it normally makes quite a fuss the first time the Plate On button is pushed. The FM 20T on the other hand, is mellow and even-tempered.

WYJB 95.5 Mhz, class B, transmitter Albany, NY
WYJB 95.5 Mhz, class B, transmitter Albany, NY

One other thing of note; The FM20T is still on its original tube.  I looked up the maintenance records for this transmitter, it was installed in December of 2000.  Eleven years later, the 4CX15000A (ed note; 4CX12000A) is still cranking out 15 KW TPO, which is impressive.  I found that high-power ceramic vacuum tubes actually seem to last longer when run closer to their limits than those that are running at half power.

Judicious management of filament voltage is required to achieve this type of longevity.  There is a set procedure for installing a large ceramic vacuum tube:

  1. After the tube is in the transmitter, run it at a full filament voltage for at least an hour or so before turning on the plate voltage.  This allows the getter to absorb any stray gases in the tube.
  2. Once the plate voltage is applied, proper tuning should be completed as quickly as possible.  Tuning procedures vary from transmitter to transmitter, however, the general idea is to obtain the maximum power output for the least amount of plate current while keeping the PA bandwidth within acceptable limits.  Some transmitters can get narrow-banded at high efficiencies, which manifests itself as higher AM noise.
  3. After the tube has been in use for 90-100 hours, the filament voltage should be reduced gradually until a drop in the transmitter output power is noticed, then increased by 0.1 volts.

This maximizes the filament life for that particular transmitter and power output.  Once the filament can no longer boil off enough electrons, the tube power output drops and it is time to replace it.

This site also has two other radio stations, WZMR, 104.9  and WAJZ 96.3 , both class A using solid-state transmitters of less than 1,000 watts:

WAJZ and WZMR Energy Onix solid state transmitters
WAJZ and WZMR Energy Onix solid-state transmitters

Not the prettiest sight in the world, but it does stay on the air.  There is no money to go back and neaten up this work, unfortunately.

The tower supports all three antennas.  There was some discussion of a common antenna for all three stations, however, WZMR is a directional station, thus it would require its own antenna.  Doing a common antenna for the other two stations was cost prohibitive, so the tower supports three two bay antennas.

WYJB, WZMR, WAJZ FM antennas, New Scotland, NY
WYJB, WZMR, WAJZ FM antennas, New Scotland, NY

The stations are all located in the New Scotland, NY tower farm.  WYJB is licensed to Albany, WZMR is licensed to Altamont and WAJZ is licensed to Voorheesville.