The phone company came out and cut over the T-1 circuit on Wednesday, June 2nd. This really kicked things into high gear. By that afternoon we had moved the Prophet systems automation rack up to the new location and started broadcasting from there.
Unfortunately, the backup plan, which was to use the phone company’s DSL circuit to relay audio to the transmitter site, fell through at the very last minute. I think the phone company mistakenly turned off the DSL service to the old studio ahead of schedule. The net result was 2 hours off air in the middle of the day, which we were seriously trying to avoid. Once it was done, however, there was no going back, so we worked extra hard to get back on the air from the new location.
Naturally, while all this is going on, the electrical inspector shows up to do the final electrical inspection for the town building department.
Here is a nice progression on the equipment racks:
Equipment rack with automation system
After the T-1 circuit was cut over, we began broadcasting from the new location with the equipment rack automation system using the production room as a studio for live elements and voice tracking.
Equipment rack, wired to both studios
The wiring on the equipment rack is completed.
Completed with phone system and network switch
The equipment rack is completed, the phone system is installed, and the computer network is wired and tested. The yellow light on the top of the rack is a silence sensor.
The old WKZE studio
The old WKZE studio was ripped out on Thursday. The console was removed and rebuilt with a new control surface
The new WKZE air studio completed, console is a Radio System millennium 12
The production room was completed, speakers hung, etc.
The production room is long and narrow
All set and ready to be “customized” by the DJ’s. Monday morning, the staff will roll into their new digs, which is always fun. In comparison to most studio moves and built outs these days, this one was relatively small and simple. The last studio consolidation project involved 5 radio stations and ten studios. That one took place in steps over several months.
There are still many hollow state (AKA tube type) transmitters floating around out there in the broadcast world. High power, especially high power FM transmitters are often tube types and there are many good attributes to a tube transmitter. They are rugged, efficient and many of the well-designed tube units can last 20-25 years if well maintained.
The downside of a tube transmitter is tube replacement. Ceramic tubes, like a 4CX20,000 or 4CX35,000C cost $6-9K depending on manufacture. A well-maintained tube and last 3-4 years, I have had some lasting 8 years or more. My personal record was for a 4CX35,000C that was a final PA tube in a Harris MW50A transmitter. The tube was made by EEV (English Electrical Valve, now known as E2V) and lasted approximately 84,000 hours, which is 9.58 years. When it finally came out of service it looked like it had been through a fire, the entire metal plate body was dark blue. I took it out because the power was beginning to drop a little and it was making me nervous.
This was not an accident, I did it by maintaining the filament voltage and keeping the tube and transmitter clean. The tube filament supplies the raw material for signal amplification. Basically, the filament boils off electrons, which are then accelerated at various rates and intensities toward the plate by various control grids. The plate then collects the amplified signal and couples it to the rest of the transmitter. When a tube goes “soft,” it has used up its filament.
I had a long conversation about this one day with Fred Riley, from Continental Electronics, likely the best transmitter engineer I have ever known. At the time, the consensus was to lower the tube filament voltage by no more than 10%. On the 4CX35,000C, the specified filament voltage is 10 volts, therefore, making it 9 volts was the standard procedure. What Fred recommended was to find the performance “knee,” in other words, where the power began to drop off as the filament voltage is lowered. Once that was determined, set the voltage 1/10 of a volt higher. I ended up running that EEV tube at 8.6 volts, which was as low as the MW50’s filament rheostat would go.
The other important thing about tubes is the break-in period. When installing a new tube, it is important to run only the filament voltage for an hour or two before turning on the plate voltage. This will allow the getter to degas the tube. New tubes should be run at full filament voltage for about 100 hours or so before the voltage is reduced.
Tube changing procedure:
Remove power from transmitter, discharge all power supply caps to ground, hang the ground stick on the HV power supply.
Remove the tube, and follow manufacturer’s procedures. Most ceramic tubes come straight up out of their sockets (no twisting).
Inspect socket for dirt and broken finger stock. Clean as needed. Finger stock, particularly in the grid section, is important for transferring RF. Broken fingers can lead to spurs and other bad things
Insert new tube, follow manufacturer’s recommendations. Ceramic tubes usually go straight down, no twisting.
Make all connections, remove grounding stick, half tap plate voltage supply if possible, close up transmitter
Turn on filaments and set voltage for manufacturers’ recommended setting. Wait at least 90 minutes, preferably longer.
Turn on plate voltage and tune transmitter. Tune grid for maximum current and or minimum reflected power in the IPA. PA tuning should see a marked dip in the PA current. Tune for dip, then load for maximum power.
Turn off transmitter, retap plate supply for full voltage
Turn on transmitter and plate supply, retune for best forward power/efficiency ratio.
After the 100-hour mark, reduce filament voltage to 1/10 volt above performance knee.
Of course, every transmitter is slightly different. There may not be a dip in the plate current if the transmitter is running near its name plate rating, in which case one would tune for maximum forward power.
This system works well, currently one of the radio stations we contract for has a BE FM20T with a 4CX15,000A that has 9 years on it, still going strong.
While the FM frequency band (88 to 108 mHz) is mostly line of sight, there are things that cause long-distance reception hundreds or sometimes even thousands of miles from the transmitter. For a radio engineer, this can lead to all sorts of problems. Some are serious like STL cutouts, and some are quite funny, such as the general manager panicking when several new stations suddenly pop up in town. One of the many jobs of a broadcast engineer is to avoid problems and fix them if they show up (preferably the former).
Tropospheric Ducting prediction map
The first and most common of these phenomena is Tropospheric ducting. This happens in warmer weather when there is a high-pressure system nearby and is more prevalent over flat terrain. What happens is a warmer layer forms in the atmosphere above a cool layer. That is why it is also known as “temperature inversion.” This causes a higher refractive index, which means that normally the signal would carry on out into space, however, upon encountering this warm layer it is bent back to Earth. It can last a few minutes to several hours. It affects all frequencies but is most prevalent above 100 mHz.
In some more severe cases, FM stations can travel 500 or more miles and override the local station’s transmitter site 15 miles away. In the age of digital STLs, co-channel, and adjacent channel interference can cause the STL receiver to unlock and mute. Analog STLs will become hissy or drop out altogether. It can be a big problem.
Unfortunately, not a lot can be done about main channel interference. It will go away eventually, and no, the station causing the interference is not operating illegally or any other thing. One consolation, if the duct is open in one direction, it is also open in the other, so say hello to all your new temporary listeners in East Podunk.
As far as STL paths go, the best defense is to have a good strong signal at the receive site. Boosting the signal with a preamp at the back of the STL receiver will not do anything. Larger, higher gain antennas at the transmit and receive will help, and more transmitter power will help. Sometimes diversity receiving antennas will help because at the 950 frequencies, 100 feet or so of altitude may make all the difference. Other than that, things like a backup RPU path using a lower frequency, a backup T-1, a backup ISDN line, a Comrex Matrix, basically anything to restore programming.
There is a tropospheric ducting prediction site called Worldwide Tropospheric Ducting Forecasts. They produce daily maps and predictions based on weather patterns.
Night and Day layers of the Ionosphere
The next propagation type known to abnormally affect VHF frequencies is called Sporadic E or E skip. This happens went ionized particles appear in the E layer of the ionosphere and it is more prevalent during the high period of the sunspot cycle when the atmosphere is unsettled due to solar storms. It is more likely to affect frequencies below 125 mHz, so main channel interference may be noted, but STLs and other broadcast auxiliary services will not likely see any effects.
This can happen any time of the year in any terrain and in any weather condition although it seems to be more prevalent in summer and for some unknown reason, around Christmas.
Ionospheric propagation is also known as skywave and is responsible for long-distance communications in the MF (AM broadcast band) and HF (Shortwave broadcast band).
During sunlit periods, the Ionosphere breaks down into several layers; the D layer, which is responsible for the absorption of AM signals during the daytime. The E layer, which normally reflects signals less than 10 MHz. The F1 and F2 layers, which primarily affect HF and lower VHF, from 10 – 40 MHz or so.
During sporadic E events, the E layer becomes heavily ionized in specific small thin areas, sometimes called clouds. This can last a few minutes or up to several hours. The effect is normally more pronounced with lower frequencies.
In this internet age, there is, of course, a website that can predict or at least define sporadic E, DXMaps.com has maps similar to the tropospheric ducting maps above.
Ionospheric propagation map
Occasionally, solar storms will affect communications on all frequencies. The last time I heard this was in the last sunspot peak around 2000 or so. I was listening to the radio and all the stations faded for several seconds. It turns out a huge solar flare had erupted and sent a stream of particles through the Earth’s atmosphere. I happened to be driving down the road and immediately my cell phone started ringing. Listening to the panicked program director on the other end, you’ve thought the earth has stopped spinning on its axis. Anyway, it does happen once in a while.
The lease is up, it’s time to move! Yay, we get to rip apart the old place and redo it! Again! It seems to be a matter of course that every few years a radio station will move. Such is the case with WKZE in Red Hook (the town, not the area in Brooklyn). Their lease is up on the “Grotto” location, so the owner has decided to move to a new location, closer to the center of town.
The new location was the former thrift shop. I know this because while I am working there, a constant stream of older people stop by and tell so. Once, while working alone doing some pre-move work punching down wires and computer network cables, I had to use the facilities. There I sit, on my porcelain throne, when I hear, “Hello?” in an old shakey voice. A quick glance at the door reveals it is not locked. Oh, NOs! Okay, don’t say anything, she’ll go away.
“Hello?”
“Hello?”
“Hello, is anybody here?”
“Hello? Very strange, the doors are open but nobody is here. Hello?”
Oh for the love of Pete, “I’m in the bathroom,” I finally said.
“Where is the bathroom?” said the interloper.
I refused to say anything else and she finally left. She could have taken all my tools if she wanted to.
Anyway, the studios themselves are pretty simple, one production studio and one air studio. A T-1 line to the transmitter site, turned out the be the hardest thing about the entire operation. We moved the old Radio System consoles rather than purchasing new equipment. Radio Systems has a program called a Millennium upgrade, where you buy a new control surface, which replaces all moving parts, for something like $2,300.00 or so. For that, basically, a new console is had.
Radio Systems Former RS-12 now Millennium 12 console
The new production room is long and narrow.
WKZE new production room
The air studio is large and spacious. They often have live music from this studio, which is really cool. The station uses Prophet Systems automation equipment, although it is live most of the time.
WKZE air studio before the furniture is installed
The main office area is one large room where desks will be located.
WKZE office, painted no furniture yet
We are moving in stages:
Prep work, installing all the computer network cable, phone system cable, pulling all the audio and control wiring. Then the contractor finished up the drywalling and painting. Nice Colors!
Ordering phone lines and T-1 line. Ahhh, the phone company, such a pleasure to deal with, we had to pull a new cable through the underground conduit from the street to the building because the old cable did not have enough pairs. The conduit length is about 75 feet or so.
Removed the old production room console and took it to the shop to rebuild. It was not that difficult really, although a little cumbersome. I throughly cleaned out all the dust dirt and other detreious materials from the console frame and install the new control surface. I also checked all the power supply voltages with an oscilliscope to make sure there was no ripple. The original consoles were made in 1992, not bad for an 18 year old board.
Built a new production room with the rebuilt board.
Tested all computer jacks, audio wiring, etc prior to move.
Move T-1 circuit and all office and studio telco lines to the new location. Fortunately, the phone company is a local company not the big V we have in other cities. They were able to work with us and get things paralleled to the new location, something a large company might not have understood.
On the air from the production room at the new location
Remove the main rack, intact and move it to new location
Remove office phone system and install at new location
Remove and rebuild old air studio console
Install rebuilt air studio console in new studio, wire
Transfer operation to new studio
Right now, we are on step #6. That is going to be done next Tuesday (the day after memorial day) morning I believe. We should have the move completed by the end of the week. I’ll post updates as they become available.
