tech stuff – Page 61 – Engineering Radio

Lightning Damage

It is that time of the year again, at least in the northern hemisphere, for thunderstorms. I am a big proponent of grounding everything, there is simply no such thing as too much grounding. I took a course when I was in the military given by Polyphaser in which grounding for lightning protection and EMP was emphasized. It was very interesting in several respects.

One commonly held belief is that when lightning strikes an object, the ground immediately absorbs all of the charge. That is not true in most cases due to ground resistance. Eventually, the ground will absorb the charge but it can take several seconds to do this, especially with a big strike. Equipment is damaged by current flow, therefore, every effort must be made to keep all of the equipment at the same potential, even if that potential is 10KV. That is where a single-point ground bus comes in. Bonding every piece of equipment to a common ground bus ensures that no one device is at a lower potential while the charge dissipation is occurring.

The second misunderstanding about lightning is that it is DC voltage. That is true, however, a lightning strike has an extremely fast rise time, on the order of 30 microseconds. That makes it behave more like an AC voltage of around 10 KHz. Therefore, ground bus wires need to have a minimum inductance. Solid #2 wire is best, keeping it as straight as possible and using long sweeping turns where needed. All bonds should be exothermically welded (CAD weld).

Ground system installed at WKZY, WHHZ and WDVH, Trenton Florida

The ground system was installed at WKZY, WHHZ, and WDVH-FM transmitter site in Trenton, Florida. Central Florida is the lightning capital of the US. Prior to doing this work, the Harris FM25K transmitter was knocked off the air at least once a month. Since this was installed in 2005, they have had zero lightning-related damage. The ground rods are 20 feet long, driven down into the water table, spaced 20-30 feet apart.

All coax shields and metal conduits that come into the building should be bonded to the ground system where they leave the tower and where they enter the building. At most tower sites, I install a ground ring around the outside of the building with rods every 20 feet or so. From that ring, 5 to 6 radials outward 40 feet with ground rods every twenty feet works well. I also install 5 to 6 radial out from the tower base with the same configuration. The tower and building grounds are bonded together. This is important because when the tower gets hit, the ground will quickly become electrically saturated. If the building and the equipment inside are at a different potential, current will begin to flow toward the lower potential, thus damaging gear.

All Coax, control, and AC cables in and out of sensitive equipment should have ferrite toroids on them. Transmitter manufacturers normally supply these with new solid-state transmitters, as MOSFETs are particularly sensitive to lightning damage.

Lightning damage to rack mounted equipment

This is a Potomac Instruments AM-19 directional antenna monitor. It was damaged by a lightning strike two weeks ago on the WBNR tower in Beacon, NY. The case arced to the rack it was mounted in. This was a large strike, as several components in the phasor control circuit were also damaged. The fact that this arced means that somehow the sample lines are not attached to the single-point ground for this site, which needs to be corrected.

Insulated AM towers present special design problems when it comes to lightning protection. Generally speaking, tower arc gaps should be set so there is side by side and there is no arcing on positive modulation peaks. Depending on power levels, this can be anywhere from 1/2 inch to 2 inches. Tower impedance also plays a role in setting arc gaps. The final link between the ATU and the tower should have several turns in it. The idea is to make that path a higher impedance path for the lightning, causing it to dissipate through the arc gaps. Incoming transmission lines from the towers should be bonded to a copper bus bar at the entrance to the building. All of this grounding needs to be tied to the RF ground at the base of the tower.

Arial phone cables can act like large lightning antennas for strokes several miles away. It is very important that the cable shield and the cable termination device are bonded to the building ground buss. I have seen installations where the TELCO tech pounds in a separate ground rod outside and connects the TELCO equipment to that. That defeats the concept of single-point grounds and should be fixed ASAP.

Electrical services entrances also can act like big lightning antennas. Normally, pole-mounted transformers will filter some of this energy out. Internal electrical distribution systems can also add impedance, and thus act as inadvertent filters for lightning. In most mountaintop transmitter sites, however, some type of power line surge protection is needed.

LEA series surge protector — Inside view of LEA surge suppressor

There are two types, series, and parallel. Parallel types are the least expensive and least intensive to install. They are usually found mounted next to or on the service panel and fed with their own breakers. They usually have some type of MOV or similar device that acts as a crowbar across the AC mains, conducting spikes to the ground. Series types go in between the service entrance and the main panel. They include a large inductor designed to force spikes off into shunts. A series-type protector offers more complete protection than a parallel.

Moving the WKZE studio, Part II

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:

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.

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 was ripped out on Thursday. The console was removed and rebuilt with a new control surface

New WKZE air studio completed, console is a Radio System millennium 12 — The new WKZE air studio completed, console is a Radio System millennium 12

The production room was completed, speakers hung, etc.

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.

Filament Voltage Management

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.

E-skip, tropospheric ducting and other VHF propagation phenomena

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).

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.

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 Map — 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.