This lovely transmitter is 33 years old! I thought we’d celebrate by changing the electrolytic capacitors! It appears that some of the capacitors were changed in 2009, but many are original to the transmitter. Gates Air recommends replacing the electrolytic capacitors during the course of regular maintenance cycles. Dried-out capacitors can lead to a variety of mysterious fault conditions including low drive levels, poor audio quality, difficulty starting the transmitter, and so on. See Harris service bulletin AM-579-JK.
Some of the Low Voltage Power Supply capacitors were at least partly dried out. They felt a little bit light and one of them rattled when I shook it.
Replacing large PA capacitors
Gates Air has a full replacement kit, part number 973-2100-391. When I looked into it, the price of this kit is very reasonable and is closely aligned with the prices from Mouser Electronics.
Old capacitors for disposal
Here is a full list of capacitors needed, I put the Mouser part numbers in just in case:
Nomenclature
Amount
Gates Air PN
Mouser PN
Cap, 5,100 uf 350 V
17
524-0341-000
598-DCM512T350DG2A
Cap, 5,500 uf 200 V
4
524-0219-000
75-36D552F200DF2A
Cap, 15,000 uf 100 v
2
524-0322-000
594-MAL210119153E3
Cap, 76,000 uf 40 v
4
524-0342-000
75-36DX763G040DF2A
Cap, 120,000 uf 40 V*
2
524-0380-000
75-36DX124G040DJ2A
Large Capacitors for DX-50 transmitter
*See Harris service bulletin AM-474-TLH for information on the -8 volt power supply.
Board is green, Returned to service
Most of the capacitors in the PA section were original to the transmitter, as well as those in the 30-volt and 60-volt driver supply.
One important detail; pay attention when installing these things. You do not want to reverse the polarity on an electrolytic capacitor, it will likely explode. These units are pretty big and the explosion would be loud and messy.
With that done, I also went through the transmitter and reset all of the voltage levels according to the factory test data sheet. When it was returned to the air, it sounded great!
Call it climate change or an unfortunate coincidence; we seem to be getting more icy weather in this area. It used to be this region would see one mild event every one or two years. Recently, however, we are getting two to three moderate to severe events per year.
This can create problems for the utility company. Even if the power stays on, the transmitter may not. Excessive ice on the antenna may cause the transmitter to fold back or shut down completely.
We have several clients that have various FM antennas with electric resistance type de-icers. One client has three such stations however I found there were no automatic controllers at any of them. Back in the day, when there were people working at the station, they probably turned the de-icers on and off manually via the remote control. These days, not so much. When we began servicing these facilities, the previous engineer stated that he turned the de-icer breaker on around Thanksgiving and turned it off around Easter. Not terribly efficient.
As a part of moving into a new transmitter building, I began looking for something that would automatically turn the de-icer on when it is precipitating at or close to freezing temperatures and then turn it off after a couple of hours. That would certainly reduce the electric usage for that transmitter site and keep the transmitter happy.
I found this simple snow melt controller:
ETI LCD-8 snow melt controller
This is sold on Amazon for about $570.00. This has an internal relay that can switch 240 volts at 16 amps. However, that 240-volt heating circuit goes up to the top of the tower where the FM antenna is mounted making it vulnerable to lightning damage. I figured an outboard relay switched on and off by this controller was a better way to go. That way, there is an operating indicating lamp and a bypass switch.
De-icer controller relay
Outdoor icing sensor mounted on the ice bridge.
Now, the de-icer stays off most of the time. When it is needed, it comes on automatically and turns off three hours after the precipitation has stopped. Since installing last fall, it has worked well and the station stayed at full power through at least two ice events.
I measured the current on each leg, which was 2.6 amps or 624 watts. That is the same as it was before. A quick calculation, I estimate the number of hours this system was previously energized when the breaker was left on all winter to be roughly 3,400. Thus 3,400 hours x 624 watts = 2112 kWh. These days, our electric rates are running $0.16 to $0.18 per kWh so the total cost would be $380.00 to run continuously. The control system will pay for itself in less than two years.
This one is targeted mostly toward my European readers (however, read on).
I received the following email from Olkesandr in Ukraine, it seems the Russians stole his transmitter:
Hello!
My name is Oleksandr (last name redacted). I am chief editor of Ukrainian radio station CCR 648 AM. We are looking for an used am transmitter 25 or 50 kwt. Probably Your company has one for sale?
That is interesting. I asked for a few more details and received the following:
I am originally from Crimea. But in 2014 I had to leave my native town. I have been living in Kyiv since 2014. In 2017 our team of journalists launched informational broadcasting to the occupied Crimea from Chongar (it’s 1 km from Crimea in Kherson region). First we started broadcasting on 105.FM 5 kwt. But in 2018 our signal had been jammed by russians occupants. In 2019 we started broadcasting on 648 AM (10 kwt). In 2021 we increased the power to 25 kwt. But in February 2022 our transmitter was captured by russians. Now we are looking for an 25-50 kwt AM transmitter. We are going to install it in Kherson region (in controlled by Ukraine territory). I supposed we’ll be able to cover by our signal all Kherson region, Zaporizhzhya and Crimea.
Digging around, I found two news stories about it: Apparently, the Russians removed the Transmitter. By the way, Krym (pronounced cream) is Crimea in Ukrainian and Russian.
Missing Harris DX-50 transmitter, serial number MPS104705-00001
That is an interesting setup; the FM antenna is a stack of six, looks like 1/2 wave spaced six-element yagis, vertically polarised. The AM is a slant wire that goes almost to the top of the tower.
That area is still occupied by the Russians. As it is one of the two usable land transportation routes, it is likely that it will be unusable for some time after it is deoccupied.
So, here is the ask; I know that many Medium Wave transmitters have been turned off in Europe over the last several years. Is there any in that power range that is available to be moved to Ukraine? Preferably something that is still in good working order and on or close to 648 KHz. It is a long shot, but worth asking.
This is an important question these days. We are running into more situations where timing is important, especially when audio and video codecs are concerned. If there is too much time differential, the codec will unlock. More often, digital transmission methods require precise timing to prevent jitter and dropouts. Some equipment has 10 MHz or 1PPS inputs. Some equipment does not and relies on NTP to keep things in sync.
While searching online for GPS time sever, I came across this post where Austin built a Stratum 1 level time sever with a Raspberry pi and an inexpensive GPS receiver. I thought to myself; damn that sounds interesting. While a Raspberry pi is a hobbyist toy, the same setup can be done with a more serious computer to create a solid NTP server for a facility or LAN.
A little about NTP time servers; Stratum 0 server is directly connected to an atomic clock. Since GPS satellites have atomic clocks, that makes them a Stratum 0 server. Stratum 1 servers are connected to Stratum 0 servers. Stratum 2 servers are connected to Stratum 1 servers and so on. The time accuracy for a Stratum 1 server is 10 microseconds.
First, I wiped my SD card and loaded a fresh install of Raspberry pi OS. Then followed along with the instructions. For this install, I opted for the cheaper GPS receiver, the GT-U7 (not an affiliate link) from Amazon for $10.99. It comes with a cheap little antenna, which actually worked sitting inside on my desktop while I was configuring the software.
This little module is designed for a drone but works well in this application. The 1PPS output looks clean on the scope. Here is the pinout between the GT-U7 and the Raspberry pi:
GT-U7 pin
pi pin
Use
Color
vcc
1
+3.3 vdc
Green
gnd
6
ground
Brown
txd
8
rxd
Orange
rxd
10
txd
Red
pps
12
GPIO 18
Yellow
I found this really nice aluminum case in a pile of disused junk at a transmitter site. It used to be for a digital TELCO STL circuit. I figured it would be nice to put the Raspberry pi and GPS receiver in a suitable home.
Raspberry pi 3 is mounted on a piece of scrap sheet steel designed to slide into the aluminum case.
We have several of these nice Panasonic GPS antennas left over from various installs. I pressed one into service on the roof of my house.
Panasonic CCAH32ST01 GPS antenna
I think a high-quality antenna is pretty important to get consistent good performance from this setup. There are three slight problems, however. Unfortunately, this antenna has been discontinued by the manufacturer. Also unfortunate, the GT-7U boards have one of those little IPX RF connectors. Fortunately, I found a short jumper with an F SMA connector. Finally, it requires +5 VDC and the GT-7U runs on 3.3 VDC. The pi does have a 5-volt rail, so I used this 2-way power divider to feed 5 volts to the antenna from one port and the received RF from the antenna goes to the GT-U7 from the other port.
If you are interested, here are the commands to get this thing running:
sudo apt get update
sudo apt get upgrade -y
sudo apt install pps-tools gpsd gpsd-clients chrony
The next step is to make sure the serial port is turned on and enable the ssh login shell since this is going to live in the basement and I don’t want to run down there to fool around with it.
sudo raspi-config
Then go to interface options, serial interface, and enable. The login over the serial interface can be left off. If ssh access is needed, enable ssh, then exit.
Once those packages have been downloaded and installed, some config file editing is needed. You may use whichever method you like, I tend to use nano. First, the /etc/config.txt and add the following to the file:
The uart needs to be enabled if you want to receive NMEA data (NMEA stands for National Marine Electronics Association) It is helpful to see if or how the GPS is working.
Next, the /etc/modules and add:
'pps-gpio'
Reboot, then see if the pps module is working:
lsmod | grep pps
The output should look like this:
Next, there are a few more configuration files that need to be edited.
/ect/default/gpsd – there is a default file that comes with the package, it needs to be modified to start the daemon automatically and look for the pps signal on ttyS0.
Now check and see if the GPS module is working by typing cgps or gpsmon. The output should look something like this:
It did not take the module too long to find and lock onto GPS. If you don’t see something like this in five minutes or so, go back and check your wiring, and make sure that the data connections are made right. The GT-U7 has a little red LED that is lit when the PPS pulse is not being sent. If this light is not on at all, check your power connection. If it is on steady, check your antenna. If it is flashing, but you are not seeing any output in cgps or gpsmon, check your data connections.
Next and last configuration file is the /etc/chrony/chrony.conf file. At the top of the file, I added the following lines:
#custom lines for PPS
server time-a-g.nist.gov iburst
server time-d-g.nist.gov
server 3.us.pool.ntp.org
server time.windows.com
server time.apple.com
# add refclock pps
refclock SMH 0 delay .1 refid NEMA
refclock PPS /dev/pps0 refid PPS
#my home network
allow 192.168.1.0/24
Leave the rest of the file alone. Basically, the time servers are added to compare the GPS time and act as a backup. The hosts on my home network are allowed to query this host and use it as an NTP server.
Restart Chrony:
sudo systemctl restart chrony
Wait a couple of minutes and check the chrony console to see what is happening: chronyc sources. Should look something like this:
This was after the server had been running for a day. Chrony is great because it measures the hardware performance and creates a delay file. This is used to anticipate any hardware-added delays that the system might have. The last sample column is of interest, the number indicates the offset between the local clock and the source at the last measurement. The far column is the margin of error or greatest variation +/- of the expected values. A value of 0.0000000042 seconds or 0.042 microseconds is pretty good for an $11.00 piece of hardware. Now every host in my house is syncd to satellite within 0.042 microseconds, in lockstep through the time-space continuum.
If I were to do this professionally, I would use better hardware. I think the pi 4 has better serial and ethernet interfaces, more RAM, and a quad-core processor. Last I looked they were $75.00 at Newark.
The GPS module was the cheapest I could find on Amazon. I am slightly concerned about the longevity of this device. Perhaps it will run for a long time, or perhaps not. A quick search brought up several “hats” (plug directly into the 20-pin header). These range in price from about $30.00 to $60.00. What is required of any GPS module is 1PPS output. The configuration would be about the same although some use GPIO 4 instead of 18.