AM Towers – Page 7 – Engineering Radio

Creek floods AM tower array

We have received somewhere between 5-6 inches of rain in the last four days. That, coupled with the deep snowpack and the still-frozen ground has led to some flooding. The WLNA antenna array is located along the Peekskill Hollow Creek in northern Westchester County, NY. Back in 1980, it might have seemed like a good idea to locate an AM station in a tidal swamp along the Hudson River. I am sure the land was not that expensive and from an engineering standpoint, having a continually wet, partially brackish ground system may have seemed like a slam dunk.

Unfortunately, the idea never really panned out in the application. First of all, the neighbors had other ideas, fighting the radio station owners all the way to the NY State Supreme Court. Secondly, technically, it never lived up to expectations. The original non-directional antenna on 1430 was a 1/2 wave tower which by all accounts, worked very well. It did not, however, allow for nighttime service, which is why the new sight and array were sought. By the time the system was built, AM was already in steep decline and I doubt the owners ever recouped their investment.

Fast forward to today. All five base insulators are under water and the transmitter is off the air. These are pictures from last Wednesday after the first flood waters receded from the Monday/Tuesday storm. I imagine it looks worse this morning, although I don’t own a boat and won’t be wading out there to look.

Base insulator, tower 2 WLNA array, Peekskill, NY

This is tower two of the daytime antenna array. Clearly, it spent some time underwater. We cleaned off all the debris from all the tower bases. A far worse prospect is the ATU’s:

This is the Antenna Tuning Unit for tower 1, which is the reference tower for both the day and night arrays. The E.F. Johnson contactor in the bottom of the cabinet was fully submerged for an undetermined amount of time. The bottom of the unit is covered in fine silt. The high water mark is visible on the right side of the aluminum cabinet.

The contactor is going to need to be replaced, or at least rebuilt. The ATU cabinet will need to be washed out. There are two other ATUs that suffered the same fate.

WLNA antenna array, towers 4 and 5 — WLNA antenna array, towers 3 and 5

This is the end of the catwalk next to the Peekskill Hollow Creek looking west towards the Hudson River. The water level reached the bottom of the catwalks and had receded about 4 feet when this picture was taken.

WLNA antenna array, tower 5, peekskill, ny — WLNA antenna array, tower 5, Peekskill, NY

Lookup east, upstream at tower 5.

WLNA antenna array looking north, Peekskill, NY

This is the antenna array looking north, with my back facing the creek. Tower one is the center tower, tower two is on the right and tower four is on the left. The daytime array consists of towers 1, 2, and 3 bearing 300 degrees. The night time array consists of towers 1, 4, and 5 bearing 335 degrees, so the array makes a big X in the swamp. More from the FCC database.

It is going to take a lot of work to clean out all these ATUs and repair the damage. Clean water is at least 1000 feet away. My question is; why bother? Once upon a time, this station was viable, well thought of in the community, etc. Now, I doubt anyone knows it is off the air. The current ownership over the last thirteen years did, what I’d like to call, a controlled flight into the ground. Axing staff, cutting maintenance, and generally neglecting the station. Why not take it dark for a while and figure out what to do with it? Likely somebody would buy it, even if for the land it sits on. Anyway, the grind continues…

The burned contactor fingers

This is a set of burned contactor fingers on a Harris HS-4P 30 amp RF contactor:

Harris HS-4P RF contactor with burned finger stock

The back story is this:

The contactor in question is at the base of Tower #3 of the WBNR (1260 KHz, Beacon, NY) antenna array. This is the tallest of all the towers, at 405 feet. As such, it gets struck by lightning often. There was at least one occasion where one of the inductors in the ATU got “sucked in” due to the huge magnetic field of a high current strike. It is not at all surprising to me to find other component issues in this ATU. Because of the burned contacts, I’d suspect that the station was switching modes under power, but I didn’t see that happening today.

The problem manifested itself in very high SWR after changing over from day pattern to night pattern. This did not occur every time, in fact, it only occurred once in a great while at first. Then, over the last couple of months, it began occurring more and more often. Since the snow drifts are now down to a manageable six to eight inches, it was a good day to go out and do some exploring.

First of all, I put the station into nighttime mode just to confirm that there is still an issue. The transmitter, a Broadcast Electronics AM1A showed very high SWR and carrier fold back. Left it in night pattern, but turned it off and took a walk, not a drive, to Tower #4 which is all the way at the bottom of a hill, near the old City of Beacon landfill. I figured that I would check that one first, then look at Tower #3 on the way back. When I got to Tower #3, I found the issue right away.

Fortunately, I was able to salvage a set of contact and contactor bar from another relay in the same ATU that was not using them.

The night pattern is only 400 watts, but these are tall towers, 225 degrees, therefore current and voltage are high at the base. In fact, the slightest change at the base of the nighttime towers will greatly upset things.

This is the repaired contactor. I will say, the EF Johnson RF contactors are easier to work on. Those are the ones with the big rocker bar across the top and two solenoids on either side. All of the wiring, status switches and contacts are exposed and easy to get to. This one, not so much. This is the BE AM1A transmitter

It is not a bad unit, compact, sounds good, is reliable, etc. In order to work on the power supply or anything in that top cabinet, the whole thing needs to be removed from the rack and taken down. I suppose that is my only gripe about the thing.

Milwaukee’s oldest radio station

WISN 1130 AM has been on the air since 1922, although not always with those call letters. In an interesting twist, the license was granted to the local newspaper, the Wisconsin News, and the Milwaukee School of Engineering. Initially, both entities were programming the station, however, by about 1925, the newspaper was responsible for programming and the engineering school was responsible for technical operations.

In 1941, the station increased power from 1,000 watts to 5,000 watts and added nighttime service. This is a series of pictures from that time period.

Back in 1941, nighttime interference was taken seriously. The nighttime allocation study (on 1150 KHz, WISN’s former frequency) includes co-channel stations in the US, Canada, Cuba, and Mexico.

The array consisted of four Blaw-Knox self-supporting towers in a rectangle. Notice the lack of fencing, warning signs, and the like around the towers.

From the front of the transmitter building

The site looks well designed, no doubt manned during operation, which at the time would likely be 6 am to midnight except under special circumstances. Most of these old transmitter sites had full kitchens, bathrooms, and occasionally a bunk room. The transmitter operators where required to have 1st telephone licenses from the FCC. There is only one manned transmitter site in the US that I know about; Mount Mansfield, VT. There, WCAX, WPTZ, WETK, and VPR have their transmitters.

The WISN RCA BT5E transmitter looks huge for that power level. Back in the day when AM was king, these units were designed to stay on the air, no matter what. I don’t know too much about this model transmitter, but if it is like other RCA/GE models from the same era, it has redundant everything.

Old school antenna monitor. I have never seen one of these in operation, however, as I understand it, the scope was used to compare the phase relationship of each tower against the reference tower.

These pictures are of the WISN 1150 array was it was in 1941. Since then, the station has changed frequencies to 1130 KHz and increased power to 50,000 watts daytime/10,000 watts night time. The daytime array consists of six towers and the night time array has nine towers, all of which are 90 degrees.

Special thanks to John A. for sending these pictures along.

The mechanical tower light flasher

This is a Hughey Phillips mechanical tower light flasher that has been in service since 1960. Basically, it is a motor connected to a cam that rocks a mercury relay back and forth. These were standard technology for tower lights from the 1930s through about 1970 or a little later. They were very reliable, we still have some with a “pancake motor” in use on some of our towers. They were very robust and immune to lightning damage, RF interference, and other problems. The only maintenance that I can think of is lubricating the motor bearings. Eventually, however, they do wear out. Cold weather seems to take its toll, often causing the motor to stop.

Hughey and Phillips mechanical tower light flasher

This particular unit is mounted inside the tuning house for the far tower (north tower) at the WGHQ antenna array. It has finally reached the end of it’s existence; the motor bearings are shot and it has gotten stuck in both the on and off position this year causing the FAA to be notified of the malfunction.

Today, I am replacing it with a solid-state flasher (SSAC B-KON FS155-30RF). Solid-state flasher units have been known to malfunction in high RF fields, such as AM towers. To cure that, the manufacturer has built-in 0.01 uf bypass capacitors, hence the “RF” suffix. Older units did not have built-in bypass caps, so external 0.1 uf bypass capacitors were normally installed on units mounted to AM towers. While I was working on this, I turned the transmitter down to 500 watts, no need to get any RF burns.

Naturally, this has to happen after there is two feet of snow on the ground. Also, it should be noted that this is the furthest tower away from the transmitter building. Now where did I put those snow shoes? Never mind, it has been very cold and the ground is frozen solid, I’ll take the truck… This is good because I will have all the tools, drills, nuts, and bolts without having to walk back and forth several times in the snow.

Hughey Phillips mechanical beacon flasher

I removed the motor and mercury-filled relay. I’ll have to figure out how to dispose of the relay. I then drilled a mounting hole through the base of the old flasher housing and bolted the solid-state relay to it. This is required because the solid-state relay needs a pretty good heat sink.

Turn everything back on and: Ta-da! All works normally, the tower beacon is flashing away up there. Time to leave.

Pull forward about 2 feet to turn around and CRUNCH! The truck goes through the ice of a hidden stream. Any attempt to move only makes it worse:

Put in a phone call to the one guy I know that can get me out. About an hour later he shows up with chains, a shovel, and a come-a-long. We attach the come-a-long to the fence support post and pull the truck out backward 1/2 inch at a time. It took us about an hour and a half to get it all the way out so I could drive it back across the field. I’d have taken some pictures, but my guy; was a little grumpy.

I won’t do that again.

Still, I did the job I came to do, so it was a good day after all.