Emergency AM replacement antenna

Eventually, disaster will strike. It can range from a fire at the transmitter site to a tornado at the studio.  Someday, every station on the air will be knocked off at the worst possible moment. It is the law of nature.  Perhaps the most difficult disaster to recover from is the loss of a tower at a transmitter site.  An FM tower holds the antenna, therefore, finding a tower or building nearby and placing a temporary antenna there will get the station back on the air in a reasonable fashion.

An AM tower is the antenna, which is much harder to replicate.  One possible solution is to use a temporary wire antenna while the tower is being rebuilt.  This is allowed in FCC 73.1680 emergency antennas, provided the commission is notified of the situation by informal letter.  Directional stations must operate at 25% or less of the station’s licensed power, or demonstrate that radiation limits are not being exceeded in any direction.  That usually can be accomplished by taking a set of monitor points.

A wire antenna can come in several configurations:

  1. The fastest to deploy is the random-length end-fed wire.  This can normally be attached to the existing ATU and tuned up with components on hand.  It requires having an OIB, generator, and receiver to tune, which not every station has.  In addition to that, extra components may be needed in the ATU for tuning purposes.
  2. The next easiest is a tower-length wire ready to deploy.  This is a length of wire equal to the height of the tower, with insulators and supports.  The wire should be supported as high above ground as possible using trees, wooden poles, etc.  Still requires having an OIB, generator, and receiver to tune.  Likely to be within the tuning limits of the ATU components on hand.
  3. A 1/2 wave dipole tuned for 50 ohms.  This can be connected directly to the transmitter output, thus is the best solution if the ATUs were damaged or otherwise not serviceable.  In this situation, two 1/4 wavelengths of wire are coupled at the center using a 1:1 balun.  Again, this antenna should be supported as high above ground as possible using trees, poles, and other non-conductive supports.  Can be installed in a V, inverted V, or L shape as required.

All three of these choices would likely limit transmitter power output to 1-2 KW.  Choice 3 likely represents the most efficient radiator and can be fabricated ahead of time and stored at the transmitter site.

1/2 wave dipole with 1:1 balun
1/2 wave dipole with 1:1 balun

To make a 1/2 wave dipole, cut two lengths of wire using the formula L(feet)=246/F(MHz).  This formula does not account for a velocity factor of 90%, which is typical for stranded wire.  The reason is, since an MF dipole antenna is necessarily going to be lower than 1/2 wavelength, it is better to start the antenna a little long and trim it to size for a 50-ohm impedance.  If commercially made insulators are not available, insulators can be made from non-conductive materials like PVC conduit, PEX, plexiglass, etc.  The insulators on the ends of the wire need to account for the voltage peak that will occur there.  If small “dogbone” type porcelain insulators are used, string three or four of them together using nylon or poly rope.  The insulator needs to be able to withstand 8-10 KW of power under full modulation.

A 1:1 balun will distribute the RF currents evenly on both wires, which will help improve efficiency and coverage.  Most Ham Radio Baluns are not designed to work below 1.8 MHz and therefore, will not work for this purpose.  A balun can be made with a ferrite toroid made from 68, 73, 77, or type F material.  A good choice would be Amidon FT-290-77 or FT-290-F.  The type F material has a higher AL value, thus fewer turns are needed.  In addition to that, high voltage insulated wire should be used to wind the balun.

1/2 wave dipole antenna current voltage distribution
1/2 wave dipole antenna current voltage distribution

Since, in a 1/2 wave dipole configuration, the voltage is at a minimum at the center of the antenna, and current is at a maximum, some attention needs to be paid to wire size as well.

Amidon ferrite torroid core
Amidon ferrite torroid core

To give a good idea of wire sizes required, some basic information is needed.  For a 1 KW station, it is assumed that the carrier will be modulated to 100 percent, therefore the peak envelope power will be 4 KW.  If the station is asymmetrically modulated, add another kilowatt.  Therefore, the maximum current formula is I=√(P/R).  P is the power in watts, or 5,000 and R is the radiation resistance or 50 ohms, thus I=√(5000/50) or 10 amps.   The maximum voltage is E=√(P x R) or E=√ (5000 x 50) or 500 volts.  For a safety factor, multiplying these values by 1.5 is recommended.  That will likely account for any impedance differences due to ground proximity and so forth.  Therefore for a 1 KW station, the dipole antenna should be designed for 15 amps and 750 volts.

For a 2 KW station the peak envelope power for an asymmetrically modulated transmitter is 10 KW, thus it follows that 30 amps and 1500 volts are safe working figures.

With the proper torroid core, a turns count of 7-10 turns bifilar will suffice.  Since it is a 1:1 balun, the turns count on both sides of the transformer will be the same.  The balun then should be placed in a suitable water proof housing designed to be attached to the center of the dipole antenna.  This is a good example of a commercially available 5 KW 1:1 balun for amateur radio use:

1:1 balun designed for center of 1/2 wave dipole antenna
1:1 balun designed for center of 1/2 wave dipole antenna

The antenna can be fed with RG-8, RG-8X, RG-8A, RG-214 or any other coax this is capable of handling the peak envelope power of the radio station.  The connector can be UHF, N, LC, etc.  In some cases, the may be easier to simply omit the connector and connect the coax to the balun using some type of strain relief on the cable coming out of the box.

Once this antenna is made, a bit of tuning may be required to bring it to 50 ohms.  This can be done with a bridge and generator, or with the transmitter on low power.  Either way, the measurements must be taken with the antenna at operating height as the distance to ground will effect the termination point impedance.  It may require some trial and error.

In all, a good backup antenna can be made for about $50-60 or so.  A little bit more if fancy transmission line is used.  Well worth the expense and effort to have something ready to go in a moment’s notice.

Update: I’ve been fooling around with this on EZNEC, it may not be that easy to do, especially with the lower frequencies in the AM band.  The antenna needs to be at least 0.06 wave length above ground to perform correctly.  Somewhat lower over better ground conductivity, e.g. ground radials.  Even at this height, it needs to be lengthened significantly to get the feed point impedance close to 50 ohms.

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
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:

WLNA tower 1 ATU, Peekskill, NY
WLNA tower 1 ATU, Peekskill, NY

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
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
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.

Burned RF contactor bar
Burned RF contactor bar

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.

Burned RF contactor fingers
Burned RF contactor fingers
Harris HS-4P contactor repaired
Harris HS-4P contactor repaired

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

Broadcast Electronics AM1A transmitter
Broadcast Electronics 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.

WISN night time allocation study
WISN night time allocation study

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.

WISN night time allocation ma
WISN night time allocation ma

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.

WISN antenna array
WISN antenna array

From the front of the transmitter building

WISN transmitter site, 1941
WISN transmitter site, 1941

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.

WISN RCA BT-5E transmitter, 1941
WISN RCA BT-5E transmitter, 1941

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.

RCA AM antenna monitor
RCA AM antenna monitor

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.