FM transmitter site – Engineering Radio

Fordham University WFUV

Over the last several months, I have been helping out in a small way with WFUV’s new transmitter installation. George Evans, CE for WFUV, and Bill Weeks of Wolftron Electronics did most of the work. This project’s location is unique; the transmitter is in an equipment shelter on top of the Montefiore Medical Center in the Bronx. That complicated the removal of the old transmitters and installation of the new transmitters.

WFUV tower atop the Montefiore Medical Center

This is the top of the Montefiore Medical Center in the Bronx. The building has 28 floors. To access the transmitter, one needs to go up another flight of stairs to the roof. Go outside onto the roof and take two more flights of stairs to the transmitter shelter just below the tower. Those stairs can be seen as a thin wispy thing on the left of the elevator building.

At the top of the tower, the two-bay Shively antenna is for WVBN 103.9 Mhz. WFUV 90.7 MHz is the six-bay Shively just below that.

These are the transmitters being replaced. There are two of them running combined for a TPO of 14.2 KW (including the -14 dBc HD subcarriers). They are about 20 years old.

The before picture; combined BE FMi 703 transmitters

As you can see, there is little room to work in this space. The old transmitters needed to be removed from the room, hosted down two stories to the main rooftop, wheeled around to the door, and then lowered another flight of stairs to the 28th to the elevator.

It makes me tired just thinking about it.

BE FMi 703 (less RF modules and power supplies) being lowered to the rooftop level

Out with the old, in with the new.

GatesAir FAX15K being hoisted from the roof up to the transmitter shelter

The GatesAir FAX15Ks made the trip up safely. Able Rigging from New Jersey did all of the moving into and out of the shelter. The two transmitter chassis, all of the boxes containing the exciters, RF modules, power supplies plus a 25 KW dummy load, and the cut-up for scrap Myat variable T antenna combiner were removed in one go.

The after picture; GatesAir FAX15K transmitters, two cabinet version

The FAX15K’s are in the shorter cabinets (requires two) because the taller cabinet would not fit in the elevator.

FAX15K with back doors removed, power block, combiner, directional coupler, and RF output flange.

The output of each transmitter goes to a 3-inch coax switch. The bottom port of the switch goes to the Shively filter (thence to the antenna), and the top port goes to the 20 KW dummy load.

Bill Weeks routing control wiring to coax switch

WFUV CE George Evans, heading to the job site

“How many more times do I have to climb these stairs today?”

But the view is great! Mid and upper Manhattan in the distance

Your author is about to tell a sea story…

I enjoyed working on this project.

Special Equipment

This year, winter in the Northeast has been relatively tame (so far). As I type this today, the temperature is 60 degrees F. The average high temperature this time of the year is around 40 F. This is an anomaly due to the strong El Nino currently going on in the Pacific Ocean. Next year will likely be closer to normal.

To that end, one of the problems in winter time is access to mountaintop transmitter sites. Several of the sites we maintain can only be accessed with special equipment such as a snowcat, track machine, or snowmobile. We have two or three sites that are cut off from regular vehicular access for 2-4 months per year. One site in particular has water flowing down the access road from a reservoir creating a 200-foot sheet of ice that is not even walkable.

For many years, I have been on the lookout for some special equipment that will allow us to get there safely and back.

Meet the special equipment:

The wheels were replaced with tracks and we added this stud kit for ice

Like other such items, there is a cost associated with owning this. In the past, we have paid a two-way radio company that has a larger snow machine for rides to the top of various mountains. That can get pricey if several trips are needed. We will have to figure out a reasonable fuel surcharge for the operation of this track machine.

Co-located common antenna FM stations

One of our clients needs to move to another transmitter site because their lease is expiring at the old site. We have been working on this for several months now. One of the nice features of this project is the panel antenna.

This is installed in a 2-bay 3-around configuration. I don’t see this particular model in the Kathrein catalog anymore, but there are other cross-polarized panel antennas available from them.

There are many existing services on this tower including two full-power FM stations, a translator, a VHF TV station, numerous cell carriers, etc. Once the installation is done we will have to check carefully for intermodulation.

Winter in the Northeast; there was just enough snow and slush on the access road that the truck could not make it to the top of the hill. This track machine works great. We have added a Polaris Ranger 900 to our inventory (not this machine) for winter access to several of the more difficult transmitter sites. While I do enjoy the occasional walk in the snow, the key word here is occasional.

The three stations are combined into the panel antenna with this rather nice American Amplifier Technologies C-IR-3-3-30K-N branch combiner.

The input filters needed a slight adjustment to compensate for the difference between the test load they were tuned to and the actual antenna load they will be running into

Two of the transmitters are Broadcast Electronics STX-10 units. We have had good service from the STX-10 which was installed on Mount Beacon a few years ago.

We are waiting for the Comrex Bric Link III to come back from the factory after their firmware update. They are to be used for the STL. Once they are returned, we should be good to go for site turn-up.

The Rhode Schwarz THR9 transmitter

This is part I of II.

We are in the process of installing an R&S 40 KW liquid-cooled FM transmitter. My first comment; these are well-built units. A quick look at the machining of the parts indicates attention to detail is a key design feature.

As the price of electricity continues to rise, liquid-cooled transmitters for this power level make a lot of sense.

This installation is for Pamal Broadcasting’s WHUD, Peekskill, New York. The site has undergone major upgrades in the last few years. The original 1958 World Tower Utility 80 was replaced a year ago with this Valmont 60X394. Two cell carriers, two translators, and several E911 services are now colocated on the tower.

Valmont 60X394 tower, WHUD Peekskill, NY

The transmitter building is also the original cinder block structure from 1958. When it signed on, the station had a Gates FM5B 5 KW transmitter, an RCA BFA-7, 7-bay horizontally polarized antenna with an ERP of 20 KW. In 1970, that antenna was changed out to a 6-bay circularly polarized ERI with a Harris FM20H transmitter, increasing the ERP to 50 KW. As of now, the station has a 4-bay ERI SHP-4-A-C main antenna and the TPO is 28 KW for the same 50 KW ERP. As the station’s power increased, the building became a little bit smaller than optimal. We needed to rearrange some equipment to gain space for the pump station and step-up transformer.

Rhode Schwarz recommended installing a step-up transformer for the incoming AC mains. The power supplies run most efficiently with 400 volts AC.

Hammond HPS Sentinel K dry core transformer

The Rhode Schwarz RF connection to an ERI switchless combiner

We decided to reuse the ERI switchless combiner left over from the Nautel V-40 installation. There are two Nautel V-10 transmitters with a hybrid combiner that are to be used as a backup. We won’t be running this as a combined transmitter operation, it is a way to save money rather than install a separate 3-inch coax switch. I will build a simple control panel to move the combiner position either all the way up (THR9) or all the way down (V-10s).

2.5 inch core drilled holes for coolant supply and return

Working on the liquid cooling system. I used a core drill to make the supply and return lines to the outdoor heat exchanger. I made sure that I had the shop vac (with a HEPA filter) running while drilling so that all of the concrete dust was captured. That stuff can get everywhere and has a bad tendency to destroy motor bearings. Whatever plant made these blocks in 1958, they used some hard material. It took a while for my masonry drill to get through them.