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.
Rhode Schwarz THR9 VHF transmitter
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.
Pump StationHeat Exchanger
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 transformerThe 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.
There are many times when some mathematics is needed in this profession. For one-off situations, the calculator applications found on most smartphones will work just fine. However, sometimes the calculation is complex or is needed to be repeated many times. Excel Spreadsheets have many mathematical functions built in. Plugging a formula into an Excel spreadsheet is a handy tool.
I recently acquired this rather nice precision power meter:
Mini Circuits precision power meter
It has an input power range of -60 to +20 dBm with a stern warning not to exceed +23 dBm. Since we will be using this for a variety of applications, I thought it might be useful to know approximately how much power will be presented to the instrument in any given situation. For example, we are installing a 30 KW FM transmitter soon. The directional coupler that will be used has a coupling factor of -48.5 dBm. The TPO is 28,000 watts.
The formula to convert Watts to dBm is dBm=10 X Log10(Pw) + 30, where Pw is power in Watts. Thus dBm=10 X log10(28000) + 30 or 74.4715 dBm minus the 48.5 dBm coupling factor which is 25.9715 dBm. That is too much input for this power meter. A 20 dB attenuator will need to be used.
Since I will be using this meter in other places, rather than doing that calculation over and over again, why not build an Excel spreadsheet? That would make it easy to check.
A simple Watts to dBm calculator in Excel looks like this:
=(10*LOG(C6))+30
This is copied into cell C11. C6 is the cell in which the Transmitter output power in watts is entered. The other cells contain the coupling factor (C5) and external attenuation (C7) In application, it looks something like this:
Excel spreadsheet power meter calculations
You can arrange these any way you like, just change the cell numbers to suit your needs.
I like to make the data entry cells green. You can lock the formula cells so that the formulas don’t get changed accidentally. Below the Approximate port power cell, is the IF statement that will return either a “LOW”, “HIGH”, or “OK” depending on the result value in C11. That looks like this:
It would be very easy to make a system gain/loss calculator for using the licensed ERP to calculate the proper TPO.
Other examples of useful Excel spreadsheet formulas:
To convert from dBm to watts:
=10^((B22-30)/10)
B22 is the cell in which the power in dBm is entered. These can be any place you want on the spreadsheet.
Radio Frequency to Wavelength in Meters:
=299792458/B10
Where B10 is the cell in which the frequency in Hz is entered. 299792458 is the speed of light (Meters per second) in a vacuum. If you wanted the input frequency to be in kHz, simply move the decimal point for the speed of light three places to the left, e.g. 299792.458. For MHz move the decimal four places to the left, GHz five places, etc.
Convert electrical degrees to Meters:
=(299792.458/B10)/360*B11
Where B10 is the frequency in kHz and B11 is the number of electrical degrees in question.
Where B11 is the air temperature in degrees Celsius and B12 is the frequency in Hz. Room temperature is normally about 21 degrees Celsius (about 70 degrees Fahrenheit). Humidity and altitude can also affect the sound wave velocity, which will affect the wavelength.
Base (or common point) current calculator using base impedance and licensed power:
=SQRT(B12/B11)
Where B12 is the License power in watts and B11 is the measured base impedance of the tower (or common point impedance of the phasor).
Convert meters to feet:
=B11/0.3048
Where B11 is the length in meters
Convert feet to meters:
=B12*0.3048
Where B12 is the length in feet.
Convert degrees F to degrees C:
=(B11-32)/1.8
Where B11 is the degrees Fahrenheit
Convert degrees C to degrees F:
=(B12*1.8)+32
Where B12 is the degrees Celsius. In this case, the order of operations will work without the prentices but I kept them in place for uniformity.
Convert BTU to KW:
=B11/3412.142
Where B11 is the BTU/hr
Example of an Air Conditioner load estimation:
=(B11*B12-B11)*3412.142
Where B11 is the TPO, B12 is the transmitter AC to RF efficiency. The output is in BTU.
You get the idea. Yes, there are smartphone applications as well as online calculators for most of these functions. However, I have found smartphone apps are becoming more painful to deal with as time goes on, mostly due to the ads. App developers need to make money, and you can buy apps for things that are often used. However, it is nice to have these types of calculators available offline. Besides, it is fun to play around with Excel formulas.
This particular power supply is used in Broadcast Electronics AM1A, AM2.5E, AM5E, AM6A, AM10A, FM1C, FM10T, FM20T, FM30T and FM35T transmitters. It is a Computer Products NFN 40-7610, 40 Watt, +5 VDC, +/- 15 VDC BE part number 540-0006.
BE AM1A ECU power supply, C-15 marked with pen for replacement
Generally, one component fails over time on this unit, C-15 which is a 680 uF 35 V electrolytic capacitor. When that capacitor dries out, the power supply will fail to start, do odd things like start and fail after a second or two, or cycle on and off. This will happen after the transmitter has been off for a few minutes. Replacing C-15 with a 1000 uF 50 V capacitor will fix the problem. There is enough room for the larger capacitor if the leads are left a little bit long.
BE AM1A repaired ECU power supply re-installed
We have several of these repaired units on various shelves at various transmitter sites.
As always, when replacing electrolytic capacitors, pay attention to the polarity otherwise this will happen:
Blown Electrolytic Capacitor installed backward
I suppose somebody was in a hurry to get home that day. After I installed this repaired unit, it ran for about 15 seconds and then there was a pop. I opened the door on the ECU and white smoke was wafting out from under the power supply cover. Since the Pope is still The Pope, I knew it was the electrolytic capacitor.
Back in business
Our beloved BE AM1A is back in service. This transmitter is 22 years old and we can keep it going for as long as parts are available.
Had to do some work at a transmitter site today and had to put the backup transmitter on the air for a few minutes.
WFLY backup transmitter, on the air
These were good units in their day and many continue on. This transmitter was new in 1986 and served as the main transmitter until 2015 or so. This unit still has the tube driver (4CX250B) which tended to use a set of tubes every year or so. The PA tube normally lasted 4 years or so.
Meters
I miss the analog meters sometimes. There is something satisfying watching all the meters come up together when the plate on button is pushed.
