March 26, 2012

TRANSFORMER REPLACEMENT FLASH GALLERY


August 21, 2012

In an ongoing series of events, that has led up to the reenergizing of the WMLK Radio Shortwave set, the following is an update.  The power was restored (finally) by our utility service provider on August 8, 2012.  The power company was very busy due to the damaging storms in our tri-state area and they cleared their workload and finally reached the WMLK Radio station site on the aforementioned date.  I was able to make preparations for the next stage and that would be the 16.2 KV application. Our power company supplier can only furnish 13.2 KV to our site and we have to boost the power to the higher level because of the operating requirements of our BBC 250KW set.  This set operates on the European voltage system and it was cost effective to purchase and install a transformer that was capable of compliance to the European voltage system.  As mentioned previously on this page/update a fused cabinet was installed to offer better protection for the equipment.  This took some time as it had to clear the insurance company and then be built to our specifications.

 

Today I was able to once again apply the power to the peripherals of the BBC set. Everything came up as it was prior to our losing the main power supply.  Our Engineer is scheduled to arrive during September for further testing and resume where he left off last year. The following picture depicts the BBC TX energized up to the final plate voltage stage!

 

More to come as the progress of WMLK Radio continues forward...Praise Almighty Yahweh! 

 


 

June 1, 2012

Progress continues at WMLK Radio. The following pictures show the installation of the new fused cabinet. This cabinet will afford more protection for the transformer supply that was shorted out because of our power supplier.

 

The panel that was plasma cut so the wiring could be passed between the main power cabinet and the fusing protection system.

 

The fusing cabinet joined with the main power supply.

 

The top cut from inside the power cabinet looking through to the fusing cabinet.

The wire has been ordered to connect the power supply to the fusing cabinet protection and to the power transformer.

 


 

May 17, 2012

Today the weather was conducive for removing the panel as can be seen in the following picture!

Once the panel is cut to specifications, it will be reinstalled and the new piece of equipment will be attached!

 


May 14, 2012

Today the power company finally disconnected the power to the transformer cabinet. This will allow entrance into this cabinet to remove one of the panels for plasma cutting.


April 26, 2012

Work at WMLK Radio continues to move forward!  On April 17 we took delivery of the fusing cabinet that will offer more protection against power failures and power short circuits.  The hurricane Irene wreaked havoc on the local area and caused the main power transformer to short out.  This was the fault of the power companies power protection failure but, they attributed this to an act of nature!  This cabinet will offer protection against the future acts of nature, so-called!

Cabinet in the delivery truck!

Cabinet adjacent to where it will be installed!

The pad to set the new cabinet was poured on April 25, 2012! The panel just above the pad must be cut out in two places to pass the high voltage cables through.  This will be accomplished after the power company comes out to the station location and turns off the power.  The power supplying the cabinet is thirteen thousand two hundred volts!  The panel will be taken to a nearby location where a plasma cutter will cut out the two pass way holes!

 

 


 

 

Well...Praise Yahweh, we had a very successful transition day on Wednesday 3/14/2012! We were able to take out the old TX and put in the new TX. However, some modifications will be necessary on the bus bars to align the connections from the new TX to the old connections on the secondary side feeding the transmitter side! Here are some pictures of the exchange. We want to thank TE J.S. Meyer, D. Nate Meyer, and F. Lewis for their assistance in helping me to make this exchange!

The piece of equipment that was used to lift the transformers.

Taking out the old damaged transformer.

Getting ready to put the new transformer in the power cabinet.

F. Lewis (foreground) and T. E. J. Meyer removing the shipping crate bottom from the new transformer. Notice their happy worker face!

All but finished setting the new transformer into the power cabinet. On the right (driving the rig) is D. N. Meyer. Looking into the cabinet is F. Lewis and looking at me ( the camera man) is T. E. J. Meyer.

New transformer in place and ready for connections to be made. I have made some connections already!

Carrying the lifting apparatus to its storage location. This is a very heavy piece.  

Almost in the storage area!

Here I have created a pic with notes for the manufacturing engineers on bus bar and cabinet proximity.

Off by this much in bus bar alignment!

March 14, 2012

The day has arrived for the installation of the new transformer! The transformer cabinet has been opened and all connections to the shorted transformer have been disconnected. The following picture shows the cabinet prior to the transformer removal.

 

February 24, 2012

The new transformer has arrived! This unit, as one can determine by photo comparison, is much better constructed than the previous transformer! The first photo shows the transformer prior to uncrating. You can see the blackened spot on the left side coil. This is what shorted out and caused transformer failure.

The next picture shows the new transformer uncrated.

The next pictures depict the old shorted transformer in the current cabinet!

 

Notice the different connection configurations.  This is being addressed and the solution will be implemented when the transformers are switched. The new transformer is built much better as the insulation is much better and the partitioning has been beefed up! You will notice the insulation and coil dividers are much more substantial in the new transformer! This will provide a better service all around. More to come as progress continues!


 

January 13, 2012

 

The progress of WMLK continues with the addition of new prints as seen in the following photo: Notice the large print behind the PC monitor, this is one complete print. This four section print is affixed to a six foot by eight foot board.

Also a computer and monitor were added for the updating and rapid technical access to prints and other information's needed by the engineers and technicians of WMLK Radio.

The replacement transformer is scheduled to be delivered mid-February. However, this could be contingent on the fusing apparatus necessary to protect the transformer. Engineering at the location where the new transformer is being built is actively engaged in retrofitting this into our current configuration.

We have also added a new heat supply to keep the area much warmer during the cold winter months. The WMLK Engineer, who has been working to place the BBC radio transmitter into proper working order, is scheduled to return in March. He has put five of these transmitters into service already. The future is holding good promise/progress in getting WMLK Radio back on air.


 


AUGUST 30, 2011

The antenna towers at WMLK have received a fresh coat of paint. The photos show this transition.

South antenna tower base.

South antenna tower lower and middle sections of the tower.

North antenna tower at the top sections.


 

AUGUST 23, 2011

The antenna progress has been encouraging. We have been able to purchase several pieces of sorely needed equipment. As WMLK Radio prepares for the September visit of our Engineer, peripherals have been purchased for connections to the testing equipment. Another advancement has been the repainting of the antenna towers. The elements plus the exposure to salt and industry processing residuals, has taken a toll on the paint of these antenna towers. This will be the third time in their twenty-five plus history at WMLK Radio that they will receive a facelift. The pictures below depict this current project in process.

Here Robert Branch is scraping the pole so he can apply a rust inhibitor in preparation for the new paint job!

This pole has been painted with the rust inhibitor, as you can see, up to the thirty plus foot level. Paxx, the WMLK Radio guard dog, is always ready to do his job! Here he is watching Robert do his work on the other pole. We will be bringing in a bucket truck to process the rest of the tower.


 

JULY 21, 2011

We have finally reached the final stages in our process. Our Engineer has obtained the prints that he needed on the final stage circuitry. I have purchased several pieces of equipment that were needed to match the new antenna to the BBC 250KW SW set this week. The Engineer is scheduled to visit our site during the month of September (Yahweh willing!) to make his final adjustments to the set. It has been a slow process and we were hopeful that it could have been done sooner. The cost of antenna restoration and other necessities forced the delay that we have experienced. The new testing and matching equipment was also very expensive so, we had to wait until funds were available.  Almighty Yahweh has provided the necessary funds to purchase the sorely needed equipment.  Stay tuned for new updates!


Report

Although it has taken some time, progress has been realized on the WMLK Radio antenna repair project.  As reported (HERE) the antenna suffered extensive damage from three ice and wind storms.  The antenna was insured to a certain extent, and the insurance company has made payment to Assemblies of Yahweh for damage repair.  Needless to say that the cost of repair was expensive, but necessary.  The replacement cost estimate for the antenna alone within the framework of the support towers, was well over $300.000!  This would be a complete replacement by a commercial antenna manufacturing company.  However, we can and will repair the damaged antenna for well under this price and the insurance company concurs with this decision rather than complete commercial antenna replacement. 

The repair parts, wire, insulators, spacers, and other components, are either in hand or on order.  Some of these parts have a substantial lead time as they must be manufactured for design and antenna specifications.  All repair materials should be in hand by years end, if all goes well.  If the weather is not severe, some work on the Reflector Screen can take place during the winter months. However, if the weather is non-conducive, the repair must wait until Spring.  The entire grid work must be replaced as the damage to this section of the antenna was severe.  We are using a number 8 Alumoweld for the  catenarie framework.   What is Alumoweld?  The following supplies the information on Alumoweld:

 AlumoweldŽ Aluminum-Clad Steel Wire and Strand

Alumoweld is an aluminum-clad steel wire that offers the advantages of each metal and the desirable qualities of both. It has comparable corrosion resistance to solid aluminum wire and eight times the strength. Compared to steel wire, it has the same high tensile strength but furnishes much higher conductivity and provides much greater longevity.
In the finished size, Alumoweld has an aluminum coating equal to 25 percent of the cross-sectional area of the composite wire, and a coating thickness guaranteed to be a minimum of ten percent of the wire radius. The thick aluminum coating provides an electrical conductivity equal to one-third that delivered by the same size solid aluminum wire. The conductivity, combined with the high strength of Alumoweld's steel core, makes it an extremely versatile, highly acceptable substitute for solid aluminum in many applications.

 This design and high tensile strength properties supply the dynamics necessary to support the number 8 hard drawn aluminum wire within the catenaries.  Because of the reduced weight supplied by the incorporation of aluminum wire, the Reflector Screen can be large in size.  The dimensions for this section of the antenna are 31.25 meters by 31.35 meters.  This would be 102.5 feet by 102.5 feet.  The antenna has sixty-four (64) horizontal wires exactly spaced with eleven vertical (11) wire with measured placement.  This configuration contains a tension support system on each side.  The work must be accomplished with the use of a crane for several days.

As the work on rebuild and restoration continues, the antenna progress will be posted.

 


 

After months of anticipation, work began on the WMLK Radio antenna.  The following photos depict the crane in the field and the two man basket in the air.  The reflector screen is being disassembled to make way for the new wiring.  The storm damage was extensive and will require many hours to restore the antenna into operable state.  Photos taken June 8, 2009.

 

This is the motorized unit that will be used to repair the reflector screen and the antenna array!  This unit extends over 120 feet and that is what it takes to reach the top of the antenna array.


The wind and storms still are having an effect on the antenna array.  This past weekend (March 12-14, 2010) brought more high winds and destruction to our area.  The element array already damaged by several previous storm suffered even more damage.  The winter months do not allow us to reconstruct the element array until the weather warms up.  The ground is very soft and the equipment we use to repair the antenna is very heavy and will sink into the soil causing an imbalance in the system.  This sets off the safety system and shuts the high lift down.  Very dangerous!  Here are some more pictures taken today (March 16, 2010).  The sky is clearing up and the weather is supposed to start warming up, hopefully!  Soon, Yahweh willing, we will be able to repair the element array. 

Tuning stub on left side of picture and crossover feedline from vertical feed assembly.

Feedline crossover from vertical feed.

Part of the tuning stub.