Broadcast RF System Optimization

By Walter Mamak, P. E., Andrew Corporation

You’ve upgraded your station’s equip-
ment. Now you need to optimize your
system before it goes on the air.
Broadcast RF systems are complex.
Well thought out, detailed planning
right from the start can’t be overempha-
sized. With a good plan, system per-
formance testing will move quickly and
cost less.
Though system performance has
many facets, this discussion will focus
on the physical layout of a typical pas-
sive RF system and the technical con-
cerns that impact optimizing VSWR
performance.
A few words of caution: It is essential
that everyone is on board and that
activities of station engineering and
management, equipment suppliers,
consulting engineers, tower vendor,
installation crew, and the system opti-
mization service are coordinated.
Even the best system optimization
procedure will not compensate for non-
optimized components, poor system
design, or faulty installation processes.
For installations on an existing tower, a
site inspection is recommended prior to
the design.
Always insist on trained, knowledge-
able engineering technicians to opti-
mize and monitor installation of all
components. These services are avail-
able to broadcasters without in-house
expertise.

System Setting for an existing installation is by site inspection performed

The system discussed is typical for a US broadcaster
for either NTSC analog or upgrading to DTV and provid-
ing coverage on a UHF channel.
A high power system will require an ERP of 1500 kW
to cover the market. The transmitter has a 60 kW TPO.
Because of power and specialized radiation pattern
requirements, a high power, top mounted, 25 gain direc-
tional antenna with 6-1/8 – 75 ohm rigid transmission
line was specified.
The new antenna system will be added to an existing
tower already loaded with broadcast, cellular, and
microwave equipment.
System Layout – Antenna and Transmission Line
After antenna selection comes the physical details of
the entire passive RF system and its installation at the
site. The ultimate performance of the system depends on
proper planning in this initial phase.
The position of the antenna on the tower is deter-
mined by availability of space, antenna pattern and gain,
the signal coverage map that must be attained, and wind
and weight load. The impact of other equipment on the
tower may also play a role in antenna and line place-
ment.
Proper mechanical and structural interface between
the antenna and tower varies with the antenna selected.
Generally, this detail is required for fastening the antenna
to the tower structure, providing adequate space for the
antenna input and transmission line connections, routing
the transmission line to the antenna, and positioning the
antenna in proper orientation to attain the designed cov-
erage. The only way to ensure correct tower information
prior to preparing the system design.
Antenna orientation involves two distinct parameters.
Is the antenna main beam aimed at the correct azimuth
position? And, in the case of a side mount antenna, has
an RF scattering study been completed and the antenna
correctly located to minimize pattern degradation by the
surrounding tower structure, transmission lines, and
other tower appurtenances?
Important installation considerations for a top mount
antenna:
1. Obtain antenna structural loads and mounting inter-
face details from manufacturer.
2. Obtain tower structural analysis to confirm its
adequacy for the antenna and transmission line
3. Coordinate antenna mounting details with tower
vendor. Not all antennas are furnished with the
required mounting bolts.
4. Determine the azimuth position of the antenna, the
tower, and the tower mounting bolts. Coordinate this
data with antenna manufacturer, tower vendor, and
installation crew.
5. Have a mechanical layout confirm that the transmis-
sion line will be correctly routed to the antenna. This is
often forgotten for installations on existing towers.
Engineering considerations of structural weight, wind,
and thermal characteristics must be considered for
long-term, high performance of the system.
6. Be especially careful of towers with existing installa-
tions. Many changes occur over time, and detailed,
accurate engineering drawings may not be available.
If not, order an on-site field inspection by a qualified
tower inspection service.

1.
If a side mount antenna is chosen, the following consid-
erations are important:

1. Perform a “scattering analysis” (figure 1) to obtain the

best RF signal coverage. Antenna manufacturers typi-
cally have developed proprietary software; however,
accurate detailed information on the tower’s physical
details is required.
2. Obtain details of the antenna mounting requirements
from the vendor. Side mount antennas can be leg
mounted or face mounted. This selection is based on
the azimuth pointing direction required, available
space on tower to clear other obstructions, and struc-
tural requirements of the tower.
3. Review transmission line routing to ensure tower brac-
ing and/or other tower appurtenances do not obstruct
the correct routing and support of the transmission
line for weight, ice, and wind load. Figure 2. A typical transmission line system layout developed by
using 3-D software.

Optimization of these parameters is no trivial undertak-

ing. At the most basic level, the dichotomy of several of
these parameters is apparent.

1. Physical size and RF system loss versus tower struc-

tural loading. The transmission line system is the
single highest contributor to tower loading
2. Ease of installation versus optimization of power out-
put and attenuation. Simplified routing can lower the
installed cost of the system
3. Structural support type and location versus flexibility
for thermal expansion/contraction. Proper location and
selection of the line, hangers, and guides minimizes
stress on line components, but confinement of the line
can produce unwanted thermal stress concentrations.
Figure 1. A typical plot produced by scattering analysis.
4. Mechanical routing simplicity versus reduction of sys-
tem components. Minimizing elbows and elbow com-
Transmission Line Considerations plexes will improve overall transmission line system
performance. See figure 3.
The choice of transmission line must be a balance of
cost with the mechanical, structural, thermal, and practi-
cal considerations of routing the line from the transmitter,
to and through the tower, and to the antenna input.
For this application, a single channel rigid transmission
line was chosen. Other choices are available depending
on the need for broadband service, power handling
capacity, tolerable level of line attenuation, tower wind
load limitations, structural mounting details, and overall
cost effectiveness. Given these parameters, a station
may choose broadband rigid line, circular or rectangular
waveguide, or flexible coaxial cable.
A detailed plan for the transmission line system
includes a complete bill of material; design drawings,
with all components positioned in the system; routing of
the transmission line from the gas barrier in the equip-
ment building through the ice bridge and up the tower to
the antenna input flange; flange, hanger and guide loca-
tions; and, finally, a plan for installing the line on the sta- Fgure 3. Installation with Andrew WIDELine™
tion’s tower (figure 2). rigid coaxial transmission line system.
2.
5. Location of structural supports coordinated to existing
tower structural steel. Additional tower steel adds to
design and installation expense.
6. Strategically locate fine matcher sections (tuners) to
optimize system performance.
7. Verify proper seating of fine-matcher hardware.
8. Verify pressure integrity of system by performing timed
pressurization drop test.
If waveguide is chosen, additional inspection points
include:

System Testing and VSWR Optimization 1. Check constant force springs for proper extension,
tightness of hardware; and re-apply corrosion-inhibit-
A station has come a long way once all major compo- ing spray lubricant, as required.
nents have been selected. But, what about those compo- 2. Inspect the bearing flange; verify bolt torque.
nents? Tower installation is a lengthy, labor intensive, 3. Verify that one vertical hanger is installed for every two
costly process. All components must be up to the task of sections of waveguide above the specified level in the
integrating into a top performing, long serving system manual. Below this level, one horizontal restrainer is
after the installation is complete. installed per waveguide section.
Were all components delivered undamaged and in 4. Verify that the guideline pins are aligned in the same
good working order? Have the RF tuners, strategically plane.
located throughout the system, been optimized? Were
the electrical and mechanical ground checks of the Note: To avoid additional personnel costs, systems should be
antenna performed? This pre-lift performance verification pressurized and holding pressure for at least 24 hours prior
to the beginning of system sweep optimization services.
is conducted when the antenna is delivered to the site.
An engineering technician should supervise unloading of
After visual and mechanical verification of the trans-
the antenna and perform detailed visual, pressurization,
mission line installation, RF sweep measurements are
and VSWR sweep tests. This assures it is in factory qual-
performed, and VSWR recorded per the manufacturer
ity condition.
procedure. A number of procedures for sweeping, tuning,
Best current practice requires system sweep and opti-
and testing transmission line can be found in general
mization services after the transmission line system is
practice. Several independent-contractor engineering
completely installed. This entails a detailed analysis by a
services offer system optimization. Additionally, site tech-
qualified engineering technician using suitable equip-
nical advisory service field engineers with experience in
ment. Many consultants and some equipment suppliers
new equipment installations can be hired to manage the
offer this service.
installation process.
To obtain the best results, the transmission system
Typically, RF sweep measurement is an interactive
should be inspected after installation to ensure structural
process to optimize the return loss performance. A net-
and mechanical integrity prior to the final system sweep.
work analyzer is used to determine the characteristics of
Inspections should be done from the input flange of the
the transmission line and adjust the system’s fine match-
transmission line system to the top of the tower. Follow
ers to achieve optimum performance. This is accom-
up inspections should be conducted at least once per
plished by attaching transitions (adapters) to the trans-
year, more frequently in a high humidity or corrosive
mission line near the gas barrier. This adapter is tuned to
environment or in high wind areas.
better than −50 dB (R.L.). Initial data is then taken in
both frequency and time domain (TDR). By using mod-
Inspection points for all transmission line systems:
ern TDR techniques over broad bandwidths, the most
severe mismatches can be identified because the tuning
1. Check the complete transmission line system for com-
process is usually initiated at these points with the fine
pliance to design drawings.
matchers designed into the system layout.
2. Verify line is plumb to 1/8 inch per 100 feet.
Broad bandwidth, high resolution TDR measurements
3. Check for damaged hangers and ground straps.
check for anomalies in the installation, such as pinched
a. Verify free movement of spring hangers and
gaskets, split bullets, loose hardware, and elbow com-
transmission line.
plexes that exhibit high VSWR. It may be necessary to
b. Verify proper extension of spring hangers.
replace components or correct faulty installation proce-
4. Check all mounting hardware for compliance to torque
dures before finalizing system sweep measurements.
requirements.
Proceeding in this manner, each of the fine matcher
5. Check field-cut sections for proper fit by observing for
locations is optimized to yield the best system VSWR.
binding or stress between adjacent sections of trans-
When complete, the system should be re-inspected for
mission line.
pressure integrity. Usually, long transmission line sys-
6. Check for proper clearances between transmission
tems can be expected to maintain 0.5 psi pressure drop
line sections and tower structural steel or other
in a 24-hour period.
obstructions that may damage the transmission line
under extreme conditions of thermal expansion/con-
traction.
3.
 Depending on the consultant or service provider, an
array of measurements is performed and could include
the following. See figure 4.
1. VSWR and Return loss plots with each 6, 25, and 100
MHz span.
2. TDR (VSWR) format with each 6, 25, 100 MHz span.
Final Thought
A truly optimized system includes good planning, a
detailed design, high quality products, certified equip-
ment installation crews, and qualified system optimiza-
tion services. Pre-test inspections are essential.
Skimping here may result in costly on-site expenses for
crews and RF technicians and ultimately have a negative
impact on station performance.

About the author: Walter Mamak, PE, is product engineering

manager for Andrew Corporation, broadcast products division
and is responsible for new product engineering, project manage-
ment and broadcast customer service. Questions or inquiries can
be sent to him at wally.mamak@andrew.com.

Figure 4. Typical Smith chart polar plot of system VSWR.

Andrew Broadcast Systems

1-800-DIAL-4RF

Connecting the Wireless World

Andrew Corporation
10500 W. 153rd Street
Orland Park, IL 60462 USA
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From North America: www.andrew.com products and services presented in this bulletin
Telephone: 1-800-255-1479 are subject to change without notice.
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Bulletin 10922 (7/03) Copyright © 2003
International: From North America:
Telephone: +1-708-873-2307 Andrew Corporation, Orland Park, IL 60462 USA
1-800-861-1700
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