When our control room for live video was installed, it was installed in a hurry. Now, that’s not a finger-point at anyone that was involved, we really only had about 5 days to make it work before Opening Day in the new building. Since then, equipment, functionality, and — you guessed it — more cable has been added to the mess of audio and video cable running along the wall.
About 6 weeks ago, we began plans for a project to clean this all up. The big goals were…
- Move our audio operations to the adjacent room, essentially creating the ability to have a broadcast mix.
- Move a majority of our production gear to a rack, and relocate the cabling in order to clean things up.
The big deal of this project was the time window — The control room simply must be operational on the weekends, so we had a limited amount of time to do what we needed to do without putting the service in jeopardy. We ended up splitting the project across 2 weekends: The first week would be dedicated to audio work (the smaller half of the project), and the more intense video half of the project would take place on the second week.
During "Audio Week" (June 16-20), we also did some preliminary stuff for "Video Week" (June 23-27) — this included tracking down and labeling every incoming and outgoing video/audio line, as well as installing a new Mid-Atlantic ERK Series rack for the video gear to move into. Quite a few of our video lines came up to the control room through the floor (the control room is on a mezzanine, so installing the rack also meant cutting some holes in the floor with a core drill so that wires could be pulled back into the floor and up through the new holes to the rack. The concrete floor of the control room sits over top of a drop ceiling, so this would be easy in theory.
The first step was to prep the floor area where the rack was going and cut the holes that the wire would pass through. God had a hand in this project from start to finish, and it became evident on the morning I was headed towards NPCC with the core drill that I just rented. Dave H. — one of our control room operators, was already on the scene and ready to help out with the drilling. Not only that, but Dave H. has extensive experience with concrete, and this was HUGE because I had absolutely none of that, much less any experience operating a core drill. The morning would not have gone nearly as smooth had Dave not been there.
After the holes were cut and the rack was secured to the floor, we ran some 22/2 cable between the control room desk, and rack, and the new "broadcast mix room." Once we did some soldering and verified that all our connections were in good shape, we took a break for the weekend.
The video rebuild was a bit more involved. There were quite a few lines to move from their old locations, and the goal was to get everything functional by Thursday. The first step involved gutting the entire control area and moving all our video gear to temporary storage.
Once all the cables were disconnected, they were pulled down through their conduits to the drop ceiling area below…
After all that, we began the process of moving gear and wire into the new rack.
We did run into a couple small snags with some over our CAT5 that is used to send XGA signals to the stage, but no show-stopping problems. And again, God’s hand was very evident this entire week. Volunteers made themselves available to help with wire pulling and cleanup and just about everything worked the first time around. On a side note, I claimed a huge personal victory this week by going up 30 or so feet in a scissor lift to install a lipstick camera on the auditorium ceiling without freaking out (I battle acrophobia and have a tendency to "lock up" at around 15-20 feet).
We ended up finishing the project Thursday night around 6:30pm.
There’s still a little bit of touch-up work to do for aesthetics and friendliness, but functionally everything checks out good and signal is flowing everywhere it needs to be.
Some thoughts from this project:
- I’m getting better at detailed planning. I’ve always been good at execution, but often times I would jump into something without nailing down the details, and it would result in a lot of problems. I feel real good about how this project panned out.
- The volunteers that helped in this project were invaluable and absolutely crucial to its completion. Thank you guys!
- The HD-SDI signal format is my friend. One 75-Ohm cable for 1080i is sweet.
- Next time we do a big wiring project, we need to rock up some cable trays.
- Zip ties are so out.
- Velcro is so in.
- I used to be able to bust out all sorts of productivity by going all night — not the case anymore. I really had to pace myself on this project and quit when I was tired.
Looking forward to the next project!
(Want more pictures? They can be found here.)