Ametek CH44-VER08 User guide

April 2023
Power-Line Carrier
RF Hybrids
Balanced & Skewed
(and Optional Boards)
System Manual
CH44–VER08
AMETEK Power Instruments
4050 N.W. 121st Avenue
Coral Springs, FL 33065
1–800–785–7274
1–954–344–9822
www.ametekpower.com

April 2023 i
RF Hybrids System Manual
e recommend that you become thoroughly familiar with the information in this manual before
energizing your hybrid unit. Failure to do so may result in injury to personnel or damage to the
equipment, and may affect the equipment warranty.
AMETEK does not assume liability arising out of the application or use of any product or circuit
described herein. AMETEK reserves the right to make changes to any products herein to
improve reliability, function or design. Specifications and information herein are subject to
change without notice. All possible contingencies which may arise during installation,
operation, or maintenance, and all details and variations of this equipment do not purport to be
covered by these instructions. If you desire further information regarding a particular in-
stallation, operation, or maintenance of equipment, please contact your local AMETEK
representative.
Copyright ©
By AMETEK Power Instruments
ALL RIGHTS RESERVED
AMETEK does not convey any license under its patent rights nor the rights of others.
W
IMPORTANT
!

ii April 2023
New in this Version of the Hybrids System Manual
A new option board, the PLC Test Board, was added. Specifications for the Balance Transformer and
Balanced Combiner were added, and other device specifications were updated.
Schematics are available upon request.

April 2023 iii
RF Hybrids System Manual
Preface
Scope
This manual describes the operation, specifications, features and typical applications of the Balanced
Hybrid (CH20-BALMN-001) and the Skewed Hybrid (CH20-SKWMN-001). The former sometimes
referred to as B and the latter S. Various option boards are also covered in this manual. It is intended
primarily for use by engineers and technicians involved in the installation, alignment, operation, and main-
tenance of the hybrid assemblies.
Equipment Identification
Each hybrid assembly is identified on its nameplate.
Production Changes
When engineering and production changes are made to one of the hybrid assemblies, a revision notation
is reflected on the part number, related schematic diagram, and associated parts information.
Warranty
Our standard warranty extends for 10 years after shipment. For all repaired units or advance replacements,
the standard warranty is 90 days or the remaining warranty time, whichever is longer. Damage clearly
caused by improper application, repair, or handling of the equipment will void the warranty.
Equipment Return & Repair Procedure
To return equipment for repair or replacement:
1. Call your AMETEK representative at 1–800–785–7274 or e-mail us at
repair[email protected].
2. Request an RMA number for proper authorization and credit.
3. Carefully pack the equipment you are returning.
When returning any equipment, pack it in the original shipping containers, if
possible.Any damage due to improperly packed items will be charged to the cus-
tomer, even when under warranty.
4. Make sure you include your return address and the RMA number on the pack-
age.
5. Ship the package(s) to:
AMETEK Power Instruments
4050 NW 121st Avenue
Coral Springs, FL USA 33065

iv April 2023
Table of Contents
Chapter No. Page No.
1. Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–1
2. Purpose, Basic Operation & Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–1
3. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–1
4. Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–1
5. Balanced Hybrid / Balance Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–1
6. Skewed Hybrid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–1
7. Typical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–1
Two Transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–2
Single FSK Bi-Directional Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–2
Dual FSK Bi-Directional Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–2
ON/OFF DCB with FSK Bi-Directional Channel . . . . . . . . . . . . . . . . . . . . . . . . . .7–2
ON/OFF DCB with Dual FSK Bi-Directional Channel . . . . . . . . . . . . . . . . . . . . .7–3
Balance Transformer for Phase-to-Phase Coupling . . . . . . . . . . . . . . . . . . . . . . . . .7–3
Balanced Combiner for Phase-to-Phase Coupling . . . . . . . . . . . . . . . . . . . . . . . . . .7–3
8. PLC Test Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–1

Chapter 1. Ordering Information
Copyright © AMETEK Power Instruments
Hybrids Catalog Number Position
Typical Catalog Number HYB1RU FM B2 S1 N
1 – Base Unit1HYB1RU
2 – Chassis Option
Flush Mount FM
Projection Mount PM
3 – Quantity of Balanced Hybrids2
None B0
One B1
Two B2
Three B3
Four B4
4 – Quantity of Skewed Hybrids2
None S0
One S1
Two S2
Three S3
Four S4
5 – Hybrid Options
None N
Balanced Combiner3B
6 – Other Optional Boards (Quantity)2,4
Blank Indicates No Optional Boards
Balance Transformer BT (1–4)
PLC Test Board TS (1–4)
1 2 3 4 5 6
Notes:
1Hybrids are shipped with the following defaults:
• All empty chassis slots already have blank rear cover plates installed automatically & are included in the price of the chassis.
Additional spare blank rear cover plates must be purchased separately.
• Viewed from the front, hybrids are inserted into the chassis from left to right. Balanced hybrids first, then followed by any skewed
hybrids.
• Viewed from the front, optional boards are inserted from right to left, with the TS board in the right-most position(s).
2Max number of boards in a chassis is 4. So the total number of Balanced (B) + Skewed (S) + Optional Boards can not exceed 4.
For example, HYB1RU-FM-B3-S2-N is an invalid number because it calls for 5 hybrids total (B3, S2).
3Balanced combiner includes interconnecting cables and requires position 3, of the catalog number, to be “B4”. This option is for
redundancy in phase-to-phase coupling schemes.
4Position 6 is only used when an optional board is present. Otherwise this catalog number position is blank. There can be more than
one type of optional board and thus multiple suffix codes.
BT1
Fully Loaded Chassis

Page 1–2 April 2023
RF Hybrids System Manual
Description Part Number Equivalent Old Hybrid Type
Balanced Hybrid (Resistive) CH20-BALMN-001 Resistive H1RB or H1RB-40
Skewed Hybrid (Resistive) CH20-SKWMN-001 Skewed H1SB or H1SB-R
Balance Transformer CH20-BALMN-002 Resistive H1RB or H1RB-40
PLC Test Board CH20-TSTMN-001 None
PLC Test Board (special)* CH20-TSTMN-002 None
Table 1–1. Hybrids & Optional Boards
Table 1–2. Chassis
Table 1–3. Hybrid Accessories.
Description Part Number Main Purpose
Projection Mounting Brackets 1088-820 Change Flush Chassis to Projection Mount
Blank Rear Cover Plate (1 Slot) 1088-834 Cover a Rear Slot after Removing a Hybrid
Coax Cable Male BNC-BNC 1.5 ft. 01W1-COAX2-111 Interconnect Hybrids & Carrier Sets
Coax Cable Male BNC-BNC 5 ft. 01W1-COAX5-111 Interconnect Hybrids & Carrier Sets
Coax Cable Male BNC-BNC 12 ft. 01W1-COAXA-111 Interconnect Hybrids & Carrier Sets
Male BNC to Female UHF Adapter 01NC-A8313-000 Mate RG213/RG8 Coax Directly to Output
BNC “T” Connector 01NC-UG274-000 Parallel Receivers onto Hybrid RX Port
Description Mounting # PLC Test Boards Part Number
1RU flush chassis with no PLC Test Board slot Flush 01088-780
1RU flush chassis with 1 PLC Test Board slot Flush 11088-780-1
1RU flush chassis with 2 PLC Test Board slots Flush 21088-780-2
1RU flush chassis with 3 PLC Test Board slots Flush 31088-780-3
1RU projection chassis with no PLC Test Board slot Projection 01088-824
1RU projection chassis with 1 PLC Test Board slot Projection 11088-824-1
1RU projection chassis with 2 PLC Test Board slots Projection 21088-824-2
1RU projection chassis with 3 PLC Test Board slots Projection 31088-824-3
Note: If a Balance Transformer module is needed in the chassis an extra front overlay is required for it.
* Swaps LED colors (see Chapter 8 – JMP5)
Loose Piece

Chapter 2. Purpose, Basic Operation & Testing
Copyright © AMETEK Power Instruments
2.1 Purpose & Basic Operation
Hybrids have been used from the beginning with
Power-Line carrier and their basic operation is still
the same as when they originally were developed
many years ago. The hybrid’s primary purpose is to
combine multiple Power-Line carrier (PLC) signals
onto one common coax cable without causing inter-
ference between different transmitters or between
the transmitters and receivers. This is necessary
because two transmitters connected directly
together will load each other down and can cause
signal clipping and intermodulation distortion. Also
a local high powered transmitter can interfere with
a local receiver that is set to receive a weak signal
level from the far-end transmitter. Hybrids solve
these issues by providing isolation between the two
devices being combined while at the same time
allowing them to be combined onto a common coax
without too much signal loss. Isolation is especially
important when there is close frequency spacing
between carrier sets which is most often the case.
Using hybrids allows the minimum frequency
spacing between carrier sets.
Hybrids are completely bi-directional and have
nothing in them to direct signal flow from the inputs
to the output or vice versa. They act as a combiner
in one direction and a splitter in the opposite
direction. So, going in one direction at the transmit-
ting end of the line, the hybrid combines, but at the
receiving end of the line it splits. The hybrid
labelling of the “inputs” and the “output” is for the
local transmitter’s signal direction.
The application of a “balance transformer” used in
phase-to-phase coupling at the transmitting end, for
example, is a hybrid being used backwards as a
splitter instead of a combiner. In this example, the
output becomes the input and the 2 inputs become
outputs.
PLC hybrids are completely passive devices and
consist only of transformers, resistors, capacitors,
and inductors (depending on the type of hybrid).All
components are rated to handle more power than is
specified on their inputs. This type of design adds to
their long life and robustness.
2.1.1 Multiple Transmitters/Receivers
If multiple transmitters and receivers need to be
combined onto one coax cable, then the hybrids can
be stacked together to achieve this. This is
necessary as each hybrid can only combine 2
devices at one time. So, if 3 devices need to be
combined, then normally 2 hybrids will be required,
if 4 devices, then 3 hybrids and so forth. The
exception is that hybrids are not needed to isolate
high impedance receivers from one another as
receivers can be directly connected together.
2.1.2 Hybrid Types
There are two main types of PLC hybrids: Balanced
(B) and Skewed (S). The balanced hybrid has equal
losses from the inputs to the output.And the skewed
hybrid has unequal (skewed) losses from the inputs
to the output. The skewed hybrid is only used for
combining a transmitter and receiver, never for 2
transmitters. When 2 transmitters are combined, the
balanced hybrid is always used. The skewed hybrid
favors the transmit’s side over the receive side with
less than 0.5 dB loss on the transmit side. (See
Table 2–1). This is done to improve the overall
system signal-to-noise ratio by 3dB by getting 3dB
more transmit power out to the line. At the receive
end of the power line, both the signal and the noise
get equally attenuated so more loss on the receive
side doesn’t affect the S/N ratio. At the transmit
end, only the transmit signal gets attenuated as it
goes out to the power-line so we want to keep atten-
uation low.

Page 2–2 April 2023
RF Hybrids System Manual
A basic balanced hybrid can be used to illustrate
how it isolates two inputs from one another and
matches impedances as shown in Figure 2–1. The
hybrid acts as a balanced bridge network and when
the output’s load resistance is exactly twice the
center tap resistor value you get infinite loss, theo-
retically, between the 2 inputs. The hybrid, in this
case, is made up of a resistor of 25 ohms, and a
transformer with a center tap on the primary. The
transformer turns ratio is √2/1 with the √2 turns on
the center tapped primary.
Let’s assume the secondary of the transformer is
terminated with a 50 ohm resistor and a voltage (V)
is applied to input port #1. The 50 ohm load will be
reflected in the primary of the transformer as a 25
ohm quantity from point (a) to the center tap (ct).
This is because there is 1 turn on the primary, (a) to
(ct), for every √2 turns on the secondary. The
impedance will be transferred as the square of the
turns ratio, which in this case is 2 to 1. The voltage
V will divide equally between the 25 ohm resistor
and the 25 ohm reflected load into the top half of
the primary. Thus each voltage has a value of V/2,
and in the direction as shown. Since the center
tapped primary of the transformer will act as an
autotransformer, a voltage V/2 will also appear on
the other half of the primary between point (ct) and
(b). The voltage appearing across input port #2, due
to the voltage V at input port #1, is the sum of the
voltages around the loop from (g) to (y). This
resultant voltage is 0 volts. And as shown in Figure
2–1, the hybrid isolates the voltage at one input port
from the other input port. A price must be paid for
this isolation and that is in the loss from the inputs
to the output. One half the power is dissipated for
each input in the center tap balance resistor causing
a 3 dB minimum loss in the power going to the
output from each input.
Figure 2–1.
Resistive Hybrid.
Input
Port
#1
Input
Port
#2
V
(x)
V/2
V/2
V/2
(g)
(y)
(a)
(b)
(ct)
0
50 W
2:1
2
V
25 W

April 2023 Page 2–3
Chapter 2. Purpose, Basic Operation & Testing
Input 1
Balance
Port
Transhybrid
Loss – Isolation
=dB
∞
Input 2
Output
TX Path
Loss = 0 dB
IDEAL
HYBRID
TX / RX Path
Loss = 0 dB
Figure 2–2.
Ideal Hybrid Characteristics.
Hybrid Type: Ideal Balanced Skewed
Insertion Loss
Loss IN 1 to OUT: 0 dB 3.5 dB Max 0.5 dB Max
Insertion Loss
Loss IN 2 to OUT: 0 dB 3.5 dB Max 14.5 dB Max
Transhybrid Loss*
Isolation IN 1 to IN2: ∞dB 30 dB Min 40 dB Min
Table 2–1. Hybrid Losses.
2.2 Ideal Hybrid Characteristics
• Two input ports are completely isolated from one another.
• Two input ports have no loss to the output port.
• Internal balance port Z = Output port’s connected Z
(There is infinite isolation for inputs when these impedances are exactly equal.)
* With exact impedance matching on output.

Page 2–4 April 2023
RF Hybrids System Manual
2.3 Testing
There are no adjustments necessary for the hybrids, but testing for correction operation is recommended.
A frequency selective voltmeter is recommended to verify proper operation of the hybrids. See list of
suggested suppliers below.
1. Check losses (between inputs and from each input to output) per Table 2–1, or the specification
tables, to see if close to expected values exist, using a bridging frequency selective voltmeter
connected to the front test points.
a) When measuring isolation between inputs, measure frequency F1 going into input 1 and verify
that the same frequency is at least 20 dB lower on input 2 with the output of the hybrid connected
to a 50 Ω* load or to a line tuner with less than 10% reflected power. The higher the reflected
power is between the output and the line tuner then the worse (lower) the isolation will be between
the two inputs. When the line tuner is equal to 50 Ω* for the TX frequency then the isolation will
be at a maximum.
b) When measuring the level of one particular frequency, compare the level of that frequency at
the input versus the output and verify that the loss does not exceed the value in Table 2–1 or the
specifications table.
2. The whole system should be connected when doing this test. If it is not connected to the coupling
capacitor (CCVT), use a power-line simulator on the line side of the Line Tuner .
High Impedance Frequency Selective Meter (30–535 kHz)
PowerComm Solutions PCA-4125
Signal Crafters Model 110
Spectrum Analyzer (Various Suppliers)
Table 2–2. Test Equipment.
*(or 75 Ωdepending on hybrid setting)

Chapter 3. Specifications
Copyright © AMETEK Power Instruments
Table 3–1. General Chassis Specifications.
Specification Value
Temperature Range –20° to +60° C
Hybrid Capacity Up to 4 Hybrids
Mounting Space
(Normal Operation)* 1 RU, No Blank Space Required Above or Below
Mounting Space
(High Power Operation)** 1 RU, with an Additional 1 RU Above & Below
* All Transmitters ≤15 W. ** Transmitters > 15 W.
Table 3–2. Single Chassis: Weight & Dimension Specifications
Equipment Net Weight Height Width Depth Rack
lbs Kg inches mm inches mm inches mm Space
with 4 Hybrids 7 3.2 1.72 43.7 19.0 483 12.9 328 1 RU

Page 3–2 April 2023
RF Hybrids System Manual
Table 3–3. Balanced Hybrid Specifications.
Specification Value
Frequency Range 30–535 kHz
Max Power Each Input 25 Watts
Input 1 & Input 2 Impedance 50 Ohms
Output Impedance 50 or 75 Ohms
Insertion Loss: Each Input to Output* 3.5 dB Max
Transhybrid Loss: Isolation Between Inputs* 30 dB Min
Phase of Input 1 to Output 0 degrees
Phase of Input 2 to Output 180 degrees
* With Exact Impedance Matching on Output
Table 3–4. Skewed Hybrid Specifications.
Specification Value
Frequency Range 30–535 kHz
Max Power TX Input 100 Watts
TX Port Impedance 50 Ohms
RX Port Impedance 50 Ohms or High Z
Output Port Impedance 50 Ohms
Insertion Loss: TX Port to Output* 0.5 dB Max
Insertion Loss: Output to RX Port * 14.5 dB Max
Transhybrid Loss: Isolation Between Inputs* 40 dB Min
* With Exact Impedance Matching on Output

April 2023 Page 3–3
Chapter 3. Specifications
Table 3–5. Balance Transformer Specifications.
Specification Value
Frequency Range 30–535 kHz
Max Power for Input 100 Watts
Output 1 & Output 2 Impedance 50 Ohms
Input Impedance 50 or 75 Ohms
Insertion Loss: Input to each Output * 3.2 dB Max
Insertion Loss: End-to-End ** 0.4 dB Max
Insertion Loss: End-to-End with 1 Phase Shorted to Ground ** 7 dB Max
Insertion Loss: End-to-End with 1 Phase Open ** 6 dB Max
Phase of Input to Output 1 0 degrees
Phase of Input to Output 2 180 degrees
* With Exact Impedance Matching on Output
** With having a Balance Transformer at each end of the line
Table 3–6. Balanced Combiner Specifications.
Specification Value
Frequency Range 30–535 kHz
Max Power for Each LINE Port 25 Watts
Input Impedance of Each LINE Port 50 or 75 Ohms
TX Path Insertion Loss 7 dB Max
RX Path Insertion Loss 0.5 dB Max

Page 3–4 April 2023
RF Hybrids System Manual
Table 3–7. PLC Test Board Specifications.
Specification Value
Frequency Range 30–535 kHz
Max Power for IN Port (in test mode) 20 W Continuous, 40 W for 2 min.
Max Power for LINE Port (in test mode) 10 W Continuous, 20 W for 2 min.
Max Insertion Loss (when in service) 0.2 dB
Min Isolation from IN to LINE (in test mode) 50 dB
TX Reflected Power (in test mode) <0.5 %
TX Reflected Power
(in service w/50 ohms 1% load tied to LINE port) <0.5 %
RF Signal LED Turn-On Threshold
(normal LED jumper setting) +23 dBm (0.2 W) Signal Level
RF Signal LED Turn-On Threshold
(bright LED jumper setting) +20 dBm (0.1 W) Signal Level

Chapter 4. Chassis
Copyright © AMETEK Power Instruments
4.1 Hybrid Chassis
4.1.1 General
Please refer to Figure 4–1. The hybrid chassis is a 1
RU tall chassis holding up to 4 hybrids. It was
designed to extend back slightly further than the
carrier set so that its connections are easily acces-
sible. The hybrids themselves insert from the rear of
the chassis, sliding into horizontal card guides until
the test points protrude through the front panel. So
it is important to not run any wiring across the rear
of this 1 RU chassis that would prevent the hybrids
from being added or removed in the future. The
hybrids are held in place by 2 Captive mounting
screws on the hybrid connector plate. Empty slots
are covered with a blank cover plate that also
screws on.
Notes:
Hybrids are shipped with the following defaults:
1. Any empty chassis slots have blank rear cover
plates installed automatically & included in the
price of the chassis. Additional blank rear cover
plates must be purchased.
2. Viewed from the front, hybrids are inserted into
the chassis from left to right. Balanced hybrids are
first, followed by any skewed hybrids. Viewed from
the front, all optional boards are inserted from right
to left. If no Balanced hybrid exists, then the
Skewed hybrid will be in the left most slot.
4.1.2 Rear
There is a chassis ground stud (#8-32 screw) that
should always be grounded to earth ground using a
reasonably short #10 gauge wire or larger for
optimum surge protection. This ground connection
satisfies the Ametek requirement to have the shield
of the coax grounded when coming into the panel
before getting to the carrier sets. Although, if
desired, the customer may ground the coax shield
on a terminal block before coming into the hybrid.
Again, it is important to not run any wiring across
the rear of this 1 RU chassis that would prevent the
hybrids from being added or removed in the future.
4.1.3 Front
The front of the chassis is standard for each of the 4
slots, except for optional boards. The test points are
either black or red in order to indicate which type of
hybrid is plugged into a particular slot. Any
optional board will have its own special label
covering the standard front slot label.
As noted on the front panel:
•Black test points extend through the front
panel for the Balanced hybrid or optional
board(s).
•Red test points are on the Skewed hybrid.
The red labels underneath the test points
apply to the Skewed hybrid only.
Please refer to Figure 4–1.
4.1.4 Mounting
The chassis has ventilation holes on the sides and
top/bottom.
Typically the chassis mounts flush to the front of
the panel. On chassis 1088-780 the flush mounted
brackets are integral to the unit.
But if desired, the unit can be projection mounted
by ordering chassis 1088-824 with separate (not
integrated) projection-mount angle brackets. The
two choices are listed under the hybrid accessories.
(See Chapter 1). The brackets may be turned
forward-facing or rear-facing depending on how
much projection mounting offset is needed.
Please refer to Figures 4–2 & 4–3.
Normal Operation
All Transmitters ≤15 W:
The chassis may be mounted without any space
separating it and the device above or below it.
High Power Operation
Transmitters > 15 W:
We recommend leaving 1 RU of space above and
below the hybrid chassis in order to operate at up to
60° C ambient temperature.

Page 4–2 April 2023
RF Hybrids System Manual
Figure 4–1. Front and Rear Panels – Hybrids.
Front
Front View
Expanded
Rear
I2N COM OUT LINEI1N
TX RX
POWER INSTRUMENTS

April 2023 Page 4–3
Chapter 4. Chassis
Figure 4–2. Front and Rear Panels – Optional Boards.
Front
Front View Expanded
(Test Board)
Front View Expanded
(Balancing Transformer)
Rear
BALANCING TRANSFORMER
OUT1 OUT2 IN
COM

Page 4–4 April 2023
RF Hybrids System Manual
Figure 4–3. Standard Mounting.
Ground
Stud

April 2023 Page 4–5
Chapter 4. Chassis
Figure 4–4. Projection Mounting.
Ground
Stud