Hubbel RFL PLC Hybrid Pro User manual

HPS/RFL GARD Pro System 1 Hubbell Power Systems, Inc. –RFL™ Products
June 2019 (c)2019 Hubbell Incorporated
RFL™ PLC Hybrid Pro
User Guide
This entire document is the property of Hubbell Power Systems, Inc. (HPS) and may not be reproduced,
transmitted, published or stored in an electronic retrieval system, in whole or in part, by any means –
electronic or otherwise. For permission, contact: [email protected]
Hubbell Power Systems, Inc. –RFL™ Products
353 Powerville Road ● Boonton Twp., NJ 07005-9151 USA
Tel: [phone] ● Fax: [phone]
Email: [email protected] ● www.rflelect.com
Publication Number RF-MCHYBRIDPRO-01
Version 01, Printed in U.S.A.
June 3, 2019

HPS/RFL GARD Pro System 2 Hubbell Power Systems, Inc. –RFL™ Products
June 2019 (c)2019 Hubbell Incorporated
NOTICE
The information in this manual is proprietary and confidential to Hubbell® Power Systems, Inc. (“HPS”). Any
reproduction or distribution of this manual, in whole or part, is expressly prohibited, unless written permission is given by
HPS.
This manual has been compiled and checked for accuracy; however, HPS makes no representation or warranty as to the
accuracy or completeness of the information in this manual. The information in this manual does not constitute a warranty
of performance. HPS reserves the right to revise this manual and make changes to its contents from time to time. We
assume no liability for losses incurred as a result of out-of-date or incorrect information contained in this manual.
HPS shall not have any liability resulting from the use of the information in this manual. This manual does not purport to
cover all details or variations in equipment, nor provide for every possible contingency to be met in connection with
installation, operation, or maintenance of this specific product. Should further information be desired or should particular
problems arise which are not covered sufficiently for the purchaser's purposes, the matter should be referred to your RFL
product representative or RFL Customer Service Department at [e-mail], or by visiting the
website at www.rflelect.com/Support.
NOTES
It is recommended that this product be opened immediately after receiving and inspected for proper operation and signs of
impact damage.
For information regarding product warranty and repairs, please visit the HPS/RFL website at www.rflelect.com/Support or
e-mail the RFL Customer Service Department at [email protected].

RF-MCHYBRIDPRO-01 Hubbell Power Systems, Inc. –RFL™ Products
June 2019 3 973.334.3100
Table of Contents
1Safety Instructions............................................................................................................. 6
1.1 Warnings and Safety Summary...................................................................................................6
1.1.1 Safety Summary.................................................................................................... 6
1.1.2 Additional Warnings............................................................................................... 8
1.1.3 Additional Cautions................................................................................................ 8
2Introduction........................................................................................................................ 9
3Example Applications and Recommended Configurations.............................................. 10
3.1 One Transmitter, One Receiver (FSK)......................................................................................10
3.2 Two Transmitters, Two Receivers (FSK) .................................................................................10
3.3 Three Transmitters, Three Receivers (FSK)..............................................................................11
3.4 Two Transmitters, Two Receivers (FSK and On-Off/DCB).....................................................12
3.5 Two Transmitters, Two Receivers, Phase-to-Phase Coupled (low-loss method) ..................... 12
3.6 Two Transmitters, Two Receivers, Phase-to-Phase Coupled (high reliability method) ...........13
3.7 Two Independent Relay Channels, Three-Phase (Mode 1) Coupled.........................................14
4Hybrid Module Descriptions............................................................................................. 15
4.1 Balanced Hybrid........................................................................................................................15
4.2 Skewed Hybrid..........................................................................................................................17
4.3 Skewed Hybrid Front Panel Test Switch...................................................................................19
4.4 Splitter.......................................................................................................................................21
4.5 Splitter/Combiner......................................................................................................................23
4.6 Bypass Hybrid ...........................................................................................................................25
4.7 1RU Hybrid Chassis..................................................................................................................28
5Testing and Verification................................................................................................... 30
5.1 Testing the Balanced Hybrid.....................................................................................................32
5.2 Testing the Skewed Hybrid .......................................................................................................33
5.3 Testing the Splitter ....................................................................................................................34
5.4 Testing the Splitter/Combiner ................................................................................................... 35
5.5 Testing the Bypass Hybrid.........................................................................................................36
6Compatibility and Part Numbering, New and Legacy Hybrids......................................... 38
List of Figures
Figure 1 –Grounding................................................................................................................................6
Figure 2 –One Transmitter, One Receiver –(FSK)...............................................................................10
Figure 3 –Two Transmitters and Two Receivers (FSK)........................................................................10
Figure 4 –Three Transmitters, Three Receivers (FSK)..........................................................................11
Figure 5 –Two Transmitters, Two Receivers (FSK and On-Off/DCB).................................................12
Figure 6 –Two Transmitters, Two Receivers, Phase-to-Phase Coupled (low-loss method) .................12
Figure 7 –Two Transmitters, Two Receivers, Phase-to-Phase Coupled (high reliability method) .......13
Figure 8 –Two Independent Relay Systems, Three-Phase (Mode 1) Coupled......................................14
Figure 9 –Balanced Hybrid, Functional Diagram..................................................................................15

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Figure 10 –Balanced Hybrid, Top View................................................................................................16
Figure 11 –Balanced Hybrid, Rear Panel...............................................................................................16
Figure 12 –Balanced Hybrid, Front Panel (test points) .........................................................................17
Figure 13 –Skewed Hybrid, Functional Diagram..................................................................................17
Figure 14 –VSWR / Reflected Power Measurements with Skewed Hybrid Front Panel Test Switch..20
Figure 15 –Skewed Hybrid, Top View..................................................................................................20
Figure 16 –Skewed Hybrid, Rear Panel.................................................................................................20
Figure 17 –Skewed Hybrid, Front Panel (test points)............................................................................21
Figure 18 –Splitter, Functional Diagram...............................................................................................21
Figure 19 –Splitter, Top View...............................................................................................................22
Figure 20 –Splitter, Rear Panel..............................................................................................................22
Figure 21 –Splitter, Front Panel (test points).........................................................................................22
Figure 22 –Splitter/Combiner, Functional Diagram..............................................................................23
Figure 23 –Splitter/Combiner, Equivalent Circuit.................................................................................23
Figure 24 –Splitter/Combiner, Top View..............................................................................................24
Figure 25 –Splitter/Combiner, Rear Panel.............................................................................................24
Figure 26 –Splitter/Combiner, Front Panel (test points)........................................................................25
Figure 27 –Bypass Hybrid Application .................................................................................................25
Figure 28 –Bypass Hybrid, Functional Diagram ...................................................................................25
Figure 29 –Bypass Hybrid, Functional Schematic.................................................................................26
Figure 30 –Bypass, Top View ...............................................................................................................27
Figure 31 –Bypass, Rear Panel..............................................................................................................27
Figure 32 –Bypass, Front Panel (test points).........................................................................................27
Figure 33 –1RU Hybrid Chassis, Front View, Door Closed .................................................................28
Figure 34 –1RU Hybrid Chassis, Front View, Door Open....................................................................28
Figure 35 –1RU Hybrid Chassis, Rear View.........................................................................................29
Figure 36 –1RU Hybrid Chassis, Dimension ........................................................................................29
Figure 37 –Example Terminations, Balanced Hybrid, Insertion Loss Test, TX1 to OUT ....................31
Figure 38 –Example Terminations, Skewed Hybrid, Insertion Loss Test, LINE to RX .......................31
Figure 39 –Measuring Balanced Hybrid Insertion Loss, TX1 to OUT..................................................32
Figure 40 –Measuring Balanced Hybrid Isolation, TX1 to TX2...........................................................32
Figure 41 –Measuring Skewed Hybrid Insertion Loss, TX to LINE.....................................................33
Figure 42 –Measuring Skewed Hybrid Insertion Loss, LINE to RX.....................................................33
Figure 43 –Measuring Skewed Hybrid Isolation, TX to RX.................................................................34
Figure 44 –Measuring Splitter Insertion Loss, IN to LINE 1 ................................................................34
Figure 45 –Measuring Splitter Output Phase Angle Relationship, LINE 1 to LINE 2..........................35
Figure 46 –Measuring Splitter/Combiner Insertion Loss, IN 1 to LINE 2 ............................................35
Figure 47 –Measuring Splitter/Combiner Isolation, IN 1 to IN 2..........................................................36
Figure 48 –Measuring Splitter/Combiner Phase Relationships, IN 1 to LINE 1, LINE 1 to LINE 2....36
Figure 49 –Measuring Bypass Insertion Loss, LINE 1 to LOCAL........................................................36
Figure 50 –RFL Hybrid-Pro Ordering Code/Smart Number.................................................................40

RF-MCHYBRIDPRO-01 Hubbell Power Systems, Inc. –RFL™ Products
June 2019 5 973.334.3100
List of tables
Table 1 –RFL PLC Hybrid Pro –Part Numbers and Descriptions..........................................................9
Table 2 –Balanced Hybrid Specifications..............................................................................................16
Table 3 –Skewed Hybrid Jumper Settings.............................................................................................18
Table 4 –Skewed Hybrid Specifications................................................................................................19
Table 5 –Splitter Specifications.............................................................................................................22
Table 6 –Splitter/Combiner Specifications............................................................................................24
Table 7 –Bypass Hybrid Specifications.................................................................................................26
Table 8 –Chassis Dimensions................................................................................................................29
Table 9 –Balanced Hybrid Loss Characteristics....................................................................................32
Table 10 –Skewed Hybrid Loss Characteristics....................................................................................33
Table 11 –Splitter Loss Characteristics.................................................................................................34
Table 12 –Splitter/Combiner Characteristics.........................................................................................35
Table 13 –Bypass Hybrid Characteristics..............................................................................................37
Table 14 –New / Legacy Conversion.....................................................................................................39

RF-MCHYBRIDPRO-01 Hubbell Power Systems, Inc. –RFL™ Products
June 2019 6 973.334.3100
1 Safety Instructions
1.1 Warnings and Safety Summary
The equipment described in this manual contains high voltage.
Exercise due care during operation and servicing. Read the safety
summary below.
!
1.1.1 Safety Summary
The following safety precautions must always be observed during operation, service, and repair of this
equipment. Failure to comply with these precautions, or with specific warnings elsewhere in this
manual, violates safety standards of design, manufacture, and intended use of this product. HPS/RFL
assumes no liability for failure to comply with these requirements.
Ground the Chassis
The chassis must be grounded to reduce shock hazard and allow the equipment to perform properly.
The Chassis is provided with a rear-panel protective earth terminal, which must be connected to a
proper electrical ground by suitable cabling. The location of the protective earth terminal on the
RFL™ PLC Hybrid Pro system is shown below. Refer to the wiring diagram supplied with the unit for
additional information on chassis and/or cabinet grounding.
Ground wire: 12-14 gauge
Attach the ground
wire to the nearest
panel grounding bar.
Figure 1 –Grounding
A protective earth stud at the right rear of the RFL™ PLC Hybrid Pro system chassis is the main
ground for the RFL™ PLC Hybrid Pro system.

RF-MCHYBRIDPRO-01 Hubbell Power Systems, Inc. –RFL™ Products
June 2019 7 973.334.3100
Do not Operate in an Explosive Atmosphere or in Wet or Damp Areas
!
Do not operate the product in the presence of flammable gases or fumes, or in any area that is wet or
damp. Operating any electrical equipment under these conditions can result in a definite safety hazard.
Keep Away from Live Circuits
Operating personnel should never remove covers. Component replacement and internal adjustments
must be done by qualified service personnel. Before attempting any work inside the product,
disconnect it from the power source and discharge the circuit by temporarily grounding it. This
will remove any dangerous voltages that may still be present after power is removed.
Unrestricted operator access is only permitted to the front of the unit when hazardous voltage is
applied. It is the responsibility of the installer to restrict access to the rear terminal blocks where
hazardous voltage may exist.
Do not Substitute Parts or Modify Equipment
!
Because of the danger of introducing additional hazards, do not install substitute parts or make
unauthorized modifications to the equipment. The product may be returned to HPS/RFL for service
and repair, to ensure that all safety features are maintained.
Read the Manual
!
Operators should read this manual before attempting to use the equipment, to learn how to use the
equipment properly and safely. Service personnel must be properly trained and have the proper tools
and equipment before attempting to make adjustments or repairs.
Service personnel must recognize that whenever work is being done on the product, there is a potential
electrical shock hazard and appropriate protection measures must be taken. Electrical shock can result
in serious injury, because it can cause unconsciousness, cardiac arrest, and brain damage.
Throughout this manual, warnings appear before procedures that are potentially dangerous, and
cautions appear before procedures that may result in equipment damage or service outage if not
performed properly. The instructions contained in these warnings and cautions must be followed
exactly.

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June 2019 8 973.334.3100
1.1.2 Additional Warnings
WARNING!
Follow all your company’s policies and procedures regarding the installation of AC powered or DC
powered equipment. If there is a conflict between any procedure in this manual and your company’s
safety rules, then your company’s safety rules must take priority.
1.1.3 Additional Cautions
CAUTION
Any installation using an enclosed cabinet with a swing-out rack must be securely fastened to the floor.
This will prevent the cabinet from falling forward when the rack is moved outward.

RF-MCHYBRIDPRO-01 Hubbell Power Systems, Inc. –RFL™ Products
June 2019 9 973.334.3100
2 Introduction
The RFL™ PLC Hybrid Pro hybrids are passive devices used to couple power line carrier (PLC)
signals to/from the transmission line for relay protection communication channels. The hybrids are the
interface between PLC transmitters and receivers in the control building and the line tuner in the
switchyard. They are installed in a 1RU chassis which is typically installed next to the transmitters /
receivers. Generally, HPS/RFL hybrids perform two basic, simultaneous functions:
-Isolate transmitters from transmitters, or transmitters from receivers
oPrevent transmitters from loading/interfering with each other
oPrevent local transmit signals (high level) from appearing as noise to local receive
signals (low level)
-Combine and split signals to set them up for the appropriate line coupling scheme
oOnto one coax cable for single-phase-to-ground coupling
oOnto two or three coax cables for phase-to-phase and 3-phase (mode 1) coupling
An ideal hybrid would perform these functions at no cost. However, a price is paid –a loss of signal
power through the hybrids. The most common hybrid names are also a description of their loss
characteristics: a balanced hybrid is so named because the losses are “balanced” (equal), while in a
skewed hybrid the losses are “skewed” (unequal). Hybrid design and PLC channel design must take
these losses into account to minimize their effect on the channel performance. Improper application of
hybrids will result in excessive channel losses, inadequate isolation between channels, or both.
HPS/RFL hybrids are installed in a 1RU chassis, and each chassis can hold up to 3 hybrids. This is
enough for the most common carrier coupling schemes (occasionally a second hybrid chassis must be
used which can be stacked on top of the other). Below is a listing of the different hybrids HPS/RFL
offers, along with a short description.
Table 1 –RFL™ PLC Hybrid Pro – Part Numbers and Descriptions
Description
Typical Application
RFL P/N
Balanced hybrid
Combine transmitters
RF-107970
Skewed hybrid
Combine transmitters and receivers
RF-107975
Splitter
Phase-to-Phase coupling (low loss method)
RF-107980
Splitter/Combiner
Phase-to-Phase coupling (high reliability method)
RF-107990
Bypass
Linear three-terminal system, or passing signal
around a discontinuity
RF-107985
1RU Chassis
Hybrids are installed in the chassis (up to 3)
RF-106665-1
Blank Panel
Cover a slot
RF-106666-1

RF-MCHYBRIDPRO-01 Hubbell Power Systems, Inc. –RFL™ Products
June 2019 10 973.334.3100
3 Example Applications and Recommended
Configurations
When applying hybrids, the number of transmitters and receivers, as well as the application of each
(DCB/On-Off or transfer trip/FSK), will determine what hybrid configuration will work best for each
system. There are several different ways to connect hybrids but generally there are best practices that
should be observed. The examples shown below illustrate typical hybrid configurations and show how
hybrids work together. The exact performance characteristics of individual hybrids are discussed later
in this manual.
3.1 One Transmitter, One Receiver (FSK)
TX
SK
RX
to/from Line Tuner
Figure 2 –One Transmitter, One Receiver –(FSK)
The configuration shown in FIGURE 2is the simplest hybrid configuration. Here, a skewed hybrid is
used to combine a single transmitter / single receiver onto one coax cable for connection to a single
tuner. This is a typical single-function, single-phase-to-ground coupled FSK system.
3.2 Two Transmitters, Two Receivers (FSK)
TX1
TX2
BAL
SK
RX1
RX2
to/from Line Tuner
Figure 3 –Two Transmitters and Two Receivers (FSK)
The system shown in FIGURE 3is an expansion of the system in FIGURE 2. Here, there are two
transmitters, so a balanced hybrid (used to combine transmitters) is added. The output of the balanced