Thanks for the response. Feedback will help make the document better. Individual answers below:
1) No exact number for a short cable run. 25 feet should be fine. 100 feet would probably have some significant attenuation. A dryer coupler would probably be fine in a 1000 sq. ft. home, especially if the dryer is near the distribution panel.
2) The simulation just included a resistive load directly across the panel with no allowance for wiring inductance. The further away from the panel it is, the less effective it would be. I do not use a coupler, so I do not have quantitative measurements for our exact situation. However, I HAVE measured significant drop through 50 feet of wiring. Extrapolating that to how our electrical distribution is configured, I would not expect a dryer coupler to work nearly as well as a coupler installed at the distribution panel.
3) Use whichever is closest to the distribution panel. That will reduce line inductance, and result in a stronger coupled signal.
4) While it doesn't meet code, many here are sufficiently skilled to pop in a 240V breaker with a capacitor connected across it. Anyone not comfortable working around an electrical panel should either solicit help from a friend with such skills, or hire an electrician to install a coupler by the code. If you hire an electrician, a good tuned circuit passive coupler installed next to the distribution panel is the best way to go. BTW, that's my eBay listing, and the electrician warning is to prevent people who don't know what they are doing from getting hurt. If you have a 240V appliance near the distribution panel, the plug-in coupler should work fine.
5) The main function of the PZZ01 is to block X10 signals from coming into the house via the powerline. This should prevent interaction with a neighbor's X10 system. They say it also works as a coupler, but I don't know how effective it is compared with the XPCP or equivalent. (I wonder if they got that PZZ01 name from misswiring it at some point....)
The XTB-II is a different animal. Its function is to drive a very strong signal into the powerline. It does not block signals coming from your neighbors. While not designed as a signal coupler, it does provide that function because it connects to both phases. The plug-in XTB only drives a single phase, and should be paired with good tuned-circuit coupler if both phases are used.
6) I don't think there are many 3-phase systems in North America, but that is common in Europe. What is needed for a coupler depends on whether it is a "Y" or "Delta" connection. 240V "Y" has to deal with nasty voltages. Delta should have drive on the phase most used for X10, and a "signal divider" used to couple half of that signal to the other two phases. Obviously, those systems also need transmitters that output on all 3 phases.
7) Aluminum wiring is a whole different subject. There is nothing inherent in aluminum wiring that will cause a problem for X10. I would however investigate having those improper connections changed as they will be a fire hazard as the wiring continues to age. That is something that you might have negotiated to have done by the prior owners.
Hope this answers your questions.
Jeff