Value Points - Copper vs.

Aluminum Conductor
There is a common misconception that a distribution transformer
with copper windings is in some way more efficient, more
reliable, or has higher short-circuit strength when compared to a
transformer with aluminum windings.

Recommendation Because Cooper Power Systems aluminum-wound and

copper-wound units run at equivalent operating temperatures,
Improvements in technology regarding the use of aluminum in the insulation systems age at the same rate for each design.
transformers have made aluminum-wound transformers the ideal
choice for today’s applications. Lower First Cost
Whether low losses are the goal or not, aluminum windings
Rationale are less expensive than copper windings. The following
Operating Cost example shows two equivalent loss designs, one with
Cooper Power Systems designs aluminum-wound aluminum windings and one with copper windings.
transformers with windings of a larger cross-sectional area The Bottom Line
than would be used for a copper wound unit. This larger
cross-sectional area translates to a lower current density and Cooper Power Systems designs its aluminum-wound coils
an equivalent operating temperature. By reducing the current using the same thermal, dielectric and mechanical performance
density in the windings, a low-loss design can be achieved requirements as for its copper-wound coils. In pad-mounted and
with aluminum or copper windings. substation designs, Cooper Power Systems aluminum-wound
units and copper-wound units serve their loads equally well.
Reliability
A transformer’s life is defined by the life of its insulation system.

Example: 2500 kVA, 3-phase padmount transformer, 13800 Delta - 480Y/277

Copper Primary
All Aluminum Winding All Copper Winding
Aluminum Secondary
No Load Losses (Watts) 2155 2272 2144
Load Losses (Watts) 17,725 17,225 17,544
Total Losses (Watts) 19,880 19,497 19,688
Efficiency at 50% Load 99.5% 99.5% 99.5%
Efficiency at 100% Load 99.2% 99.2% 99.2%
Dimensions (H x W x D) 72″ x 66″ x 55″ 64″ x 68″ x 52″ 64″ x 68″ x 58″
Price $36,745.00 $42,565.82 $39,843.27
In this example, while the losses of all three units are roughly equivalent, when compared to the price of the
aluminum-wound unit, the copper-aluminum-wound transformer is $3100 (8.5%) more expensive, while the
copper wound transformer is $5800 (16%) more expensive.

For an in-depth, technical explanation on this issue, please see reference document R210-80-3.

www.cooperpower.com

B210-99028 • April 2011 • Replaces 99028 Cooper Power Systems is a valuable trademark of Cooper Industries in the U.S. and other countries. You are not permitted to use the Cooper Trademarks without the prior written consent of Cooper Industries.
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