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Replacing aluminum conductors with copper conductors in power and distribution transformers up to 10 MVA

Design issues and differences in material properties must be considered before proceeding

  • August 2010
  • Number of views: 7461
  • Article rating: 2.5

Richard Huber, P. Eng.
Richard Huber Engineering, Ltd.
North Vancouver, British Columbia
Canada
Technical Services Committee Member

Introduction
There are many transformers in use rated up to 10 MVA (10,000 kVA) that were originally wound using aluminum conductors. When dam­aged or when selected for rewind, the aluminum conductor is often replaced with copper conductor. This is usu­ally fairly routine when the conductor changes are undertaken within the bounds of the original transformer design. It is this type of change that will be reviewed in this article. It is not the intent to provide information here for the complete redesign of the transformer. It is important that all coil dimensions remain as close to the originals as possible.

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Categories: Transformers, Wire
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Getting The Most From Your Electric Motors

Getting The Most From Your Electric Motors - coverThis 40-page booklet provides great advice for obtaining the longest, most efficient and cost-effective operation from general and definite purpose electric motors.

This booklet covers topics such as:

  • Installation, startup and baseline information
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  • Motor and baseline installation data
  • How to read a motor nameplate
  • Motor storage recommendations

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READ MORE ABOUT THE FEATURES AND BENEFITS

EASA/AEMT Rewind Study

EASA Rewind Study cover

The Effect of Repair/Rewinding on Premium Efficiency/IE3 Motors
Tests prove Premium Efficiency/IE3 Motors can be rewound without degrading efficiency.

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ANSI/EASA AR100-2020

ANSI/EASA AR100-2015 cover

Recommended Practice for the Repair of Rotating Electrical Apparatus
This is a must-have guide to the repair of rotating electrical machines. Its purpose is to establish recommended practices in each step of the rotating electrical apparatus rewinding and rebuilding processes.

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EASA Technical Manual

EASA Technical Manual cover

Revised May 2024
The EASA Technical Manual is the association's definitive and most complete publication. It's available FREE to members in an online format. Members can also download PDFs of the entire manual or individual sections.

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