But there is also another type of energy loss associated with transformers called “copper losses”. Transformer Copper Losses are mainly due to the electrical resistance of the primary and secondary windings. Most transformer coils are made from copper wire which has resistance. This resistance opposes the magnetising currents flowing through them. Not only that, when a load is connected to the transformers secondary winding, large electrical currents flow in both the primary and the secondary windings, electrical energy and power (or the I2 R) losses occur as heat. Generally copper losses vary with the load current, being almost zero at no-load, and at a maximum at full-load when current flow is at maximum.
A transformer’s rating can be increased by better design and transformer construction to reduce these copper losses. Transformers with high voltage and current ratings require conductors of large cross-section to help minimise their copper losses. Increasing the rate of heat dissipation (better cooling) by forced air or oil, or by improving the transformers insulation so that it will withstand higher temperatures can also increase a transformers rating.