What happens while VFD outgoing cable is in aluminium conductor?

If the outgoing cable from a Variable Frequency Drive (VFD) comes into contact with an aluminum conductor, it can lead to several potential issues and risks. Here are some possible consequences:

Electrical Conductivity

Aluminum is a conductor of electricity, but it has a lower conductivity compared to copper. When the VFD cable, which typically contains copper conductors, comes into contact with an aluminum conductor, it can result in a poor electrical connection. This can lead to increased resistance, voltage drops, and inefficient power transmission. The higher resistance can cause overheating and energy losses in the system.


When dissimilar metals like aluminum and copper come into contact, a process called galvanic corrosion can occur. This is due to the electrochemical potential difference between the two metals. Over time, galvanic corrosion can degrade the metal surfaces and impair the electrical conductivity, leading to poor connection quality and potential system failures.

Intermittent or Unstable Connections

The contact between the VFD cable and aluminum conductor may not provide a secure and stable connection. This can result in intermittent electrical contact, leading to power fluctuations, voltage drops, and even system malfunctions. Unstable connections can also cause electrical arcing, which poses a risk of fire hazards.

Increased Heat Generation

Poor electrical connections due to the aluminum contact can result in increased resistance and higher temperatures in the affected area. The excess heat can cause insulation degradation, cable insulation melting, or even fires.

To ensure a safe and reliable electrical installation, it is crucial to follow proper wiring practices and use compatible materials. When connecting a VFD to an electrical system, it is recommended to use cables and conductors with the same material (preferably copper) throughout the installation. This helps maintain a consistent and reliable electrical connection, minimizing the risks associated with dissimilar metals.

If you suspect that a VFD cable has come into contact with an aluminum conductor, it is advisable to have a qualified electrician or technician inspect the installation, identify any potential issues, and rectify the situation to ensure proper electrical performance and safety.