To calculate the amount of copper required for a transformer, follow these steps:

1. Determine Key Parameters:

Rated Power (S): in kVA

Primary & Secondary Voltage (V1, V2)

Primary & Secondary Current (I1, I2)

Winding Material: (Copper or Aluminum)

Current Density (J): for Copper, typical values range from 2.5 to 5 A/mm².

Turns per Volt (T/V)

Window Space Factor (k_w): typically 0.3 to 0.4 for core-type transformers.

—

2. Calculate Primary & Secondary Turns:

N_1 = \frac{V_1}{T/V}, \quad N_2 = \frac{V_2}{T/V}

—

3. Compute Cross-Sectional Area of Wire:

A_1 = \frac{I_1}{J}, \quad A_2 = \frac{I_2}{J}

= cross-sectional area of primary & secondary winding wire in mm²

= current density (A/mm²)

—

4. Compute Length of Copper Wire:

L_1 = N_1 \times \text{mean turn length}, \quad L_2 = N_2 \times \text{mean turn length}

—

5. Compute Copper Volume and Weight:

V_{\text{Cu}} = (L_1 \times A_1) + (L_2 \times A_2)

\text{Mass of Copper} = V_{\text{Cu}} \times \text{Density of Copper}

Density of copper ≈ 8.96 g/cm³.