Can someone recommend some products for insulating AWG 10 bare wire and connectors? Maybe some kind of insulating cover?

 

How much are you insulating against?

 

You can get heavy wall heatshrink for very large gauge.
Max.

 

How much are you insulating against?

For 50amp current on a load of about 10 milliohms.

 

We don't need to insulate against the current. What's the voltage?

 

Wire insulation isn't concerned with current unless you're considering how hot the wire will get.
50 amps, 10 Ga. 1001 ft/ohm
(Let's call it 1000 ft/ohm just to make the math easier.)
For every inch there will be 0.2083 watts.
That inch of wire is bigger than the size of a 1/2 watt resistor, so I guess you're not going to get awfully hot. maybe 50C to 70C, but that's a pure guess based on experience.
I'd say you should be more concerned with the voltage the insulation has to resist.

 

I am running the device from a 50amp DC current source, not a voltage source.

 

I don't believe that I have ever personally insulated a wire. They used to have what we called an electrical varnish. You could dip, brush or spay it. I think it was good for 600 volts or such. That was long ago. Sometimes we would apply it to metal chassis to prevent arcing.

I'm sure they have better stuff now.

Search on google.

 

A Google of "electrical wire insulation sleeve" will bring up a few dozen examples of insulation sleeve which will work under a wide range of temperatures and voltage breakdown limits. Then for where insulation meets connector there is heat shrink tubing which comes in many flavors so choose what will work for your application.

I am running the device from a 50amp DC current source, not a voltage source.

That's here nor there, depending on the resistance of the device there is a voltage drop across the device and that is the working voltage you need insulation for. With a 50 Amp load you should be able to use light welding cable which is insulated and offers flexibility. A 50 Amp load is not that much and something like AWG 6 or AWG 4 would be more than adequate AWG 6 should be about a 0.182" or 4.62mm diameter and AWG 4 slightly larger so not very thick. You buy your insulation based on Wire OD and insulation ID.

Ron

 

I am running the device from a 50amp DC current source, not a voltage source.

Are you saying there is no voltage in the current source?
50 amps times 0.01 ohms = 0.5 volts DC
Why do you consult electronic specialists for insulation that will survive 0.5 volts?
Is that the only consideration for your insulation needs?
If so, any insulation ever invented will be more than enough.

 

He might need it for accidental metal contact protection. There could be different reasons.

 

There could be different reasons.

Yebbut...try prying one out of him.

 

!: What length or wire are you trying to insulate
2: What voltage are you using
3: Why are you using bare wire
There is wire commercially available which is already insulated to do what you want( guessing from your post). If you REALLY want to insulate the wire yourself(length unknown) there is sleeving available(heatshrink or silicon). Connectors can be insulated with heatshrink or suitable tape or if you have joints you can use epoxy filled joiners.

 

I am using this part from lesker to connect to a power supply. The wire is AWG 10 and bare, we want to put some insulation for safety.

http://www.lesker.com/newweb/feedthroughs/power_feedthroughs.cfm?pgid=5kv_cf
part # EFT0543093 ELEC F/T,5KV,30A,(4).094" CU COND,2.75"UHV

 

I am using this part from lesker to connect to a power supply. The wire is AWG 10 and bare, we want to put some insulation for safety.

http://www.lesker.com/newweb/feedthroughs/power_feedthroughs.cfm?pgid=5kv_cf
part # EFT0543093 ELEC F/T,5KV,30A,(4).094" CU COND,2.75"UHV

Tell me more. I assume this "feed through" from lesker is to pass power into a vacuum chamber (tool) for a deposition process. Is that correct?

If so, I would avoid putting any DIY hardening/curing/drying polymer insulation on the inside of the vacuum chamber because you will never get a decent vacuum if the residual monomer or solvent remains in the polymer (which is hard to avoid). Look for low out gassing materials. Also, most vinyl or polyurethane tubing insulation will out gas forever and you'll never get a good vacuum needed for CVD/PVD / e/beam or whatever type of experiment requiring such a flange.

10 wag wire is not going to bounce around and get tangled - it will stay where you put it.

For outside the chamber, assuming that is how you are using it, almost any "sleeve" material will work (see " heat sharing tubing" suggested above. You can also use rubber tubing or vinyl tubing from the chemistry lab. You have no risk of arc/spark at the single-volt or sub-volt supply you are working with. Also, if you do get a dead short, your "current supply" will limit current (keep current at same value) anyhow
.

 

Teflon plumbers tape would fit the bill if temps are under 500F.

Can be easily taken off and quickly re-applied, and is pretty much chemically inert.

 

There is a product called split loom ... It is a flexible plastic covering that is easily installed and removed. ... Can be stabilized by using an occasional wire tie. ... Comes in different diameters ... Purchase by the foot, at various auto parts stores.

 

I am using this part from lesker to connect to a power supply. The wire is AWG 10 and bare, we want to put some insulation for safety.

http://www.lesker.com/newweb/feedthroughs/power_feedthroughs.cfm?pgid=5kv_cf
part # EFT0543093 ELEC F/T,5KV,30A,(4).094" CU COND,2.75"UHV

OK, through the bulkhead. While I see AWG 12 as a poor choice for a 50 Amp load it's your call. I gave a few links to insulation in an earlier post that should work out for you.

Ron

 

If it's inside the chamber use glass (pyrex/quartz/ceramic) tubing.

 

I used to do some Hi-Pot testing (High Potential). That means you apply a high voltage to two wires and measure the cross bleed between them. That evaluates the resistive capability of the insulation between the wires.

Funny, you ask about insulation on a bare wire. Bare wire you say? OK, I get it now. You want to add insulation to a bare wire so it's no longer bare. Like others are saying, we need to know the voltage. And then maybe someone here will know the answer. I know I sure don't.