DAA1093 AAR S-501 / RP-585 125°C XLPO DLO Diesel Locomotive Wire 600V/2000V
DAA1093 is a 125°C diesel locomotive (DLO) wire to AAR S-501 and RP-585: annealed tinned copper with flame-retardant XLPO insulation, rated -55°C to 125°C, in 600V sizes from 18 to 8 AWG and 2000V sizes from 18 AWG to 597 MCM.
- Voltage600V and 2000V
- ConductorTinned copper, ASTM B33/B172
- InsulationFlame-retardant XLPO
- Temperature range-55°C to 125°C
- Overload / short circuit130°C / 250°C
- Sizes, 600V18 AWG to 8 AWG
- Sizes, 2000V18 AWG to 597 MCM
- StandardAAR S-501 / AAR RP-585
DAA1093 is a single-conductor diesel locomotive wire (DLO) with a flexible, annealed tinned copper conductor and a flame-retardant crosslinked polyolefin (XLPO) insulation. It is made to AAR S-501 and AAR RP-585, the wire and cable practice used for North American locomotives and rail cars, and it is offered in a 600V range and a 2000V range.
The thermoset XLPO is rated 125°C, with a 130°C overload and a 250°C short-circuit rating, and it does not crack in the cold down to -55°C. Compared with welding cable it has better insulation, a longer service life and higher voltage ratings, which is why it is used for motor leads and power wiring that vibrates and moves in service.
Browse the ICEA mining cable category for related cables.
Application & Features
Selection overview
On a diesel-electric locomotive the diesel engine drives a generator, and heavy wiring carries its output through the electrical cabinet to the traction motors on the bogies. That wiring sits in a hot, oily and vibrating space and is bent around tight corners, so it needs a flexible conductor and an insulation that resists heat, oil, abrasion and flame. DAA1093 wire is built for this duty, and the same properties suit it to mining equipment, motor leads, shipyards and generator systems.
The XLPO wall resists cut-through, crush and scrape abrasion better than rubber, EPR and chloroprene insulations, and it is more flexible and handles overloads better than fluoropolymer insulations. It withstands moisture, sunlight, oil, acids, alkalis, heat and chemicals, and it gives low smoke and acid gas in a fire. These properties matter most at clamps, bends and terminal lugs, where wiring in vibrating equipment usually wears first.
- Diesel-electric locomotivesPower and motor-lead wiring between generator, electrical cabinet and traction motors.
- Mining and heavy equipmentMotor leads and power wiring on mobile mining equipment such as diesel-electric haul trucks.
- Shipyards and generator setsFlexible leads for generator systems and shipyard power where oil and sunlight resistance count.
- Two voltage ranges600V wire from 18 to 8 AWG and 2000V wire from 18 AWG to 597 MCM, color-coded by size.
Specifications
Technical data
Typical DAA1093 values for the 600V and 2000V ranges. The final construction is confirmed on the TEBAOFLEX datasheet issued with your quotation.
Electrical, thermal and material data
| Parameter | Value |
|---|---|
| Voltage rating | 600V, 2000V |
| Conductor | Annealed, tinned copper per ASTM B33, B172, AAR S-501 and AAR RP-585 |
| Insulation | Flame retardant crosslinked polyolefin (XLPO), thermoset |
| Temperature rating | Rated 125°C, maximum 130°C overload, 250°C short circuit |
| Temperature range | -55°C to 125°C |
| Standard | AAR RP-585/S-501 |
| Insulation reference | ICEA S-66-524 (S-95-658) |
| Properties | Flame retardant; excellent fluid/oil resistance; moisture and sunlight resistant |
| Environmental | REACH and RoHS compliant |
| Ampacity basis (*) | Single conductors in air, 40°C ambient, 125°C insulation rating |
600V DAA1093 wire: dimensions, ampacity and weight
| Product number | Size (AWG) | Stranding | Max. cond. diameter (in) | Max. cond. diameter (mm) | Insulation wall (in) | Insulation wall (mm) | Nom. diameter (in) | Nom. diameter (mm) | Ampacity* at 125°C (A) | Approx. weight (lb/kft) | Approx. weight (kg/km) | Standard color |
|---|---|---|---|---|---|---|---|---|---|---|---|---|
| TEBAOFLEX-18-600V | 18 | 19/30 | 0.049 | 1.24 | .030 | .76 | 0.109 | 2.76 | 19 | 11 | 16.4 | Yellow |
| TEBAOFLEX-16-600V | 16 | 19/29 | 0.055 | 1.40 | .030 | .76 | 0.116 | 2.94 | 25 | 13 | 19.3 | Red |
| TEBAOFLEX-14-600V | 14 | 37/29 | 0.076 | 1.93 | .030 | .76 | 0.137 | 3.47 | 42 | 21 | 31.3 | Dark Gray |
| TEBAOFLEX-12-600V | 12 | 37/27 | 0.099 | 2.51 | .030 | .76 | 0.157 | 3.98 | 55 | 29 | 43.2 | Light Blue |
| TEBAOFLEX-10-600V | 10 | 27/24 | 0.118 | 3.00 | .030 | .76 | 0.178 | 4.52 | 72 | 44 | 65.5 | Dark Gray |
| TEBAOFLEX-8-600V | 8 | 37/24 | 0.140 | 3.56 | .045 | 1.14 | 0.232 | 5.89 | 97 | 64 | 95 | Dark Gray |
2000V DAA1093 wire: dimensions, ampacity and weight
| Product number | Size (AWG/MCM) | Stranding | Max. cond. diameter (in) | Max. cond. diameter (mm) | Insulation wall (in) | Insulation wall (mm) | Nom. diameter (in) | Nom. diameter (mm) | Ampacity* at 125°C (A) | Approx. weight (lb/kft) | Approx. weight (kg/km) | Standard color |
|---|---|---|---|---|---|---|---|---|---|---|---|---|
| TEBAOFLEX-18-2KV | 18 | 19/30 | 0.049 | 1.24 | .045 | 1.14 | 0.139 | 3.53 | 19 | 15 | 22.3 | Dark Gray |
| TEBAOFLEX-16-2KV | 16 | 19/29 | 0.055 | 1.40 | .045 | 1.14 | 0.144 | 3.65 | 25 | 17 | 25.3 | Orange |
| TEBAOFLEX-14-2KV | 14 | 37/29 | 0.076 | 1.93 | .045 | 1.14 | 0.164 | 4.16 | 42 | 25 | 37.2 | Light Gray |
| TEBAOFLEX-12-2KV | 12 | 37/27 | 0.099 | 2.51 | .045 | 1.14 | 0.187 | 4.75 | 55 | 34 | 50.6 | Blue |
| TEBAOFLEX-10-2KV | 10 | 27/24 | 0.118 | 3.00 | .045 | 1.14 | 0.208 | 5.28 | 72 | 51 | 75.9 | Dark Gray |
| TEBAOFLEX-8-2KV | 8 | 37/24 | 0.140 | 3.56 | .055 | 1.40 | 0.252 | 6.40 | 97 | 71 | 105.7 | Dark Gray |
| TEBAOFLEX-6-2KV | 6 | 61/24 | 0.190 | 4.83 | .055 | 1.40 | 0.300 | 7.62 | 131 | 108 | 161.0 | Dark Gray |
| TEBAOFLEX-5-2KV | 5 | 91/24 | 0.244 | 6.20 | .055 | 1.40 | 0.354 | 8.99 | 156 | 149 | 221.7 | Dark Gray |
| TEBAOFLEX-4-2KV | 4 | 105/24 | 0.264 | 6.71 | .055 | 1.40 | 0.376 | 9.55 | 172 | 177 | 263.9 | Dark Gray |
| TEBAOFLEX-3-2KV | 3 | 125/24 | 0.288 | 7.31 | .055 | 1.40 | 0.401 | 10.18 | 194 | 204 | 303.6 | Dark Gray |
| TEBAOFLEX-2-2KV | 2 | 150/24 | 0.325 | 8.26 | .055 | 1.40 | 0.431 | 10.95 | 232 | 240 | 357.8 | Dark Gray |
| TEBAOFLEX-1-2KV | 1 | 225/24 | 0.390 | 9.91 | .065 | 1.65 | 0.522 | 13.25 | 266 | 354 | 526.8 | Dark Gray |
| TEBAOFLEX-1/0-2KV | 1/0 | 275/24 | 0.435 | 11.04 | .065 | 1.65 | 0.563 | 14.3 | 309 | 431 | 642.6 | Dark Gray |
| TEBAOFLEX-2/0-2KV | 2/0 | 325/24 | 0.445 | 11.30 | .065 | 1.65 | 0.578 | 14.68 | 355 | 494 | 735.1 | Dark Gray |
| TEBAOFLEX-3/0-2KV | 3/0 | 450/24 | 0.555 | 14.10 | .065 | 1.65 | 0.683 | 17.35 | 410 | 673 | 1003.4 | Dark Gray |
| TEBAOFLEX-4/0-2KV | 4/0 | 550/24 | 0.575 | 14.61 | .105 | 2.67 | 0.792 | 20.11 | 481 | 851 | 1266.4 | Dark Gray |
| TEBAOFLEX-313-2KV | 313MCM | 775/24 | 0.700 | 17.78 | .105 | 2.67 | 0.917 | 23.29 | 637 | 1131 | 1683.0 | Dark Gray |
| TEBAOFLEX-444-2KV | 444MCM | 1100/24 | 0.830 | 21.08 | .105 | 2.67 | 1.052 | 26.76 | 792 | 1607 | 2391.4 | Dark Gray |
| TEBAOFLEX-535-2KV | 535MCM | 1325/24 | 0.905 | 22.99 | .120 | 3.18 | 1.149 | 29.18 | 893 | 2000 | 2976.2 | Dark Gray |
| TEBAOFLEX-592-2KV | 597MCM | 1480/24 | 0.985 | 25.01 | .125 | 3.18 | 1.234 | 31.34 | 928 | 2200 | 3273.8 | Dark Gray |
Selection note: ampacities marked * are based on single conductors in air at an ambient of 40°C and an insulation rating of 125°C. Before ordering, ask our engineers to confirm the derated ampacity for your grouping, enclosure and ambient temperature, and the insulation color and marking your railroad or equipment builder requires.
Standards & References
Applicable standards and compliance
- Design standardMeets AAR RP-585/S-501; conductor to ASTM B33 and B172; insulation in accordance with ICEA S-66-524 (S-95-658).
- Flame and smokePasses the UL VW-1 flame test and the IEEE-383 1974 vertical tray flame test; meets UL 1685 (FT4/IEEE 1202 flame with smoke measurement); passes NFPA 130-2010, 2014, 2017, 2020.
- Rail vehicle fire safetyMeets 49 CFR Part 238 for flame (ICEA S-19-81) and smoke (ASTM E662), the transit toxicity requirements of BSS 7239, and APTA PR-E-RP-009-98 2021.
- Voltage scope600V and 2000V ratings, each with its own insulation wall thickness.
- ApprovalsTest reports, certificates and marking requirements are confirmed and quoted per order.
Construction
Material and build-up
DAA1093 is a single-conductor wire with two elements: a flexible stranded conductor and one thermoset insulation wall. The wall grows with voltage and size: 600V wire has a .030 in wall up to 10 AWG, while the 2000V range runs from 1.14 mm on the small sizes to 3.18 mm on 535 and 597 MCM.
- Conductor: Annealed, tinned copper per ASTM B33 and B172, finely stranded from 19/30 on 18 AWG to 1480/24 on 597 MCM for flexibility.
- Tinning: The tin coating protects the fine strands against corrosion in oily, humid equipment spaces and keeps lug terminations reliable.
- Insulation: Flame retardant crosslinked polyolefin (XLPO), a thermoset compound rated 125°C with 130°C overload and 250°C short-circuit ratings.
- Color code: Standard insulation colors mark the size, for example yellow for 18 AWG and red for 16 AWG at 600V, orange for 16 AWG at 2000V, and dark gray for most larger sizes.
FAQ
Selection questions
What is DAA1093 diesel locomotive wire?
DAA1093 is a 125°C XLPO-insulated DLO wire made to AAR S-501 and RP-585. DLO stands for diesel locomotive cable: a flexible single-conductor wire first used for locomotive power wiring and now also used on mining machines, generator sets and shipyard equipment.
What is the difference between the 600V and 2000V versions?
Both use the same conductors and the same XLPO compound. The 2000V wire has a thicker insulation wall, for example .045 in instead of .030 in on 18 to 10 AWG, so its overall diameter and weight are higher, while the ampacity at 125°C is the same for a given size. The 600V range covers 18 to 8 AWG and the 2000V range 18 AWG to 597 MCM.
How are the ampacities in the tables defined?
The values marked with an asterisk are for single conductors in air at an ambient of 40°C with the insulation at its 125°C rating. Grouped wires, conduit, enclosed cabinets or higher ambient temperatures need derating, so send the installation details and our engineers return the derated value.
How does XLPO DLO wire compare with rubber-insulated DLO cable?
Rubber-insulated DLO uses an EPR insulation with a separate jacket. DAA1093 has a single XLPO thermoset wall rated 125°C that resists cut-through, crush and scrape abrasion better than rubber, EPR and chloroprene, and it stays flexible in cold weather. For portable mining power cables see the ICEA mining cable category.
What should I send for a quotation?
Send the product number or the size and voltage (600V or 2000V), the quantity and put-up (reels or cut lengths), the insulation color, the AAR, NFPA 130 or 49 CFR Part 238 requirement your project must document, and any print marking you need.
Request this cable.
Send the size and voltage, quantity and put-up, insulation color, and the rail or mining standard you must document.
Quality Assurance
Testing at every stage in our own workshop and laboratory, from incoming copper to the packed drum.
Raw Material Inspection
Every batch of copper rod, rubber compound and reinforcing material is checked before it reaches the line.
- Copper: conductor resistance, elongation and surface condition on incoming rod and drawn wire
- EPR, CPE, PUR and silicone compounds: hardness, tensile strength, elongation and ageing samples from each mix
- Suppliers and batch numbers are recorded so every drum can be traced back to its materials
Manufacturing Process Control
Stranding, insulation extrusion, core assembly and sheathing run under recorded process parameters.
- Class 5/6 stranding with lay length and tension monitored for trailing and reeling flexibility
- Continuous-vulcanisation extrusion with wall thickness and spark tests logged on every length
- Operators sign off each stage before the cable moves to the next machine
Electrical Testing
Finished lengths go through the routine tests required by the referenced VDE, ICEA, IEC or NEK standard.
- Conductor resistance and insulation resistance on every length
- Voltage withstand (3.5 kV and higher) and partial-discharge measurement in the shielded HV laboratory
- Screen and pilot-core continuity checks for mining and reeling constructions
Mechanical and Ageing Tests
Samples from production are tested for the duty a mining, crane or submersible cable will actually see.
- Tensile strength and elongation of insulation and sheath before and after ageing
- Hot-set, ozone, oil-immersion and low-temperature bending tests
- Constant-temperature water bath for insulation resistance of submersible constructions
Flame Test and Final Inspection
Before packing, the cable is checked against the order and the flame-performance requirement of its standard.
- Single-cable vertical flame test to IEC 60332-1-2 where specified
- Metre marking, printing, drum length and appearance inspection
- Test report and packing list issued with every shipment
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