COP 1638

-the new 16 kW Rock Drill

Andreas Nordbrandt, 2004-09-14
COP 1638 in brief
 A new 16 kW rock drill for Face- and Long
hole drilling Underground
 Can be used on 45 kW electrical motor power
pack
 Gradually replaces COP 1238 ME
 Developed from COP 1838 ME, and has
therefore many COP 1838 features
 Suitable as Repower rock drill. There is a big
Repowering potential, replacing used COP
1238 MEs and used Tamrock HL 500/510s
 Technical data, COP 1638 vs COP 1238 ME

COP Rock Drill 1238 ME 1638

Impact power, max [kW] 12 16
Weight, [kg] 150 170
Max impact pressure [bar] 230 200
(at the hammer)
Impact energy, [J] 240 266
Impact frequency [Hz] 50 60
Damper, type Hydraulic single Hydraulic, double
Hole range [mm] 33-89 33-76
Shank adapters R32, R/T38 R32, R/T38
COP 1638, features and benefits
 Feature - Atlas Copco double dampening system

 Benefits
- Provides good bit-rock contact which gives high penetration
rate
- Gentle to the drill steel and rock drill, absorbs harmful recoil
energy and tightens drill steel thread joints
COP 1638, features and benefits
 Feature – Pressurized mating surfaces between the parts

 Benefit – There is a 2-3 bar air pressure inside the drill,

which prevents dirt and moist from entering. This results in
longer service life of the parts and more trouble free
operation.
 COP 1638, features and benefits
 Feature (optional) – Front head designed for ultra-corrosive
environments – AW-version!
 Benefits –
 Minimized risk of water inside the drill
 Longer service life on drill housing and shank
 Longer service life on front guide

 Feature and benefit – The Impact piston design

emulates the size of the drill steel. This feature gives
minimum drill steel stress.

 Drillers who have tested the COP 1638 say it is very

easy to adapt to different rock or bit conditions
What is AW version?
 AW is an option to COP 1638 or 1838ME with a special front
head, aimed for sites where the environment is medium to very
corrosive.
 For those not familiar with the COP 1638, it is the optimal choice
for upgrading old rigs with COP1238/DCS, COP1432/DCS14 or
similar class competitor rockdrills, to provide higher productivity
and better drilling economy.
 The AW design provides mainly:
– Minimised risk of water intrusion into the rock drill and
hydraulic system
– Longer service life on the front head (corrosion resistant
material) and its comprised parts
– Longer service life of the shank adapter (zinc phosfated
surface is option)
What is AW version?
 AW version is available for dia 38 mm shank adapters as part of
complete rock drill or as a kit for retrofitting.
 The AW design is tested in corrosive environment in Poland and
Australia in more than 1.500.000 drill meters
 AW, BOM and feature numbers
3
4

2 6
1
5
Features 1 to 3
1 The flushing head is made from a high quality black polymere,
which can not corrode. As the backhammer feature is desired
also in the AW version, we do not allow the stop ring to hammer
on the flushing head. Therefore a spacer (pos 114) is
introduced.
2 Due to the space required between the two rear flushing seals,
the AW shank adapter is 20 mm longer than a standard shank
adapter (which means that an AW rock drill is 20mm longer than
a standard 1638 or 1838 ME rock drill).

A zinc-phosphate coated shank adapter is available to increase

its service life.
3 AW version front head has a much larger cross sectional areas
for evacuation of the flushing water when a flushing seal is worn.
There are 4 radial holes for the front seal and 4 large grooves
for the rear seal. Neglecting change of a worn seal therefore
reduces the risk of water inside the drill and its hydraulic
system
Features 4 to 6
4 The AW design has incorporated the water inlet connection plate
5 The AW design has 2 wipers around the front guide, to protect
the lubrication system from dirt and water.
The front wiper protects the drill from cuttings and the rear wiper
protects the lubrication system from flushing water
6 There a 3 flushing seals with the same P/N
Part numbers
 As part of complete rock drill, the designation AW is
added to a normal designation of a rock drill, for
instance: COP 1838 ME-AW-T38/05 has P/N 8311
1247 57. You find all P/N in the price list in the RDE
Rock Drills Database.
 Retrofit kit P/N is 3115 3018 80, it comprises all
included in the BOM list excluding the shank adapters
which has following P/N:
 T38 male, L=455mm, SECOROC NR.435-09108,00
R38 male, L=455mm, SECOROC NR.404-09108,00
R38 male, L=455mm, SECOROC NR.404-09108,30 (zinc-phosphated)
COP 1638 field tests summary
 3 field tests have been carried out in Australia,
Canada and Poland, replacing COP 1238 ME
on used eqipment
 Totally 2309 impact hours
 Successful tests, no problems are reported
 Shank adapter service life was increased by
in average 23% vs COP 1238 ME
 All field test sites report an increase in
productivity.
Field Test #1, Beaconsfield Mine, Australia
 Rig: Used Boomer 322 . AVO 96A021 with Feed BMHT 6314-08, compressor LE 55,
DCS-12-45-2. Rig was originally equipped with COP 1238 ME
 3 pc of test COP 1638 were run 512 , 571 and 626 impact hrs between 2003-08 and
2004-04
 Reported shank adapter average service life: COP 1238; 714 m, with COP 1638
814 m. This equals 15% improvement despite scaling with the rock drill (which is
the reason for the overall short lives) .
 Average reported penetration rate: COP1238 1.2m/min, COP 1638 1.6m/min.
Improvement by 33%.
 Current draw (1000 V system):
COP 1238 : appr 32,5A (full drilling) => 44,5 kW el power.
COP 1638 : appr. 33Amp (full drilling) =>45 kW el power.
 No rock drill problems are reported
Shank adapter life [m], Beaconsfield Penetration rate [m/min], Beaconsfield
900 2
1,9
850 1,8
1,7
800
+15% 1,6
750 1,5 +33%
1,4
700 1,3
1,2
650
1,1
600 1
COP 1238 ME COP 1638 COP 1238 ME COP 1638
Field Test #2, Agnico Eagle Mine , Canada
 Rig: Used Boomer 282 , equipped with 1 COP1238ME (left boom) and 1 COP1638 (right
boom), serial no AVO 95A113 with Feed BMH 1314 and compressor LE8UV. Power pack
DCS-12-45-2.
 Drill steel used: Secoroc T38-H35-SR35 , 14 feet long with semi-ballistic button bits, dia 48
mm and reaming holes dia 102mm. Regrinding is made every 20 meters. Bit life is 800-
1000 feet
 Start up was 2004-03-04 , and per 2004-05-06 the COP 1638 had run 202 imp hrs .
 COP 1638 has an average penetration rate which is appr. 8-10% higher than COP 1238 ME.
All reaming holes were drilled with COP 1638. Average penetration rate for COP 1638 is
2,15 m/min.
 Average shank adapter service life was 21% better with COP 1638 than with COP1238ME
(from 2075 to 2520 m)
 Current draw @ 575 V, 60 Hz
COP 1238 : 46Amp (collaring) and 51Amp (full drilling) => 40kW el. power
COP 1638 : 51Amp (collaring) and 55Amp (full drilling) => 43 kW el. power
 No rock drill problems are reported

Shank adapter life [m], Agnico Eagle Penetration rate [m/min], Agnico Eagle
2700
2,5
2,4
2500 2,3
+21% 2,2
2300 2,1
+15%
2
2100
1,9
1900 1,8
1,7
1700 1,6
1,5
1500
COP 1238 ME COP 1638
COP 1238 ME COP 1638
 Field Test #3, Polkowice , Poland
 Rig: used Boomer 281LP with serial no AVO 99A032, Feed BMH 2337L, compressor LE 55
10UV and equipped with drill system DCS-12-45-1. .
 Test object: COP 1638 R38-05-AW with stainless steel front head, replacing COP 1238ME.
 Drill steel: Boart R38-H35-R32 , 10 feet , semiballistic button bit, diameter 51 and 64 mm .
 Between 2004-04-01 and 2004-08 200 impact hrs have been drilled @ an average penetration
rate of 4.3 m/min with COP 1638.
One face is drilled 10 min faster (from 40 min to 30 min) compared to COP1238ME, which
means appr. 25% faster average peneration rate.
 Average shank adapter average service life is 2750m with COP 1638, which is 34% higher
than COP 1238ME (2050 m)
 No rock drill problems are reported.

Shank adapter life [m], Polkowice Penetration rate [m/min], Plokowice

4,6
2900
4,4
2700
+34% 4,2 +25%
2500
4
2300
3,8
2100 3,6
1900 3,4
1700 3,2
1500 3
COP 1238 ME COP 1638 COP 1238 ME COP 1638
COP 1638 P/N
COP 1638 has now following P/N (GAC 10 B, PGC 108, Rate group K6)

 8311 1249 53 COP 1638-T38E-07

 8311 1249 54 COP 1638-R38-05
 8311 1249 55 COP 1638-T38-05
 8311 1249 56 COP 1638-T38-07
 8311 1249 57 COP 1638-AW-R38-05
 8311 1249 58 COP 1638-AW-T38-05
COP 1638 Pricing

IP price (2004-08, kSEK)

600

500

400

300 IP price (kSEK)

200

100

0
COP 1238 ME COP 1638 COP 1838 ME
COP 1638, Market Introduction on rigs
COP 1638 will be the main rock drill alternative on
following rigs, with start Q4 2004:

 Boomer 104
 Boomer 281 / Boomer 282
 Boomer S1L
 Boomer M2C / Boomer M2D
 Boomer L2D
 Boomer 195
 Boomer 352 / Boomer 353
Questions and answers I
 How much is common between COP 1838 ME and
COP 1638?
Although COP 1638 might look like a COP 1838 ME, the
interior parts are new in order to give best performance
at 16 kW impact power, and all the well known
properties of COP 1838 ME are provided in COP 1638.
 Which are the main benefits for a customer?
Compared to a COP 1238ME or a similar rock drill, the
COP 1638 provides a better drill steel and spare parts
economy.
 When will COP 1638 be introduced on the market?
Release will take place in MineExpo in Las Vegas in
September 2004. It will be the main rock drill alternative
on DCS Boomers from Q3 2004.
Questions and answers II
 Could old rigs be repowered by COP 1638?
So called repowering is one main target with COP 1638,
replacing old COP 1238 MEs but also competitors drills.
Suitable rigs/recommendations replacing COP 1238 with COP 1638

BOOMER REMARK / RECOMMENDATION MANUF. VOLUME

195 -All versions Compressor with 24 l/s or 25-30 in operation
better is recommended (Japan)
281 -BMH 2000 recommended >160 (not incl. RB 281)
-DCS 12-45 kW required Not all rigs fulfil the
-Water pump CR4 or better recommended recommendations (~25%
-Compressor with 8 l/s or better is or ~40 units have)
recommended, LE 55 for instance

282 -BMH 2000 is recommended >300 (not incl RB 282)

-DCS 12-45 kW is required Not all rigs fulfil the
-Water pump CR4 or better is recommendations
recommended (~25% or 75 units have)
-Compressor with 15 l/s or better is
recommended, for instance LE 75
322 -All versions ~30

352/353 -All versions with DCS 12 261 (B352) / 138 (B353)

(Compressor with 15l/s (352) / 24l/s (353) or
better is recommmended, for instance LE 75 )
COP 1638 P/N
For URE (Underground), COP 1638 has now following P/N

 8311 1249 53 COP 1638 T38E 07

 8311 1249 54 COP 1638 R38 05
 8311 1249 55 COP 1638-T38-05
 8311 1249 56 COP 1638-T38-07
 8311 1249 57 COP 1638 R38-05 AW
 8311 1249 58 COP 1638 T38-05 AW
 8311 1249 61 COP 1638 R32E-07
 8311 1249 62 COP 1638 R32-05
AW-version (Aggressive Water) is an alternative when the
flushing water causes excessive corrosion. See the following
slides
COP 1638
-Repowering

Andreas Nordbrandt / RD, 2004-08-17

Repowering instruction COP 1638
This Repowering instruction, includes:
•Why COP 1638 repowering?
•Targeted repowering rigs (AC)
•COP 1638 P/N available
•Pricing
•Installation of damper oil supply kit
•Hose connections
•Tightening torques
•Setting instructions
•COP 1638 Functional description
•COP 1638 Dimension sketch
What do we mean by Repowering?

4 Change of Rock Drill on customers rig, no matter origin

manufacturer

4 Change the Rock Drill on an Atlas Copco rig

All in order to improve the performance of the rig!!

Today Tomorrow?
Why Repowering at all?
From the Customers point of view
4 Change of drilling conditions (hole diameter, work site etc)
4 Having low penetration rate
4 Increased (or average high) drill steel and service costs
4 Facing reduced MTBF (Mean Time Between Failure)

From the SC´s point of view

4 High Gross Profit on the product (sale of separate Rock
Drill)
4 Increased turn over
4 Increased sales of spare parts
4 (Better?) contact with the customer for future sales
4 Other opportunities such as drill steel and spare parts
contracts
COP 1638 is suitable to replace COP 1238 ME.

- WHY so?

- Developed from COP 1838 ME and has therefore ”COP 1800 technique”.
- Drills faster than COP 1238ME and provides better drill tool life
- In about 4 hrs, the COP 1638 can be run
COP 1638 is suitable to replace COP 1238 ME.
- WHY so?
 COP 1638 can be used on 45 kW power pack, which is standard
with COP 1238 ME Underground
 ”COP 1800 technique”, giving following benefits vs COP 1238
− Double damper => longer drill tools life
– Pressurized mating surfaces => longer service life on parts
– Aggressive water (”stainless steel”) front head optional
− Minimized risk of water inside the drill
− Longer service life on drill housing
− Longer service life on front guide

 There is a big repowering potential with high profitability

– Replacing a COP 1238 ME on an Atlas Copco rig only takes 4h,
only the damper supply circuit has to be added. Such kits are
available
– Replace HL 500/510 on Tamrock Face drilling rigs

 From case to case, AC must help the customer to evaluate the

benefits and estimate the pay-off time
Suitable rigs/recommendations replacing COP 1238 with COP 1638

BOOMER REMARK / RECOMMENDATION MANUF. VOLUME

195 -All versions Compressor with 24 l/s or 25-30 in operation
better is recommended (Japan)
281 -BMH 2000 recommended >160 (not incl. RB 281)
-DCS 12-45 kW required Not all rigs fulfil the
-Water pump CR4 or better recommended recommendations (~25%
-Compressor with 8 l/s or better is or ~40 units have)
recommended, LE 55 for instance

282 -BMH 2000 is recommended >300 (not incl RB 282)

-DCS 12-45 kW is required Not all rigs fulfil the
-Water pump CR4 or better is recommendations
recommended (~25% or 75 units have)
-Compressor with 15 l/s or better is
recommended, for instance LE 75
322 -All versions ~30

352/353 -All versions with DCS 12 261 (B352) / 138 (B353)

(Compressor with 15l/s (352) / 24l/s (353) or
better is recommmended, for instance LE 75 )
Flow requirements for COP 1638

Impact pressure available, recommended [bar] 210

(at the pump)

Impact flow required [l/min] 75

Rotation flow recommendation [l/min] 75
Rotation pressure available min [bar] 80
Damper flow available [l/min] 8-10
Damper supply pressure, min [bar] 130
Assembly instruction

 Install the damper supply kit P/N 9106 1826 20. Follow the
hydraulic drawing 9106 1826 23 enclosed. Note, it is a general
drawing
 Connect the constant flow regulator, 3217 9193 01, close to the
main pump.
 Connect the dampening gauge, at the operator.
 Connect all hoses according to the hydraulic drawing.
 Adjust the damper, same procedure as COP 1838, accumulator
and regulator according to the enclosed instructions.
Installation of damper supply kit - Preparation

 Use the hydraulic kit 9106 1826 20, suitable for replacement of COP 1238 on
Boomer 281 or 282, drilling system DCS 12 – 45 kW.

Kit P/N 9106 1826 20, included parts:

 P/N Part Qty.

 9106 1826 23 DRAWING 1
 3217 9193 01 REGULATOR 1
 3177 3032 00 PRESSURE GAUG 1
 3177 3070 00 NIPPLE 1
 9106 1300 03 ATTACHMENT 1
 0147 1247 03 SCREW, HEX HE 2
 0301 2321 00 PLAIN WASHER 2
 0291 1128 15 LOCK NUT 2
 3176 6126 00 PLATE 1
 9106 1826 21 HOSE SET 1
 9106 1826 22 NIPPLE SET 1
Principal schematic, damper oil supply
Start to assembly the constant-flow valve, 3217 9193 01, find a suitable place close

to the pump or the operator.

Regulator
Assembly the damper pressure gauge, 3177 3032 00, find a suitable place close to
the operator.
Assembly the COP 1638 on the existing COP 1238 cradle, ensure that the bolts are
correctly righted and correct in length.
Note, rear right bolt is longer than standard for COP 1238.
Use bolt 0147 1483 03, M6S 16x70 – 8,8 Fzb.
COP 1638 hose connections
Assembly the extra hoses for the dampening function, note that the hose set, 9106 1826 21,
may have to be complemented with other hoses due to different feed lengths.
COP 1638 tightening torques
COP 1638 tightening torques
Important !!
Important !
COP 1638 - Recommended initial settings
COP 1638 – Printed matters
Following printed matters can be found in the PMI-database