Haldex GeminiMDx Manual

INSTALLATION/SERVICE
MANUAL
High Capacity Dual Dryer System
®

DUAL DRYER SYSTEM
INSTALLATION/SERVICE
MANUAL (L31279)
®
General
This manual has been designed to assist personnel
in satisfactory installation, maintenance and
troubleshooting of the Haldex GeminiMDx High
Capacity Dual Air Dryer System. The intention
has been to provide guidance on certain aspects
of the product. It is expected that this manual
will be in possession of the appropriate person
throughout the install, maintenance and/or
troubleshooting process.
Safety and Important Precautions
• All company and vehicle manufacturer’s safety
procedures must be followed when installing
the GeminiMDx Dryer.
• Always wear proper personal protective
equipment, including approved eye glasses.
• Never work on or under a vehicle unless it is
parked on a level surface and its wheels are
blocked to prevent it from moving.
• Never work on a vehicle air brake system
when the engine is running. Where
circumstances require that the engine be in
operation, extreme caution should be used to
prevent personal injury resulting from contact
with moving, rotating, leaking, heated or
electrically charged components.
• Drain all air pressure from the air system
before beginning any installation, service or
repair.
• Never connect or disconnect a hose or
line containing pressure. Never remove a
component plug unless it is certain that all
system pressure has been depleted.
• Never exceed recommended component or
system pressures.
• Do not attempt to install, remove,
disassemble or assemble a component until all
recommended procedures have been read and
are fully understood. Use only the proper tools
and observe all precautions pertaining to the
use of those tools.
• Components with stripped threads or
damaged parts should be replaced rather
than repaired. Repairs requiring machining
or welding should not be attempted unless
specifically approved and stated by the
vehicle or component manufacturer.
• Prior to returning the vehicle to service,
make certain all components and systems are
restored to their proper operating condition.
Mounting and Installation Precautions
• The GeminiMDx uses a 4-bolt mounting
pattern. See “Dimensions and Port
Identification” on Page 8.
• If the GeminiMDx is to be bolted directly to
the frame or other support member, check
the vehicle manufacturers recommendations.
• At a minimum use grade 5, 1/2” bolts and
nuts.
• The GeminiMDx must not incline in any
direction more than 15° from vertical.
• Mount in a space to avoid excessive heat
sources (175°F maximum).
• Mount with the exhaust port oriented
downward.
• Mount in an area where it is protected from
wheel or road splash.
Replacement Parts/Retrot Components
Use appropriate spare parts documentation
when obtaining spare parts. Only use Genuine
Haldex replacement parts in the repair process.
See a complete listing on Page 15.
Questions?
If you have any questions on this product or
any of the innovative products offered by
Haldex, contact your local distributor for
complete details. Technical Service or
Troubleshooting help can be obtained by
calling Haldex Technical Services Department
at 800.643.2374, follow prompts.
Important Notices
DUAL DRYER SYSTEM
INSTALLATION/SERVICE
GUIDE (L31279)
®

DUAL DRYER SYSTEM
INSTALLATION/SERVICE
MANUAL (L31279)
®
Table of Contents
GeminiMDx Manifold Dual Dryer (high-capacity air drying system)
GeminiMDx Overview ......................................................................................................... 2
GeminiMDx Anatomy.......................................................................................................... 2
Pre-Treatment
Consep (condenser/separator) Overview ........................................................................... 3
Consep (condenser/separator) Anatomy/Function ............................................................ 3
Automatic Drain Valve (ADV) Function ............................................................................. 3
Drying
DRYest Air Dryer Overview ................................................................................................. 4
DRYest Air Dryer Anatomy.................................................................................................. 4
Cartridge Canister ............................................................................................................... 4
Air Dryer Base...................................................................................................................... 4
Valve Unit............................................................................................................................. 4
Charging Phase.................................................................................................................... 5
Unloading Phase.................................................................................................................. 5
Regeneration Phase ............................................................................................................ 5
Cut-In.................................................................................................................................... 5
System Specifications ................................................................................................................ 6
Torque Specifications................................................................................................................. 6
Plumbing Schematics
Pre-Treatment and Drying .................................................................................................. 7
Drying Only.......................................................................................................................... 7
Dimensions and Port Identification.......................................................................................... 8
Electrical Diagrams
Dual Consep 12/24V Non-Heated Without Relay ............................................................. 11
Dual Consep 12/24V Heated With Electrical Relay or Timer Relay.................................. 11
Electrical Relay.................................................................................................................... 11
Timer Relay ......................................................................................................................... 11
Air Dryer Heater ................................................................................................................. 11
Operational Check .................................................................................................................... 12
Troubleshooting........................................................................................................................ 13
Suggested Maintenance Schedule........................................................................................... 14
GeminiMDx Part Number/Description Listing ........................................................................ 15
Replacement Parts/Retrofit Components................................................................................ 15
Service Kit Components Identification.................................................................................... 16
Service Kit Contents.................................................................................................................. 17
Removal/Installation Instructions
GeminiMDx......................................................................................................................... 18
Cartridge Canister .............................................................................................................. 18
Valve Unit with Integrated Purge Valve ........................................................................... 19
12/24 VDC Heater Assembly............................................................................................... 20
Outlet Check Valve Assembly ............................................................................................ 21
Turbo-Protection Valve (TPV)............................................................................................. 21
Cyclone Insert ..................................................................................................................... 22
Glossary ..................................................................................................................................... 23
©2019 All Rights Reserved
Material may only be reproduced with the written permission of Haldex.
Section Page
The products described within this literature, including without limitation, product features, specifications, designs, availability and pricing are subject
to change by Haldex and its subsidiaries at any time without notice. This document and other information from Haldex, its subsidiaries and authorized
distributors provide product and/or system options for further investigation by users having technical expertise. It is important that you analyze all aspects
of your application and review the information concerning the product or system, in the current literature or catalog. Due to the variety of operating
conditions and applications for these products or systems, the user, through their own analysis and testing, is solely responsible for making the final
selection of the products and systems and assuring that all performance, safety and warning requirements are met.
Page 1
DUAL DRYER SYSTEM
INSTALLATION/SERVICE
GUIDE (L31279)
®

DUAL DRYER SYSTEM
INSTALLATION/SERVICE
MANUAL (L31279)
®
DUAL DRYER SYSTEM
INSTALLATION/SERVICE
GUIDE (L31279)
®
Page 2
GeminiMDx Overview
In its most basic form, the GeminiMDx dual dryer is
the connection of two DRYest Air Dryers in parallel to
treat the compressed air produced by high capacity air
compressors. The GeminiMDx is a desiccant type dryer
that removes moisture and contaminants from the
compressed air before entering the air brake system.
A variant of the GeminiMDx includes a single or
dual Consep (Condenser/Separator) to pre-treat the
compressed air before entering the air dryers and
extend the life of the air dryer’s desiccant cartridge.
GeminiMDx Anatomy
The GeminiMDx consists of the following major
components: Dryest® air dryers, inlet/outlet manifolds,
control/purge manifolds, banjo bolts, sealing washers
and one or two Consep units (optional).
Dual Conseps [1]
The two Conseps are identical. They condense and
separate contaminants from the compressed air. The
Automatic Drain Valve (ADV), will drain the condensed
liquid and separated contaminants.
Dual DRYest Air Dryers [2]
The two dryers are identical. They each contain a
desiccant cartridge, turbo protection valve, purge
valve, safety valve, outlet check valve and heater.
GeminiMDx Manifold Dual Dryer
[1] [2]
[3]
[4]
[6]
[7]
[5]
Cast Aluminum Manifolds [3,4,5]
The manifolds provide a single connection for inlet/
outlet, control and purge air line connections and
parallel flow to and from each Consep or air dryer.
Sealing Washers [6]
The sealing washers provide leak-free joints between
the banjo bolts, manifolds and air dryers.
Banjo Bolts [7]
The banjo bolts secure the manifolds to the air dryers
and are hollow with cross-drilled passages to allow air
to flow to/from the manifolds to the air dryers.

DUAL DRYER SYSTEM
INSTALLATION/SERVICE
MANUAL (L31279)
®
DUAL DRYER SYSTEM
INSTALLATION/SERVICE
GUIDE (L31279)
®
Page 3
Consep Overview
The Consep consists of a condenser/separator and a
Automatic Drain Valve (ADV). The condenser/separator
will condense and separate contaminants from the
compressed air. The drain will expel condensed liquid
and separated contaminants. When it is installed and
adequately cooled, the Consep will extend the life of
the desiccant cartridge.
Consep Anatomy/Function
The compressed air is led into the Consep at the inlet
port on the side of the Aluminum Housing [1]. The
compressed air passes between the housing wall and
the Cyclone Insert [2]. The shape of the cyclone forces
the compressed air to rotate. The centrifugal effect
which occurs when the air rotates around the cyclone
forces the water and contaminants to the housing
wall. At the base of the cyclone, the compressed air
is directed upwards through the cyclone interior and
out via the outlet port at the top of the housing.
Water and contaminants which have been condensed
and separated flow downwards through a Filter [3]
and are collected in the sump of the Automatic Drain
Valve (ADV) [4]. The liquid contaminants collected in
the ADV are drained when the Shuttle [5] is lifted via
electrical activation of the Solenoid Coil [6].
Automatic Drain Valve (ADV) Function
Pre-Treatment
When air pressure is present and NO
electrical power, the Shuttle [5] is
forced against the lower seat. The
entry to the sump is open to receive
liquid contaminants.
With electrical power, the Solenoid
Coil [6] generates a magnetic field
which pulls the shuttle against the
upper seat. This closes the entry
to the sump and drains liquid
contaminants collected in the sump.
To manually drain the ADV, push the
Red Manual Drain Button [7] to
activate drainage. This function
only works if the ignition is off
and the unit is pressurized.
[1]
[2]
[3]
[6]
[4]
[5]
WET TANK
PURGE TANK
GOVERNOR
COMPRESSOR
1/4”-18 NPTF
3/4”-18 NPTF 3/4”-18 NPTF
Pre-Treatment
OUTLET
INLET
EXHAUST
[5] [6] [7]

DUAL DRYER SYSTEM
INSTALLATION/SERVICE
MANUAL (L31279)
®
DRYest Air Dryer Overview
The Haldex DRYest is a desiccant type dryer that
effectively collects and removes moisture, oil and
contaminants before they enter the compressed air
system. The DRYest provides filtered, moisture free
air to the brake system which reduces freezing and
corrosion of the components in the air system.
Anatomy
The DRYest contains three major parts: Cartridge
Canister [1] with five stages of drying, Air Dryer Base [2]
and Valve Unit [3].
Cartridge Canister [1]
The Cartridge Canister [1] is where drying and
contaminant removal occurs in the air dryer. The
GeminiMDx Dual Dryer contains the Haldex patented
MTC+ cartridge design which has five stages of drying.
The desiccant cartridge is contained by the canister
and affixed to the dryer base with an o-ring, mounting
collar and four bolts.
Air Dryer Base [2]
The Air Dryer Base [2] connects the Cartridge Canister
[1] and the Valve Unit [3]. The base has connections
for the inlet, outlet and purge reservoirs. The base also
contains the following components:
• Safety Valve [2.1]
• Outlet Check Valve [2.2]
• Turbo-Protection Valve (TPV) [2.3]
• Heater Element [2.4]
Valve Unit [3]
The Valve Unit [3] attaches to the Air Dryer Base [2]
with six screws and contains the purge valve. The Valve
Unit [3] has a control port for external air governor
connection and includes a muffler style or drain tube
style purge outlet.
Drying
Page 4
WET TANK
PURGE TANK
GOVERNOR
COMPRESSOR
OPTIONAL
PRE-TREATMENT
[1]
[2.3]
[2.4]
[2.2]
[3]
[2.1]
[2]

DUAL DRYER SYSTEM
INSTALLATION/SERVICE
MANUAL (L31279)
®
DRYest Function
Charging Phase
Air from the compressor or pre-treatment flows into
the inlet manifold and divides to enter each air dryer.
Once the inlet air pressure is greater than the TPV
[2.3] opening pressure, the air enters each Desiccant
Cartridge [1]. The air first passes through an aluminum
Inlet Filter [1.1] in the cartridge, which traps droplets
and solid particles.
The air continues traveling through several sections of
Desiccant [1.2] [1.3] [1.4], each section with increasing
sizes of desiccant, to capture contaminants. Once the
air passes through the cartridge the remaining water
and oil molecules will be captured.
As the air exits the cartridge, it passes through an
Outlet Filter [1.5], through an Outlet Check Valve
[2.2] and finally reaches the outlet manifold where it
combines with the outlet air of the second dryer.
A small portion of air from the cartridge passes to the
purge manifold where it combines with air from the
other dryer and exits the purge manifold to fill an
external purge reservoir.
Unloading Phase
When the air brake system pressure reaches the cut-
out setting of the air governor, the output of the air
governor passes to the air compressor unloader to stop
the air compression and passes to the purge valve of
each dryer via the control manifold. The purge valve
opens to atmosphere and depressurizes the air dryer.
The turbo protection valve (TPV) will close once the
inlet air is below 35 psi. The regeneration cycle will
begin. The outlet check valve will close, preventing the
back flow from the system.
Regeneration Phase
During the unloading phase, a regeneration cycle
(desorption) will remove the contaminants. Since the
cartridge is depressurized, air from the external purge
reservoir will flow back to the dryer, pass through the
purge manifold to the desiccants, collect the captured
contaminants and drain to the atmosphere via the
purge valve and silencing unit. The regeneration
cycle or purge cycle will continue until the purge
reservoir air pressure depletes to 0 psi. This will last
approximately 30 seconds. The purge valve will remain
open until the brake system decreases to the air
governor cut-in setting.
Cut-In
As air is consumed by the brake system, the air pressure
decreases until the air governor cut-in pressure is
achieved. At cut-in pressure the air governor closes,
its output air exhausts to atmosphere, the unloader
valves of the dryer close and the compressor begins to
compress air. A new charging phase begins.
Drying (cont’d)
Page 5
Charging Phase
Unloading Phase
Control Port
Purge Port
Outlet
Port
Inlet
Port
[1.4]
[1.3]
[2.3]
[1]
[1.2]
[1.1]
[1.5]
[2.2]
Purge
Port

DUAL DRYER SYSTEM
INSTALLATION/SERVICE
MANUAL (L31279)
®
System Specications
Dual Consep and
Dual Dryer
Dual Consep
Only
Dual Dryer
Only
Weight 53 lbs.
(with mounting bracket)
11 lbs. 40 lbs.
Envelope 20”W x 15”H x 12”D 6”W x 12”H x 8”D 14”W x 13”H x 10”D
Inlet/Outlet Ports 3/4” - 14 NPT 3/4” - 14 NPT 3/4” - 14 NPT
Control Port 1/4” - 18 NPT n/a 1/4” - 18 NPT
Purge Port 1/4” - 18 NPT n/a 1/4” - 18 NPT
Max. Working Pressure 150 PSIG 150 PSIG 150 PSIG
Safety Valve 160 PSIG n/a 160 PSIG
Turbo Protection Inlet Required 35 PSI n/a 35 PSI
Ambient Temperature -40°F - +176°F -40°F - +176°F -40°F - +176°F
Maximum Inlet Air Temperature +176°F +176°F +176°F
Recommended Inlet Air Temperature +40°F - +150°F +40°F - +150° +40°F - +150°
Air Flow Capacity 70 SCFM 70 SCFM 70 SCFM
Minimum Purge Volume 600 in.3n/a 600 in.3
Compressor Unloaded Time 30 seconds n/a 30 seconds
Maximum Duty Cycle 25% n/a 25%
Automatic Drain Valve 24VDC/1.0A
12VDC/2.0A
24VDC/1.0A
12VDC/2.0A
n/a
Heater Element n/a n/a 24VDC/4.0A
12VDC/8.0A
Heater Thermostat Operating Range n/a n/a Closes 45° ± 7°F
Opens 71° ± 6°F
Heater Element Resistance n/a n/a 12VDC:1.4-1.8 W
24VDC: 5.9-6.9 W
Drain Capacity n/a 1.3cc per ADV/Operation n/a
Drain Options n/a Swivel Tube, Open Muffler, Tube
Torque Specications
Consep Mounting Bolts to Bracket .........................................6-11 ft-lbs (Tighten Bolts in Cross Pattern)
Dryer to Bracket: .....................................................................35-50 ft-lbs
Consep Inlet and Outlet Manifold M22 Banjo Bolts ...............45-55 ft-lbs
Dryer Inlet and Outlet Manifold M22 Banjo Bolts ..................45-55 ft-lbs
Dryer Control and Purge Manifold M12 Banjo Bolts...............130-150 in-lbs
ADV Mounting Nuts to Consep ...............................................80-98 in-lbs
Heater Retaining Screw...........................................................45-55 in-lbs
Turbo Protection Valve ............................................................45-55 ft-lbs
Check Valve Plug .....................................................................84-94 in-lbs
Valve Unit Bolts .......................................................................62-80 in-lbs
Cartridge Canister Bolts..........................................................32-35 ft-lbs
Page 6

DUAL DRYER SYSTEM
INSTALLATION/SERVICE
MANUAL (L31279)
®
Plumbing Schematics
Page 7
Pre-Treatment and Drying
Drying Only
WET TANK
PURGE TANK
GOVERNOR
COMPRESSOR
1/4”-18 NPTF
3/4”-14 NPTF 3/4”-14 NPTF
WET TANK
PURGE TANK
GOVERNOR
COMPRESSOR
OPTIONAL
PRE-TREATMENT
1/4”-18 NPTF
3/4”-14 NPTF

DUAL DRYER SYSTEM
INSTALLATION/SERVICE
MANUAL (L31279)
®
Page 8
Dimensions and Port Identication
Dual Consep Assembly