Haldex GeminiMDx Handbuch

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

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

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