Haltech NEXUS PD16 User manual

1
QUICK START GUIDE

3
NEXUS PD16 OVERVIEW
2
Features
• 10 x 8A High Side Outputs
• 2 x 8A Half Bridge Outputs
• 4 x 25A High Current Outputs
• 8 x Inputs + Dedicated Ignition
Switch Input
• Power for Ignition Switch
• Integrated into Haltech
CAN Bus Network
• 5V Sensor Supply /
Sensor Ground
• 120A Surlock Connector
The NEXUS PD16 is Haltech’s new power
distribution product. Boasting new, innovative
yet user-friendly technology, it sets a new market
standard for power distribution systems.
Designed to integrate seemlessly
into your existing Haltech Elite
or Nexus engine management
system, the PD16 ensures safe,
dependable power delivery to
your vehicle.
NEXUS PD16 OVERVIEW
NEX-US [noun]
– a connection or series of connections
linking two or more things.
– a connected group or series
– the central or most important point or place
What’s in the box?
• Nexus PD16 Power Distribution Module
• 1 x SurLok Connector (Red) 120A
• USB-C Dust Cap
• Quick Start Guide
• USB Key
• Mounting Hardware (2 x Bolts / Nuts)
• USB-C Cable
• Haltech Product Catalogue
Optional Accessories (sold separately)
• 5m Flying Lead Harness. HT-188000
• PD16 Tube Mount Kit 1.25”
HT-039080
• PD16 Tube Mount Kitt 1.625”
HT-039082
• Plug and Pins Set, 34-Pin Keyway 1. HT-030009
• Plug and Pins Set, DTP06-4s, Black 25A.
HT-031201
• Replacement 120A Red Surlock Connector.
HT-030032
• Manual Cable Lug Crimping Tool. HT-070305
• Hydraulic Cable Lug Crimping Tool.
HT-070306

45
1Power LED
2DTC LED
3WiFi LED
425A HCO LEDs
58A HBO LEDs
68A HCO LEDs
7Battery Positive Stud
8USB-C Port (Firmware update only)
9Superseal 34-pin Connector
10 DTP4 Connector
11 Mounting Holes
NEXUS PD16 OVERVIEW
11 11
1 3 4 5 6
2 7
8 9
10
OUTPUTS
Power for Ignition Switch 1
Half Bridge Outputs (HBO) 2
8A High Current Outputs (8A HCO) 10
25A High Current Outputs (25A HCO) 4
INPUTS
Analog Voltage Inputs (AVI) 4
Synchronised Pulsed Inputs (SPI) 4
Ignition Switch Input 1
OTHER
5V Sensor Supply 1
Sensor Ground 1
COMMUNICATIONS
CAN Bus Network 1000 kbit/s 1
Full Speed USB (Firmware upgrade only) 1
ELECTRICAL
Power Supply (across power terminals) 8 to 20V
No output static current draw <200mA
Low Power Mode (USB) 4 to 5.5V
Static current draw from USB port 100mA
SurLok Connector Rating 120A (85°C) with 25sqmm (4 AWG)
DIMENSIONS
Enclosure 160 x 42 x 93.5 mm (6.3 x 1.7 x 3.7 in)
(Not including connector protrusion)
Overall 160 x 42 x 110 mm (6.3 x 1.7 x 4.3 in)
(Including connector protrusion)
Weight 0.49 kg (1.080 lb)
Operating Temperature (external) -40 to 85°C (-40 to 185°F)
Onboard Temperature Sensing Zones 5
NEXUS PD16 SPECIFICATIONS

67
Installing the software
1. Insert the supplied USB Key into your PC. If
you have lost your USB key, you can download
the Haltech NSPsoftware from the DOWNLOADS
section of the Haltech website.
NOTE: You must have the latest version of NSP
loaded on your computer.
2. If the window does not open automatically, open
My Computer and find the USB drive. Double click
on the USB drive icon.
3. Double click on the installer icon located in the
root directory of the USB drive.
4. Once the Haltech NSP software is installed,
connect your laptop to the ECU via a USB cable,
and your ECU to the PD16 via a Haltech CAN cable
and run the software (see Diagram 1).
5. The latest version of NSPwill recognise the
PDM automatically. You will see PD16 listed in the
main menu tree (see Diagram 2).
6. Enable the PD16 in the Haltech CAN System
setup page.
7. You are now ready to configure your PD16
connections in Input/Output menu (see Diagram 3).
Installing the PD16
There are several ways of installing a PD16 into
your system.
The installation method will depend on whether
you are wiring it into an existing system and using
the PD16 to power your ECU, or using the PD16 as
a peripheral power supply with an Elite or Nexus
VCU.
We have provided diagrams for the most common
types of installations. They are meant to be used
as guides only as all installations are different and
specific to the car/engine/existing wiring.
It’s always a good idea to consult a qualified auto
electrician before attempting to install any engine
management components, especially If this is your
first installation.
Wiring the PD16
To function correctly, the Haltech Nexus PD16
must be connected to battery positive and battery
negative at all times. It’s important to use correct
gauge cables when connecting the Nexus PD16 to
the battery terminals.
Connect the Nexus PD16 to the positive battery
terminalvia the supplied RED SurLok connector
using 4AWG cable.
Connect the Nexus PD16 to the negative battery
terminal via 18AWG wire(s) on Connector A - Pins
31, 32, 33 and 34.
HALTECH CAN
USB
NEXUS PD16 INSTALLATION Diagram 1
Diagram 2
Diagram 3
FUSE
A31-34A31-34
A13
IGNITION
SWITCH
IGNITION
SWITCH
A26
A13
HCO1
+12V
TO
HALTECH
ECU
HCO1
+12V
TO
HALTECH
ECU
Master Power Mode - New install
Power Wiring using Pins A13 and A26.
Master Power Mode - Existing Install
Power wiring with an existing ignition switch
already in place.
There are two possible modes of operation;
“Master Power Mode” and “Peripheral Power
Mode”. The key difference is in the function of the
A25 CAN 12V pin. In the Master mode, the PD16
powers first, triggering the PDM to provide 12V to
Pin A25 to power the CAN bus. In Peripheral mode,
the Nexus VCU provides 12V to Pin A25, thus
powering up the PD16 after.
Master Power Mode
In this mode the PD16 controls the main power
supply to the ECU (common on Elite ECU
applications).
Ensure PD16 has battery power and ground. The
ignition switch can be a simple switch connecting
Pins A13 (Ign. Switch Input) and A26 (Low Current
Constant 12V) together. This will power the PD16
once the switch is closed.
NOTE: Ensure there are no other connections to
Pins A13 and A26.
In this mode, the PD16 will provide 12V to the CAN
bus network via Pin A25 (HCO1)as shown in the
diagram on page 10.
This can be used to power an Elite ECU. If the
installation has a switched positive signal (from an
OE Ignition Switch), it can be connected directly to
A13 (Ign. Switch Input).
Pin A26 (Low Current Constant 12V) can be
removed from the harness in this scenario.

89
MOUNTING TEMPLATE
MOUNTING TEMPLATE

10 11
A31-34
HALTECH CAN
Half Bridge Outputs (HBO)
Half Bridge Outputs are push-pull, pulse width
modulated (PWM) outputs. If not being used as
push-pull drivers, Half Bridge Outputs can be
used as generic high/low PWM outputs capable
ofsinking 8A to ground and driving 8A to 12V up
to 2.2kHz.
HBOs can be used to control any push-pull type
device when used as generic high/low switched or
PWM outputs.
Half Bridge Outputs can be used as generic low-
side DPOs or to control devices such as high-side
driven solenoids, high side switched automatic
transmission solenoids, etc.
Specs:
• Overcurrent and Overtemperature Protection
• 0 to 27V voltage feedback
• High side current feedback
• Capable of 0-100% duty cycle
• 2.2kHz switching speed
ELECTRIC WATER PUMP
HBO1
GROUND
HBO 1
HBO 2
VAREX ACTUATOR
In this mode the PD16 acts as a
peripheral device to provide the ECU
additional I/O (common on Nexus VCU
applications). The PD16 is switched on
and off via CAN power connection.
Ensure PD16 has battery power and
ground. The ignition switch will be
ignored, meaning pins A13 (Ign. Switch
Input) and A26 (Low Current Constant
12V) will not be used.
Connect the CAN power output from
your ECU or VCU directly to Pin A25
(CAN +12V “Wake-Up”) on the PD16.
This can be done using a standard
Haltech CAN cable as shown in the
diagram above.
NEXUS PD16 WIRING
HALTECH CAN
IGNITION
SWITCH
A26
A13
HALTECH
CAN
HALTECH CAN
IGNITION
SWITCH
A26
A13
Elite 550,750,950,VMS (Single Connector) wiring in “Master Power” Mode.
Elite 1000,1500,2000,2500 (Twin Connector) wiring in “Master Power” Mode.
Refer to PD16 Wiring Diagram for more details wiring instructions.
Peripheral Power Mode (Voltage Sense)
HALTECH CAN
HALTECH CAN
CAN HUB
O2 WB KEYPAD
iC-7 DASH
Haltech CAN Expansion
Typical multi-device Haltech
CAN network installation using
CAN Hub where PD16 powers
the ECU.

12 13
8A High Current Outputs (8A HCO)
The Nexus PD16 features 10 high side outputs
capable of driving 8A to 12V. Each output has a
software programmable fuse current.
Once the electronic fuse blows the output turns
off for a software programmable delay duration,
before reactivating the output.
Use the NSP software to define the maximum
number of retries before the output is deactivated
untilthe next power cycle. The PD16 LEDs display
the output state.
8A HCOs are PWM capable and can be used
to power CAN devices or solenoids as well as
transmission shift solenoids, water pumps, etc.
Specs:
• Automatic overcurrent protection
• Flyback protected
• 0 to 30V voltage feedback
• High side current feedback
• 100Hz max switching speed
• Capable of 0-100% duty cycle
25A High Current Outputs
The four high/low outputs on the Nexus PD16
are capable of sinking 25A to ground and driving
25A to 12V. Each output has a programmable fuse
current, slow-start current and duration.
Once the electronic fuse blows the output turns
off for a pre-programmed delay duration before
reactivating the output. The PD16 LEDs display the
output state.
25A HCOs are PWM capable and can be used for
ignition power and injector power as well as to
PWM thermofans and fuel pumps etc.
Specs:
• Automatic overcurrent protection
• Flyback protected
• 0 to 30V voltage feedback
• High side current feedback
• 1kHz max switching speed
• Capable of 0-100% duty cycle
ELECTRIC WATER PUMP
8A HCO
GROUND
25A HCO
TO GROUND
THERMOFAN
Example 25A HCO Wiring Connections
Example 8A HCO Wiring Connections
NEXUS PD16 WIRING Analog Voltage Inputs (AVI)
Analog Voltage Inputs accept variable voltage
signals from 0V to +5V such as signals from
pressure, temperature and fuel level sensors.
These inputs can also accept switched inputs that
change between two different voltage levels.
The On Voltage and Off Voltage define what the
thresholds are between the on and off states.
The voltage can be viewed as a channel in NSP to
determine the thresholds for a switched input.
Common examples of switched inputs include A/C
Request switch and intercooler spray switch.
AVIs have a software selectable 1K pull-up
resistor to 5V, which can be enabled or disabled
within the Setup page.
Pull-up resistors are generally enabled for
temperature related sensors and switched to
ground inputs.
Specs:
• 0 to 5V
• 100 samples per second
• Selectable 1k pull-up to 5V
• -10 to 30V indefinite withstand
• 1.5kHz signal frequency max
• AVI-1 has a switchable 240Ω pull up that allows
direct connection with fuel level sender input.
AVI
AVI
SIGNAL
GROUND
SIGNAL
GROUND
SENSOR
+5V
TEMPERATURE
SENSOR
ROTARY TRIM MODULE
HT-010504
AVI
AVI
SIGNAL
GROUND
SIGNAL
GROUND
SENSOR
+5V
TEMPERATURE
SENSOR
ROTARY TRIM MODULE
HT-010504
Pull-up resistors are generally enabled for
temperature related sensors and switched
to ground inputs. The following configuration
requires the pull-up resistor be enabled.
NOTE: AVI-1 has 1k or 240Ω pull up options for
fuel level sensors.
For in-depth product overviews,
step-by-step set up guides, software
walk-throughs and tech tips go to
the Haltech YouTube channel.
SCAN ME 
Sensors with a +5V supply do not require the pull-up
resistor be enabled, for example, rotary trim modules.
Any Sensor +5V pin can be used with any Signal Ground
pin for sensors.

14 15
NEXUS PD16 WIRING
At Haltech we make every eort to design and manufacture fault-free products
that perform up to or above the market expectations. All our products are covered
by a Limited 12 Month Warranty.
Haltech Limited Warranty
Unless specied otherwise, Haltech warrants its products to be free from defects in material or
workmanship for a period of 12 months from the date of purchase.
If the Haltech product is found to be defective as mentioned above, it will be replaced or repaired
if returned prepaid along with proof of purchase. Proof of purchase in the form of a copy of the
original purchase invoice, receipt or bill of sale which indicates that the product is within the
warranty period, must be presented to obtain warranty service.
Replacement or repair of a defective product shall constitute the sole liability of Haltech. To
the extent permitted by law, the foregoing is exclusive and in lieu of all other warranties or
representations, either expressed or implied, including any implied warranty of merchantability or
tness. In no event shall Haltech, be liable for special or consequential damages.
Product Returns
Please include a copy of the original purchase invoice, receipt or bill of sale along with the
unused, undamaged product and its original packaging. Any product returned with missing ac-
cessory items or packaging will incur extra charges to return the item to a re-saleable condition.
All product returns must be sent via a freight method with adequate tracking, insurance and proof
of delivery services. Haltech will not be held responsible for product returns lost during transit.
Returns of Products Supplied in Sealed Packaging
The sale of any sensor or accessory supplied in sealed packaging is strictly non-refundable
if the sealed packaging has been opened or tampered with. This will be clearly noted on the
product packaging. If you do not accept these terms please return the sensor in its original un-
opened packaging within 30 days for a full refund.
A sensor or accessory product may be returned after 30 days of purchase (with its sealed pack-
aging in tact) for credit only (no refunds given) and will be subject to a 10% restocking fee.
Installation of Haltech Products
No responsibility whatsoever is accepted by Haltech for the tment of Haltech Products. The
onus is clearly on the installer to ensure that both their knowledge and the parts selected are cor-
rect for that particular application. Any damage to parts or consequential damage or costs result-
ing from the incorrect installation of Haltech products are totally the responsibility of the installer.
Always disconnect the battery when doing electrical work on your vehicle. Avoid sparks, open
ames or use of electrical devices near ammable substances. Do not run the engine with a
battery charger connected as this could damage the ECU and other electrical equipment.
Do not overcharge the battery or reverse the polarity of the battery or any charging unit. Discon-
nect the Haltech ECU from the electrical system whenever doing any welding on the vehicle by
unplugging the wiring harness connector from the ECU.
After completing the ECU installation, make sure there is no wiring left un-insulated. Uninsulated
wiring can cause sparks, short circuits and in some cases re. Before attempting to run the en-
gine ensure there are no leaks in the fuel system.
All fuel system components and wiring should be mounted away from heat sources, shielded
if necessary and well ventilated. Always ensure that you follow workshop safety procedures. If
you’re working underneath a jacked-up car, always use safety stands!
____________________________________________________________________________
Haltech O󰀨-Road Usage Policy
In many states it is unlawful to tamper with your vehicle’s emissions equipment. Haltech products
are designed and sold for sanctioned o󰀨-road/competition non-emissions controlled vehicles
only and may never be used on a public road or highway.
Using Haltech products for street/road use on public roads or highways is prohibited by law un-
less a specic regulatory exemption exists (more information can be found on the SEMA Action
Network website www.semasan.com/emissions for state by state details in the USA).
It is the responsibility of the installer and/or user of this product to ensure compliance with all
applicable local and federal laws and regulations. Please check with your local vehicle authority
before purchasing, using or installing any Haltech product.
WARRANTY CERTIFICATE
NEXUS PD16 WIRING
Synchronised Pulsed Inputs (SPI)
SPIs are capable of measuring the position, duty
cycle, frequency or state of a signal, as well as
analog voltage inputs. These inputs are suitable
for sensors such as fuel composition sensors, road
speed sensors and GPS Speed inputs.
SPIs are compatible with digital (hall effect or
optical) and reluctor (analog) based sensors, have
a maximum input voltage rating of 30V and can
measure up to 15KHz maximum frequency.
Specs:
• -0.5 to 12V digital input
• 0 to 5V analog input
• Selectable 1k pull-up to 5V
• -15 to 30V indefinite withstand
• 15.9kHz signal frequency max
SPI
SIGNALGROUND
HCO
FREQUENCY BASED FLEX FUEL SENSOR
TO OTHER
DEVICES
FLEX
FUEL SENSOR
FUEL SENSOR
Example SPI Wiring Connections
HT-011000
CAN Bus
The Nexus PD16 includes a single CAN bus. The
CAN Bus MUST be connected to a Haltech Elite
ECU or Nexus VCU for the PD16 to operate.
Specs
• 1000 kbit/s
• Selectable 120R termination
• -40 to 40V short protection
• Supports Haltech Elite and Nexus series ECUs

Haltech Australia
17 Durian Place, Wetherill Park
NSW 2164 Australia
Phone: [phone]
Email: [e-mail]
Haltech New Zealand
9B Weza Lane, Kumeu 0810 NZ
Phone: [phone]
Email: [e-mail]
Haltech USA East
750 Miles Point Way,
Lexington, KY 40510 USA
Phone: [phone]
Email: [e-mail]
Haltech USA West
Race Winning Brands,
10800 Valley View Street,
Cypress, CA 90630 USA
Phone: [phone]
Email: [e-mail]
Haltech Europe
Ottogasse 2A,
2333 Leopoldsdorf, Austria
Phone: [phone]
Email: [e-mail]
Haltech UK
Unit 1, Miras Business Estate, Lower Keys
Business Park,
Keys Park Road, Hednesford, WS12 2FS
Phone: [phone]
Email: [e-mail] facebook.com/HaltechEngineManagement youtube.com/haltechecu instagram.com/haltechecu
11/2022