Haltech Nexus IO16 Input/Output Expander

Haltech NEXUS IO16 Input/Output Expander with 2.6 m Universal Wire-In Harness

Part Number: HT-196200

The Haltech NEXUS IO16 expands a compatible Haltech NEXUS or Elite ECU with 16 additional user-configurable input and output channels connected through the Haltech CAN network.

The IO16 is useful when the ECU’s onboard channels have been consumed by additional pressure and temperature sensors, wheel- or driveshaft-speed inputs, switches, trim controls, boost-control hardware, auxiliary pumps, transmission functions, or other vehicle systems. Because the module communicates over CAN, it can be installed near the devices it controls rather than routing every circuit back to the ECU.

This version includes Haltech’s 8.5 ft. (2.6 m) universal wire-in harness, providing a fully terminated IO16 connector with labeled flying leads for custom installation.

Key Features

• Adds 16 user-configurable input and output channels
• Compatible with Haltech NEXUS-series ECUs and VCUs
• Compatible with supported Haltech Elite-series ECUs
• Communicates through the Haltech CAN network
• 6 analog-voltage inputs
• 4 synchronized pulsed inputs
• 6 bidirectional half-bridge outputs
• Half-bridge outputs support high-side and low-side switching
• Up to 8 A sink or source capability per half-bridge output
• Pulse-width-modulated output control from 0–100% duty cycle
• Output switching frequency up to 2.2 kHz
• Output-current and output-voltage feedback
• Overcurrent and overtemperature protection
• Regulated 5 V sensor-power connections
• Dedicated sensor-ground connections
• Supports up to 2 NEXUS IO16 modules per ECU
• Compact IP66-rated enclosure
• Includes a 2.6 m universal wire-in harness using TXL cross-linked polyethylene-insulated wire

Kit Includes

• HT-196000 — NEXUS IO16 16-channel input/output expander
• HT-180000 — NEXUS IO16 universal wire-in harness, 8.5 ft. (2.6 m)

Technical Specifications

• Supported controllers:
  • Haltech NEXUS-series ECUs and VCUs
  • Supported Haltech Elite-series ECUs
• Total user-configurable channels:
  • 16
• Communications:
  • Haltech CAN protocol
• Main connector:
  • 34-pin AMP Superseal, Type 2 keyway
• Status indicator:
  • Green LED for normal operation
  • Orange LED for boot mode
• Operating-voltage range:
  • 8–22 V
• Maximum ambient operating temperature:
  • 221°F (105°C)
• Environmental protection:
  • IP66
• Dimensions:
  • 4.33 × 2.76 × 1.34 in. (110 × 70 × 34 mm)
• Harness length:
  • 8.5 ft. (2.6 m)
• Harness insulation:
  • TXL cross-linked polyethylene

Analog-Voltage Inputs

• 6 user-configurable analog-voltage inputs
• 0–5 V measurement range
• Software-selectable 1 kΩ pull-up resistor to 5 V
• Suitable for:
  • Pressure sensors
  • Position sensors
  • Temperature sensors
  • Rotary trim switches
  • Switch-to-ground inputs
• Indefinite input-voltage withstand:
  • −10 to 30 V
• Sampling rate:
  • 100 samples per second
• Maximum signal frequency:
  • 1.5 kHz

Synchronized Pulsed Inputs

• 4 user-configurable synchronized pulsed inputs
• 0–12 V digital-input range
• 0–5 V analog-input range
• Software-selectable 1 kΩ pull-up resistor to 5 V
• Supports frequency and duty-cycle measurement
• Compatible with Hall-effect and reluctor sensors
• Suitable for:
  • Vehicle-speed sensors
  • Wheel-speed sensors
  • Driveshaft-speed sensors
  • Flex-fuel composition sensors
  • Frequency-based sensors
• Indefinite input-voltage withstand:
  • −15 to 30 V
• Maximum signal frequency:
  • 15.9 kHz

Half-Bridge Outputs

• 6 user-configurable half-bridge outputs
• Bidirectional high-side or low-side operation
• Up to 8 A sink or source capability per output
• 0–100% pulse-width-modulated duty-cycle capability
• Maximum switching frequency:
  • 2.2 kHz
• 0–27 V output-voltage feedback
• High-side current feedback
• Overcurrent protection
• Overtemperature protection
• Suitable for:
  • Solenoids
  • Relays
  • Stepper motors
  • Small DC motors
  • High-side-powered devices
  • Low-side-switched devices
  • Moderate-current auxiliary circuits

Sensor Power and Grounds

• 3 regulated 5 V sensor-power connections
• 4 sensor-ground connections
• Any 5 V sensor-power pin can be paired with any IO16 sensor-ground pin

Application Notes

• The IO16 is an expansion device and requires a compatible Haltech ECU or VCU. It does not operate as a standalone controller.
• This HT-196200 version includes the universal wire-in harness. The bare module and plug-and-pin versions are sold under separate part numbers.
• The IO16 connects to the ECU through a Haltech CAN System port.
• A compatible Haltech CAN cable or CAN-hub connection may be required depending on the vehicle’s existing CAN-network layout and how the universal harness is terminated.
• When several Haltech CAN devices are installed, a Haltech CAN hub can simplify the network layout.
• The IO16 must be enabled in Haltech NSP before its channels become available for assignment.
• Inputs and outputs are assigned through NSP in substantially the same manner as the ECU’s onboard channels.
• Up to 2 IO16 modules can be connected to one ECU, providing as many as 32 additional channels.
• When two modules are used, the second IO16 must be assigned a different device ID so the ECU can distinguish between the two sets of channels.
• Haltech currently specifies the following minimum software and firmware versions:
  • NSP 1.40.x or later
  • NEXUS firmware 1.29.x or later
  • Elite firmware 3.13.x or later
• Some ECU functions are not available through CAN-based expansion I/O. Confirm in NSP that the intended function can be assigned to an IO16 channel before completing the harness.
• The analog-voltage inputs can be used with conventional 0–5 V sensors or configured as switched inputs.
• Enabling the internal 1 kΩ pull-up allows an analog-voltage input to support compatible 2-wire temperature sensors and switch-to-ground devices.
• The synchronized pulsed inputs can accept frequency, duty-cycle, digital, reluctor, or analog signals within their published electrical limits.
• The half-bridge outputs can switch a load to ground or provide switched positive voltage, depending on the configured function.
• The half-bridge outputs are not suitable for drive-by-wire throttle control.
• Using the half-bridge outputs requires the IO16’s constant battery-power and battery-ground connections to be wired.
• Haltech specifies a fused 30 A constant battery supply when the half-bridge outputs are used.
• The IO16 can be powered through the CAN connector when only its inputs are required, but available output current is limited in that configuration.
• Loads exceeding an individual output’s current rating must be controlled through an appropriately rated relay or external power-control device.
• Although the module provides 6 protected 8 A outputs, it is an I/O expander rather than a replacement for a dedicated high-current power-distribution module.
• Sensors connected to the IO16 should use the module’s regulated 5 V supply and sensor-ground pins where applicable.
• Do not connect the IO16 sensor ground to its power ground or tie the IO16 sensor-ground circuit to the ECU sensor ground, as this can create ground-loop and measurement errors.
• The IP66 enclosure protects against dust and directed water exposure, but the module and harness connections should still be mounted away from exhaust heat, standing water, and direct physical damage.

Haltech Usage Notice

Haltech products are designed and sold for sanctioned off-road, competition, and non-emissions-controlled applications. The purchaser and installer are responsible for confirming compliance with all applicable federal, state, and local emissions and vehicle-use regulations.