Haltech Nexus PD16 PDM Power Distribution Module

Haltech NEXUS PD16 Power Distribution Module — Module Only

Part Number: HT-198000

The Haltech NEXUS PD16 replaces conventional fuse and relay hardware with electronically controlled, programmable power distribution for engine, drivetrain, and vehicle electrical systems.

Its 16 power outputs can control circuits ranging from ECU and injector power to fuel pumps, cooling fans, electric water pumps, lighting, solenoids, and bidirectional actuators. Each output can be configured through Haltech NSP with current limits, electronic-fuse behavior, reset delays, retry limits, and other application-specific control strategies.

The PD16 connects to a compatible Haltech system through the Haltech CAN network, allowing its inputs and outputs to respond to ECU data, driver switches, CAN keypads, dash inputs, sensor values, and programmable conditions. This HT-198000 version includes the bare PD16 module and main battery-input connector; the output connectors, wiring harness, and CAN cable are sold separately.

Key Features

• 16 programmable power outputs
• 10 high-side outputs rated at up to 8 A each
• 2 bidirectional half-bridge outputs rated at up to 8 A each
• 4 high-current high-/low-side outputs rated at up to 25 A each
• 120 A main power-input connection
• Programmable electronic-fuse protection
• Configurable overcurrent reset delay and retry limits
• Output-current and output-voltage feedback
• Output overtemperature protection
• Pulse-width-modulated output control
• Individual output-status LEDs
• 4 analog-voltage inputs
• 4 synchronized pulsed inputs
• Dedicated ignition-switch input
• Regulated 5 V sensor supply and sensor ground
• Master Power and Peripheral Power operating modes
• Integrated Haltech CAN communication
• Compatible with supported Haltech NEXUS and Elite systems
• Current Multi-master CAN support allows compatible Haltech ECUs and digital dashes to share PD16 inputs and outputs
• Configuration through Haltech NSP software
• Compact enclosure with onboard temperature monitoring

Kit Includes

• HT-198000 — Haltech NEXUS PD16 Power Distribution Module
• Red 120 A SurLok battery-positive connector
• USB-C cable
• USB-C dust cap
• Mounting hardware:
  • 2 M5 bolts
  • 2 M5 nuts
• Quick Start Guide
• Haltech fabric key tag

The 34-pin main connector, 4-pin high-current-output connector, wiring terminals, CAN cable, battery cable, and output wiring are not included with HT-198000.

Technical Specifications

• Total programmable power outputs:
  • 16
• Total configurable inputs:
  • 8
• Dedicated ignition-switch inputs:
  • 1
• Main power-input rating:
  • 120 A at 185°F (85°C) with 4 AWG (25 mm²) cable
• Operating-voltage range:
  • 8–20 V
• No-output static current draw:
  • Less than 200 mA
• CAN communication speed:
  • 1 Mbit/s
• CAN termination:
  • Software-selectable 120-ohm terminating resistor
• USB connection:
  • USB-C
  • Firmware updating only
• Main harness connector:
  • 34-pin AMP Superseal, Type 1 keyway
• High-current-output connector:
  • 4-pin Deutsch DTP
• Enclosure dimensions:
  • 6.3 × 1.7 × 3.7 in. (160 × 42 × 93.5 mm), excluding connector protrusion
• Overall dimensions:
  • 6.3 × 1.7 × 4.3 in. (160 × 42 × 110 mm), including connector protrusion
• Weight:
  • Approximately 1.08 lb. (0.49 kg)
• Ambient operating-temperature range:
  • −40°F to 185°F (−40°C to 85°C)
• Onboard temperature-sensing zones:
  • 5

8 A High-Side Outputs

• 10 independently configurable outputs
• High-side switched 12 V operation
• Maximum current:
  • 8 A per output
• Pulse-width-modulated operation:
  • 0–100% duty cycle
• Maximum switching frequency:
  • 100 Hz
• Software-programmable electronic-fuse current
• Configurable reset delay after an overcurrent event
• Configurable maximum retry count
• Automatic overcurrent protection
• Flyback protection
• Output-voltage feedback:
  • 0–30 V
• High-side current feedback
• Suitable for compatible:
  • Relays
  • Solenoids
  • CAN accessories
  • Lighting circuits
  • Transmission solenoids
  • Small electric pumps
  • Other moderate-current switched loads

8 A Half-Bridge Outputs

• 2 independently configurable outputs
• Bidirectional high-side or low-side operation
• Maximum source current:
  • 8 A per output
• Maximum sink current:
  • 8 A per output
• Pulse-width-modulated operation:
  • 0–100% duty cycle
• Maximum switching frequency:
  • 2.2 kHz
• Overcurrent protection
• Overtemperature protection
• Output-voltage feedback:
  • 0–27 V
• High-side current feedback
• Suitable for compatible:
  • Bidirectional actuators
  • Small DC motors
  • Electronic exhaust-valve actuators
  • High-side-driven solenoids
  • Low-side-switched solenoids
  • PWM-controlled pumps and valves

25 A High-Current Outputs

• 4 independently configurable high-current outputs
• High-side or low-side operation
• Maximum source current:
  • 25 A per output
• Maximum sink current:
  • 25 A per output
• Pulse-width-modulated operation:
  • 0–100% duty cycle
• Maximum switching frequency:
  • 1 kHz
• Software-programmable electronic-fuse current
• Configurable soft-start current and duration
• Configurable overcurrent reset delay
• Automatic overcurrent protection
• Flyback protection
• Output-voltage feedback:
  • 0–30 V
• High-side current feedback
• Suitable for compatible:
  • Fuel pumps
  • Cooling fans
  • Electric water pumps
  • ECU power
  • Ignition and injector power
  • High-current solenoids
  • Other loads within the published current limits

Analog-Voltage Inputs

• 4 user-configurable analog-voltage inputs
• Measurement range:
  • 0–5 V
• Sampling rate:
  • 100 samples per second
• Maximum signal frequency:
  • 1.5 kHz
• Indefinite input-voltage withstand:
  • −10 to 30 V
• Software-selectable 1 kΩ pull-up resistor to 5 V
• AVI 1 also includes a selectable 240-ohm pull-up for direct connection to compatible resistance-based fuel-level senders
• Suitable for compatible:
  • Pressure sensors
  • Temperature sensors
  • Fuel-level senders
  • Position sensors
  • Rotary trim controls
  • Switch-to-ground inputs
  • Driver-request switches

Synchronized Pulsed Inputs

• 4 user-configurable synchronized pulsed inputs
• Supports:
  • Frequency measurement
  • Duty-cycle measurement
  • Signal-state detection
  • Position measurement
  • Analog-voltage measurement
• Digital-input range:
  • −0.5 to 12 V
• Analog-input range:
  • 0–5 V
• Indefinite input-voltage withstand:
  • −15 to 30 V
• Maximum signal frequency:
  • 15.9 kHz
• Software-selectable 1 kΩ pull-up resistor to 5 V
• Compatible with supported Hall-effect, optical, and reluctor sensors
• Suitable for:
  • Vehicle-speed sensors
  • Wheel-speed sensors
  • Driveshaft-speed sensors
  • Flex-fuel composition sensors
  • GPS speed inputs
  • Frequency- or duty-cycle-based sensors

Application Notes

• HT-198000 is the PD16 module-only SKU.
• The following wiring components are sold separately:
  • HT-030009 — 34-pin AMP Superseal plug-and-pin set
  • HT-031201 — Black 4-pin Deutsch DTP plug-and-pin set for the 25 A outputs
  • HT-188000 — 5 m (16 ft.) PD16 flying-lead harness
  • Appropriate Haltech DTM-4 CAN cable
• Customers wanting the module with loose connectors and terminals should select HT-198100.
• Customers wanting the module with a pre-terminated 5 m flying-lead harness should select HT-198201.
• The supplied SurLok connector must be terminated to an appropriately sized battery-positive cable. Haltech specifies 4 AWG cable for the published 120 A rating.
• The main battery cable, battery fuse or circuit protection, cable lugs, and crimping tools are not included.
• Battery negative is connected through the PD16 main harness connector rather than through a separate large ground stud.
• The total vehicle load must remain within the 120 A main-input rating. The individual output ratings cannot simply be added together to establish total available module current.
• Output-current capacity is also affected by wiring gauge, connector capacity, duty cycle, ambient temperature, and simultaneous loading.
• The PD16 uses programmable electronic protection rather than replaceable blade fuses for its controlled outputs.
• Each output’s current limit should be set above the circuit’s normal operating current but below the safe continuous capacity of the wiring, connector, and connected load.
• Loads with high startup or inrush current—particularly pumps, fans, and motors—may require soft-start configuration or sufficient transient-current allowance.
• The 25 A outputs can be configured as high-side or low-side outputs. The selected wiring arrangement must match the output configuration in NSP.
• The two half-bridge outputs can be paired with compatible bidirectional devices or used individually as conventional high-side, low-side, or PWM outputs.
• The USB-C connection is used for PD16 firmware updates. Normal configuration is completed through the compatible Haltech master device in NSP.
• The PD16 supports 2 primary operating modes:
  • Master Power Mode: The PD16 powers up from the ignition-switch input and can provide switched power to the ECU and Haltech CAN network.
  • Peripheral Power Mode: The PD16 is awakened by CAN-system power from a compatible ECU, VCU, or other supported Haltech master.
• In Master Power Mode, the PD16 can replace much of the conventional ECU, injector, ignition, pump, fan, and auxiliary fuse-and-relay arrangement.
• The PD16 is not a fully independent, self-configuring standalone PDM. It requires a compatible Haltech master device for assignment and control.
• Haltech’s current Multi-master CAN architecture allows a supported NEXUS or Elite ECU and a compatible iC-7 or uC-10 dash to control separate PD16 inputs and outputs.
• With current firmware, some installations can operate the PD16 from a compatible Haltech dash without an ECU. The dash serves as the master controller in that arrangement; the PD16 is not operating independently.
• Haltech currently specifies the following minimum versions for Multi-master CAN:
  • NEXUS ECU firmware 1.28.x
  • Elite ECU firmware 3.12.x
  • PD16 firmware 1.09.x
  • iC-7 or uC-10 firmware 2.28.x
  • NSP software 1.40.x
• An individual PD16 input or output cannot be assigned simultaneously to more than one master device.
• When an output assignment conflict occurs, the output enters its configured safe state.
• Output safe-state behavior should be configured for loss of CAN communication.
• The PD16’s regulated 5 V supply and sensor ground can support compatible sensors connected directly to its inputs.
• The ignition-switch input can accept a conventional switched-positive ignition signal or operate with Haltech’s simplified Master Power wiring arrangement.
• Individual output LEDs indicate circuit status and assist with installation and fault diagnosis.
• Optional tube-mount kits are available for:
  • HT-039080 — 1.25 in. (31.75 mm) tubing
  • HT-039082 — 1.625 in. (41.275 mm) tubing
• Although the module can eliminate many conventional relays and fuses, the main battery feed still requires correctly selected primary circuit protection and wiring.

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.