Nexus IO16 Input and Output Expander

Nexus IO16 - 16 Channel Input and Output Expander

Overview


The Nexus IO16 16-Channel Input and Output Expander is a Haltech CAN device that enhances the functionality of a Haltech Nexus or Elite ECU by adding 16 user-configurable input and output channels, accessible through the Haltech CAN system.



An example application of a vehicle using a Nexus or Elite ECU with two Nexus IO16s, Box A and Box B, to expand the ECU’s inputs and outputs by a combined total of 32 additional channels. With its slim and compact design, the Nexus IO16 can be conveniently installed almost anywhere in the vehicle. The CAN connection simplifies wiring, eliminating the need for the IO16 to be installed or wired near the ECU.

Features

  1. 6 x Analog Voltage Inputs (AVI)
  2. 4 x Synchronized Pulsed Inputs (SPI)
  3. 6 x Half Bridge Outputs (HBO)
  4. 34-pin AMP Superseal connector
  5. Slim and compact design
  6. Can be purchased with either a plug and pins set or a 2.6m universal harness
  7. Maximum of two Nexus IO16s can be connected to each ECU

Optional Accessories

  1. HT-131001 - Plug and Pins set
  2. HT-180000 - IO16 Universal Wire In Harness 2.6m (8.5’)

Nexus Software Programmer


Haltech NSP (Nexus Software Programmer) is the software used to set up the Nexus IO16. Follow these steps to install the Haltech NSP software:

1. Download the NSP installer - Go to the Haltech website (www.haltech.com), navigate to the ‘Downloads’ section, or click on this link.


2. Run the installer file - Once the download is complete, locate the downloaded file (usually in the ‘Downloads’ folder of your computer) and double-click on the file to run the Nexus Software Setup Wizard.


3. Launch Haltech NSP - Once the installation is complete, you can launch the Haltech NSP software from the Windows ‘Start’ menu or using the desktop shortcut that was created.



Going online with the Nexus IO16


Note: Ensure your NSP software and ECU firmware are up to date or meet the minimum required versions listed below.

NSP: version 1.40.x or later
Nexus firmware: 1.29.x or later
Elite firmware: 3.13.x or later

To go online with the Nexus IO16, connect your Haltech Nexus or Elite ECU to the NSP software and access the IO16 settings within the ECU configuration.

1. Connect your ECU to NSP and enable the Nexus IO16 - Use the supplied USB cable to connect your ECU to NSP. In the navigation tree on the left pane, go to Connections > CAN > Haltech CAN System, and enable “IO16” under Input/Output Expander Boxes.


2. Plug the Nexus IO16 into the Haltech CAN System - Use a Male DTM-4 to Male DTM-4 Haltech CAN cable to connect the Nexus IO16 to the Haltech CAN System. You can connect it directly to the ECU or via a Haltech CAN hub if you are already using multiple Haltech CAN devices. 



Ensure that you connect to a CAN port assigned to the Haltech CAN System, as most Haltech ECUs have multiple CAN channels, with one channel potentially assigned to work with a non-Haltech device (e.g., OBDII, or a vehicle-specific CAN system).

3. Start using the additional inputs and outputs - At this stage, with the Nexus IO16 and ECU powered on with 12V (i.e., Ignition Key On), the Nexus IO16 should appear as “Connected” within the NSP software, with its inputs and outputs available in the NSP IO report. 


Assigning the Nexus IO16 inputs and outputs to  functions within the ECU is done in the same way as assigning the ECU’s own inputs and outputs.



Changing Device IDs

If you are using two Nexus IO16s within the Haltech CAN system, the second IO16 will need its Device ID changed (e.g., from Box A to Box B). This is required so the ECU can differentiate between the available IO16 channels and assign each channel a specific CAN ID. To change the Device ID, leave only one Nexus IO16 plugged into the CAN system—the one whose Device ID you wish to change. Navigate to the main IO16 page within the NSP software, then click on “Change ID of Device,” as shown below. 



The process is straightforward, and NSP will configure the device for you. When the process is complete, NSP will display a message (as shown below) and require you to reboot both the ECU and Nexus IO16. You can choose to do this using the reboot button in the software or cycle the power off and on using the ignition key switch.


Nexus IO16 Wiring

Power and Ground Connections

To fully utilize the Nexus IO16’s functionality, the unit must be wired to a fused (30A) constant battery power and battery ground. This connection provides the necessary current for all the Half Bridge Outputs (HBO) when driven high or low. 


Switching the Nexus IO16 is managed through the CAN connection by plugging the unit into the Haltech CAN system, either directly into a Haltech Nexus or Elite ECU or an available port on a Haltech CAN hub. This connection controls the Nexus IO16, switching it ON or OFF whenever the CAN system is powered.

Alternatively, the Nexus IO16 can be powered and switched solely through the CAN connector by plugging into the CAN system. This method is less preferred and will limit the current available to the unit. Use this approach only if you are utilizing the inputs (AVIs or SPIs) and your application does not require the use of the Half Bridge Outputs.

5V Sensor Power and Sensor Ground

The Nexus IO16 features multiple pins for a regulated 5V sensor power supply, designed to power typical 3-pin analog voltage devices such as MAP sensors, pressure sensors, position sensors, and rotary trim switches. Similarly, the Nexus IO16 features multiple sensor ground pins for earthing sensors wired directly to the Nexus IO16. Any 5V pin can be paired with any sensor ground pin when wiring sensors connected to the Nexus IO16.

NOTE: To avoid potential ground loop issues, do not connect the signal ground wires between the Nexus IO16 and the ECU, nor connect the signal ground to the power ground.

Analog Voltage Inputs


Analog Voltage Inputs (AVI) serve as input channels capable of reading variable 0 to 5V signals from sensors that measure pressure, temperature, or position. Additionally, these inputs can also accept switched
signals that change between two different voltage levels. The “On” voltage and “Off” voltage in the software settings define the thresholds between the “On” and “Off” states. The current AVI voltage can also be viewed as a channel in NSP to determine the thresholds for switched inputs. 

AVIs feature a software-selectable 1K pull-up resistor to 5V, which can be enabled within the NSP software when configuring two-pin temperature sensors or switch-to-ground inputs.

Specs:
  1. Number of channels: 6
  2. 0 to 5V readable range
  3. Selectable 1k pull-up resistor to 5V
  4. -10V to 30V indefinite withstand
  5. 100 samples per second
  6. 1.5kHz signal frequency max

Synchronized Pulsed Inputs

Synchronized Pulsed Inputs (SPI) are inputs that can measure the frequency and duty cycle of a signal. Like AVIs, they can also read 0 to 5V signals from analog voltage sensors. These inputs are suitable for various
sensors, including flex-fuel composition sensors, Hall effect or reluctor vehicle speed sensors, and driveshaft speed sensors. 

Specs:
  1. Number of channels: 4
  2. 0 to 12V digital input
  3. 0 to 5V analog input
  4. Selectable 1k pull-up resistor to 5V
  5. -15V to 30V indefinite withstand
  6. 15.9kHz signal frequency max

Half Bridge Outputs

Half Bridge Outputs (HBO) function as push-pull, Pulse Width Modulated (PWM) channels suitable for controlling stepper motors, DC motors, or simple switch-to-ground control. HBOs can also provide +12V power to high-side driven devices, such as 12V-switched automatic transmission solenoids, or function as power distribution outputs to supply 12V to various circuits in the vehicle.

WARNING! When using HBOs, ensure the Nexus IO16 is powered using the constant power and battery ground wires as described in the power and ground section.

Specs:
  1. Number of channels: 6
  2. 8A current (sink / source)
  3. Overcurrent and overtemperature protection
  4. 0 to 27V voltage feedback
  5. High side current feedback
  6. Capable of 0-100% duty cycle
  7. 2.2kHz switching speed

Nexus IO16 Pinout Information


Nexus IO16 Dimensions

Nexus IO16 Product Specifications


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