The Haltech NEXUS R3 is a new-generation Vehicle Control Unit (VCU) that integrates multiple functionalities beyond just engine control. It serves as an engine management system, a power distribution module, a data logger, a universal wideband controller, and a high-speed Wi-Fi communications module, all natively interconnected and programmable with a single piece of software.
Function Description:
The NEXUS R3 is designed to manage and control various aspects of a vehicle's engine and electrical systems. As an engine management system, it processes inputs from various sensors to control ignition, fuel injection, and other engine functions. The power distribution module allows for the control and protection of electrical outputs, while the data logger records critical vehicle data for analysis and tuning. The universal wideband controller enables precise air-fuel ratio monitoring, and the integrated Wi-Fi module facilitates wireless communication with the Haltech NSP software for configuration and data extraction.
Important Technical Specifications:
Outputs:
- Ignition: 8 channels
- Injector (peak and hold): 8 channels
- Digital Pulsed Outputs (DPO): 6 channels
- Power for Ignition Switch: 1 channel
- Half Bridge Outputs (HBO): 6 channels
- 25A High Current Outputs (25A HCO): 4 channels
- Analog Voltage Inputs (AVI): 11 channels
- Differential Engine Position Inputs: 2 (Trigger and Home)
- Synchronised Pulsed Inputs (SPI): 6 channels
- Knock Inputs: 2 channels
- Universal Wideband Controllers: 1 (NTK/LSU 4.9)
- Ignition Switch Input: 1 channel
Communications:
- CAN Bus Networks: 2 channels (1000, 500 or 250 kbit/s)
- High Speed USB 2.0 (USB-C interface): 1 connection (480 Mbit/s)
- Wi-Fi: 900 kB/s datalog extraction, hardware lockout for security
Data Logging:
- Location: Onboard
- Storage: 128MB
- Max sampling frequency: 1kHz
- Maximum channels per log: 300
Dimensions:
- Enclosure (Not including connector protrusion): 196 x 130 x 44.5 mm (7.7 x 5.2 x 1.8 in)
- Overall (Including connector protrusion): 196 x 149 x 44.5 mm (7.7 x 5.9 x 1.8 in)
- Weight: 1.15 kg (2.53 lbs)
Other:
- Operating Temperature (ambient): -40 to 85°C (-40 to 185°F)
- Inertial Measurement Sensor: Onboard, 6 Axis
- Onboard Temperature Sensing Zones: 12 zones (ECU: -40 to 125°C, PDM: -40 to 150°C)
- 4 Channel Oscilloscope: 50kSa/s per channel, 2ms/Div limit, optional external trigger
Electrical:
- Power Supply (across power terminals): 8 to 22V
- No output static current draw: < 1A
- 5V Sensor Supply: 1 channel
- 8V Sensor Supply: 1 channel
- Sensor Ground: 1 channel
- Low Power Mode (USB): 4 to 5.5V
- Static current draw from USB port: < 500mA
Usage Features:
- Software Installation: The Haltech NSP software is provided on a USB Key or can be downloaded from the Haltech website. Installation involves plugging in the USB Key and running the installer.
- Connecting to VCU: The NEXUS R3 connects to a PC via a USB-C cable, which also powers the VCU in a low-power mode, allowing for map configuration and data-log extraction.
- Wi-Fi Communication: The VCU supports Wi-Fi for communication with NSP. This feature can be enabled in the Wi-Fi Module Settings within NSP, requiring an SSID and password setup. The VCU must be powered on main power for Wi-Fi communication.
- Power and Ground: The NEXUS R3 requires continuous connection to battery positive and negative terminals using 4AWG cables and supplied SurLok connectors for proper operation.
- Ignition Switch: The VCU is turned on by connecting the ignition switch input pin (A13) to a switched +12V source. Two methods are described for wiring, one to an existing ignition key switch and another using a switched +12V source.
- Input/Output Wiring: Detailed wiring diagrams are provided for various inputs and outputs, including injector outputs, ignition outputs, half bridge outputs (HBO), digital pulsed outputs (DPO), 25A high current outputs (HCO), analog voltage inputs (AVI), synchronised pulsed inputs (SPI), and knock inputs.
- Sensor Compatibility: The VCU supports various sensor types, including Hall effect/optical and reluctor sensors for crank/cam position, temperature sensors, flex fuel sensors, and piezoelectric knock sensors.
- CAN System: The NEXUS R3 includes two CAN channels (CAN 1 and CAN 2) for expansion products and vehicle CAN devices.
- Wideband Sensor Input: An onboard wideband controller supports Bosch LSU 4.9 or NTK wideband sensors. External Haltech CAN wideband controllers can be used for multiple wideband sensors.
Maintenance Features:
- Firmware Updates: The USB-C connection allows for firmware upgrades.
- Troubleshooting LEDs: The VCU features LEDs (Power, DTC, Wi-Fi, Datalog, HCO) that indicate the unit's status and potential issues (e.g., hardware fault, DTCs present, logging status, Wi-Fi connection, output channel status).
- Overcurrent Protection: The 25A High Current Outputs have programmable fuse currents, slow-start currents, and durations, with automatic overcurrent and undervoltage lockout protection.
- Flyback Protection: Digital Pulsed Outputs include flyback protection.
- Warranty: Haltech products are covered by a Limited 12 Month Warranty against defects in material or workmanship.
- Product Returns: Guidelines for returning products, including requirements for proof of purchase, original packaging, and condition, are provided. Specific conditions apply to sealed packaging and sensors.
Safety Precautions:
The manual emphasizes important safety precautions, such as disconnecting the battery during electrical work, avoiding sparks, not running the engine with a battery charger connected, not overcharging the battery, and unplugging the VCU when welding on the vehicle. It also advises ensuring no un-insulated wiring and proper mounting of fuel system components.
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