TORP TC500 User manual

TORP CONTROLLER.
User Manual

IMPORTANT.
Please read and carefully follow the instructions in this manual. The TC500 controller must always
be used with a stock SurRon/Segway fuse! Not using the fuse with the TC500 controller is
dangerous and can cause serious damage!
Use only tools and screws that came with the controller. Using the tools and screws that were not
included in the parcel, not following these instructions, or not using the fuse, can cause serious
damages to you and your bike.
INTRODUCTION.
TC500 controller has been developed exclusively for SurRon Light Bee and Segway X260 e-bikes,
and is not compatible with any other electric motor. TC500 is not compatible with Segway X160.
TC500 controller is also not compatible with motor model number P/N: 11100-YQ2A-0100. Please
check your motor model number before installing the TC500 controller. In general, all
SurRon/Segway X260 motors, manufactured after 2018 are compatible with the TC500 controller.
TC500 controller is compatible with both versions of the stock display (L1 E & the off-road version).
Both speed and the distance are displayed on it. For the additional options, like battery monitoring
and settings, you will have to use your smartphone or buy a Torp Display, that is sold separately.
This is a plug&play controller that needs no previous knowledge of electronics and programming for
installation and setup. Everything needed for successful installation is included in the box.
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THE BOX CONSIST OF:
-TC500 controller
-Wire-harness
-5 phase screws with washers
-2 screws for fastening the controller
to the bike`s frame
-2 screws for installation of the plastic
shield
-2 hex keys
-Shield
-Short instructions
All the settings and diagnostics are managed through an
intuitive and easy-to use smartphone app for Android and
IOS. The users can use their smart-phone as a display
during the rides and to set up all the controller`s features
through the app.
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INSTALLATION.
Before starting with the installation, drain the bike`s capacitors.
Switch off the fuse
Switch on the bike and wait for the capacitors to drain.
1.
2.
1. 2.
Now you can start removing the stock SurRon controller and the battery from the frame, and lower
the skid-plate that covers the wiring.
FOR THE INSTALLATION
you will need:
-2 M5 screws (smaller screws)
-A smaller hex key
STEP 1:
Place the controller in a way that the holes on its back align
with the upper holes on the bottom front of the frame.
STEP 2:
Insert each screw in one hole and fasten them by using a
smaller hex key.
1.
2.

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STEP 3:
There is a cable on the left of the controller.
Stick it behind the controller.
STEP 4:
There are 5 screws with washers already on the
controller. Remove them from the controller and
start connecting the controller to the phase
motor wires.
DON`T MESS THIS ONE UP!
STEP 5:
Connect the power and phase motor wires as shown on
the picture using the screws with washers that you have
removed from the controller in the previous step:
Power Wires:
-The red battery wire to the positive (+) electrode
-The black battery wire to the negative (-) electrode
Phase Motor Wires:
-The Blue motor wire to the letter B
-The Green motor wire to the letter G
-The Yellow motor wire to the letter Y
STEP 6:
Use a larger hex key to gently fasten the
screws with washers. Max Torque that should
be used is 3.5 Nm!
3.
5.
6.

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STEP 7:
Put the bike`s skid-plate back to its original
position by screwing back the top screws on
each side.
STEP 8:
Use the wire harness that came with the
controller to connect the controller to the
bike. Connect the largest connector to the
controller and the three smaller connectors to
the bike`s wiring, in the same way the stock
controller has been connected.
There is also a 4th connector with a cap on it.
This connector will be used with the
dedicated display, once it is made available.
STEP 9:
Take the plastic shield that came with the
controller and mount it by placing its lower
part into the skid plate.
7.
8.
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STEP 10:
Use the longer M6 screws
and a larger hex key to
fasten the shield to the frame.
STEP 11:
Put the battery back to the frame.
STEP 12:
Connect the battery to the battery power
connector and to the 6-pin connector.
10.
11.
12.

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STEP 13:
Turn the fuse back on. Always use the
Controller with the stock SurRon/Segway
fuse!
CONNECT THE CONTROLLER
TO THE APP
for further setup.
HOW TO CONNECT?
To connect the TC500 controller with the
Torp Controller App, first go to the Google
Play Store (Android) or AppStore (IOS) and
download the App to your smartphone.
-Allow the App to access the phone's
location, photos and media and accept the
Terms & Conditions.
-Put the key into the ignition and turn on
your bike.
-The App will automatically detect your
controller.
-Choose your controller from the list. The
Bluetooth ID can be found on the label on
the side of the controller.
-Now you are connected and can start
setting up your controller.
We suggest you always ride with the app set to the 1s screen. This is how the Torp Controller
App will be able to recognize potential errors which will help our support team with detecting
and solving any problems that might occur with the controller.
13.
IMPORTANT: After the installation make sure to calibrate the throttle and Hall sensors! Check the
“Setting up the throttle” and “Calibration of hall sensors” sections of the manual and follow the
instructions.

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1st Screen: GAUGE
The TC500 controller is compatible with the stock SurRon display, where
you will be able to track your speed and distance. However, we
recommend using your smartphone as the display during the rides.
The first screen serves as a gauge, showing all your riding information in
real time. Here are also displayed all the potential errors and warnings.
THE APP OVERVIEW.
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3
4
5
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1-Motor Temperature: Monitor the Motor
Temperature in real-time.
2-Battery Temperature: Monitor the battery
temperature in real-time.
3-Controller Temperature: Monitor the
battery temperature in real-time.
4-Power Gauge: Displays the power.
5-Warnings & Errors: All Warnings and
Errors are displayed here. More details on
their meaning can be found in a table below.
6-Battery Info: State of charge (SOC),
battery voltage, and battery current.
7-Motor Info: Motor RPMs, Motor Power and
Motor Current.
8-Predict your Trip: Check the distance you
have passed, the amount of regenerated
energy, and the consumption of the battery.
You can plan your trip based on this
information.

THE LIST OF WARNINGS AND ERRORS
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-KICKSTAND: Your kickstand is lowered.
Lift it to start riding.
-CRASH SENSOR: Crash sensor activates
in case of a fall. Turn the bike off and
turn it back on after a few seconds to
continue riding.
LIMIT:
-TEMP CONTROLLER: The temperature of
the controller has reached the top limit
value. The power will be gradually
reduced.
-TEMP MOTOR: The temperature of the
motor is rising. To prevent overheating,
the power will be gradually reduced. The
motor temperature limit is set in the
“Motor Temp Cuttoff” settings on the
"Settings" screen.
-MOTOR TEMP SENSOR: Motor
temperature sensor is not connected.
Power is limited.
-LOW VOLTAGE: The battery is almost
drained or there is a voltage sag due to
the acceleration. The power will be
gradually reduced.
-LOW REGEN: The battery is nearly full.
The regen will be reduced.
-BATTERY TEMP: Battery temperature
has reached limit values so the power
will be reduced.
-BMS TEMP: Discharge mosfets in BMS
have overheated. Power will be gradually
reduced.
CUTOFF:
-CUTOFF LOW VOLTAGE: The battery is
completely drained and the bike will not
start. You can set the cutoff value in
Voltage Min setting in the App (3rd
Screen) . Charge the battery to continue
riding.
-OVERVOLTAGE: Battery voltage is
above 90V.
-UNDERVOLTAGE: Battery voltage
dropped under the values set in the
controller`s settings. Charge the
battery.
-OVERCURRENT: Motor Current is
above permitted limit.
-CONTROLLER OVERTEMP: Controller
has overheated. Wait for it to cool
down to continue riding.
-MOTOR OVERTEMP: Motor has
overheated. Wait for it to cool down to
continue riding.
-PHASE FET: MOSFET error:
Controller`s phase is in short-circuit.
Contact the manufacturer.
-HALL SENSOR: Motor Hall Sensor
connector is not connected, or there is
a problem with the Hall Sensor itself.
Check the wiring.
-THROTTLE PROBLEM: The problem
with a throttle wiring was detected,
that has been solved in the meantime.
Turn your bike off and on again to
continue riding.
-THROTTLE #1-5: Various problems
with the throttle wiring.The most
common cause for these errors lie in
one of the wires not being properly
connected or if the wire is broken. Turn
off the bike, check the wiring and turn
the bike on again.