STR-500 Vehicle Controller

Brand: TRAMPA

1 Feature Overview

Voltage: 24V – 92V (Safe for 6S to 22S LiPo). Optimal performance at 20S LiIon.
Voltage spikes may not exceed 100V.
Current: Continuous 500A, peak 680A. Values depend on temperature, switching frequency, and cooling.
1x 5V 0.5A output for external electronics.
1x switchable 5V 3A output for external electronics.
5x switchable and variable 6-24V (15A combined).
1x static output, variable 6-24V.
3.3V 0.5A output for external electronics.
9-axis IMU.
Modes: DC, BLDC, FOC (sinusoidal).
Supported sensors: ABI, HALL, AS5047, SIN/COS, and other encoders.

2 Applications

Controller for light electric vehicles.
Non street legal if not homologated.
For integration into VESC ecosystem.

3 Description

The VESC STR 500 is a versatile three-in-one vehicle controller designed primarily for use in light electric vehicles such as electric motorbikes, boats, karts, and similar applications. It incorporates a microprocessor-controlled DC-DC converter to generate auxiliary power for the vehicle's electronics.

Apart from the DC-DC converter, the STR 500 is equipped with IO functionality for controlling inputs and outputs. This feature enables direct control of various vehicle-mounted equipment, including lights, blinkers, a horn, and more. Additionally, the STR 500 includes a logging module for continuous recording onto a Micro SD-Card (?) and supports GPS (?) antenna connectivity.

For accessibility, the device offers wireless connections through BLE (?) and WiFi (?). The STR 500 is supported by the VESC-Tool, compatible with Linux, Windows, iOS, MacOS, and Android. Its features encompass a broad range of adjustments for controller setup and operation, along with real-time monitoring and logging capabilities on a computer (?️) or directly onto the STR 500 itself.

4 Typical Installation

The typical installation requires appropriate fuses on the battery connection, matching the system's current flow. The battery must be managed by a suitable Battery Management System (BMS), which should control a contactor on the positive discharge wire.

Diagram Description: The diagram shows the STR 500 controller with connections for GPS (?), Battery (Batt+/Batt-), Motor Phases (A, B, C), Fuse (?), Contactor (⚡), and Managed Battery (?). It emphasizes using appropriate fuses and a BMS.

5 Warnings

WARNING: Read the ENTIRE instruction manual to become familiar with the device and its features before operating. Failure to operate the product correctly and safely may result in damage to the product, personal property, and cause serious injury.

This product must be operated with caution, common sense, and in harmony with any regulations in place. Usage requires special mechanical and electrical ability and training. Failure to operate this product in a safe and responsible manner could result in injury or damage to the product or other property.

This product is not intended for use by children. Do not attempt disassembly, use with incompatible components, or augment the product in any way without approval from the manufacturer. This manual contains instructions for safety, operation, and maintenance. It is essential to read and follow all instructions and warnings prior to assembly, setup, or use to operate correctly and avoid damage or serious injury.

Age Recommendation: Not for children under 18 years. This is not a toy.

Throughout this document, the following terms indicate potential harm levels:

NOTICE: Procedures which, if not properly followed, create a possibility of physical property damage and little or no possibility of injury.
CAUTION: Procedures which, if not properly followed, create the probability of physical property damage AND a possibility of serious injury.
WARNING: Procedures which, if not properly followed, create the probability of property damage, collateral damage, and serious injury OR create a high probability of superficial injury.

WARNING: This device may not be used for applications requiring fulfillment of special safety standards, including but not limited to: Vehicles, aircrafts, certain machines, and operation in safety-critical environments like medical, nuclear, or military applications.

Depending on your country, safe handling for untrained persons is limited to a certain voltage range. If you lack professional training, do not operate this device above the specified voltage range, which is defined by your country's low voltage directive or similar regulations.

WARNING: Battery cells must not be overcharged or operated below their lowest specified discharge voltage. Batteries operated outside these parameters pose a serious risk of fire and/or explosion. Even a single event of overcharge or over-discharge necessitates safe disposal of the battery.

WARNING: Protection circuits must be installed between the battery and the VESC STR 500 controller, including a current-flow-controlled contactor and fuse. Do not bypass a Battery Management System (BMS).

6 Type of Batteries

This product may only be used with suitable batteries, such as Lead Acid, LiIon, LiPo, and LiFePo4. The software settings must be changed to match the cell chemistry and other cell parameters. Please refer to your battery cell's data sheet.

7 Pre-Charge

Connections to a battery must be established via a suitable pre-charge switch. The initial current flow should be routed through a 10 Ohm power resistor until all internal capacitors are fully charged. The exact resistance value depends on the STR 500 and other devices attached to the same battery.

8 Vehicle Storage / Parking

When a vehicle is parked or stored, the STR 500 should be disconnected from the battery. This can be done by physically unplugging the battery or electronically by releasing a contactor switch.

9 Charge Process of Vehicles

The charge process must be monitored at all times. Never attempt to charge a hot battery or a battery that was just used. Allow the battery to cool down before charging and before using it again.

10 Attaching the Motor and Battery Cables

Ensure you use appropriate wire gauge for the application and expected current flow. The cable entry grommets are available in different sizes to assure a perfect IP 67 rated sealing of the housing. Choose the correct size for your wire gauge. Follow the instructions below to assemble battery and motor cables.

Diagram Description: The diagram shows the STR 500 controller's main terminals. It details the process of attaching motor phase wires (A/B/C) and battery cables (Batt+/Batt-). Steps include loosening screws (?), removing connectors, extracting cubes, and re-tightening screws. It specifies torque values (e.g., M6 = 3.9Nm, M8 = 9.0Nm) and the use of self-locking washers. It also clarifies that '1' is the positive battery pole and '2' is the negative pole.

11 IO-Board Connections

The IO-Board provides various connection options. Mating wire connectors include JST PH series (for 1,2,3,4,5,9,12), Ultra-Fit 172258 (for 8), and JST PA series (for 11).

Diagram Description: The IO-Board features ports for GPS (?) antenna, USB (?) for ESP32, Micro SD-Card (?), Sensor Port (ABI, AS5047, HALL, TEMP Motor, V+), 5V outputs (3A max combined), 6-24V outputs (5A fused per channel, 15A combined), CAN (CAN-L, CAN-H), SWD/UART, and PWM/COMM. It also includes sensor protection jumpers.

12 Hibernation Switch Attachment

The STR500 can be used with a Normally Closed (NC) [NC] switch to set the device into an ultra-low power sleep mode. Connections: 1 + 3 = GND, 2 = Switch pin, 4 = 5V supply. Use the COMM port to wire up the switch.

LED Indicators:

C1 (Common used)
NC (Normally Closed)

Option 1: Using a LED (5V) illuminated power switch: Manual power on/off, LED indicates state, auto power off.

Option 2: Using a non-illuminated power switch: Manual power on/off, auto power off.

13 Avoiding Ground Loops

Ground loops can damage your devices. Follow the guidelines below to prevent them.

Diagram Descriptions: Multiple diagrams illustrate scenarios to prevent ground loops when connecting multiple VESC devices. These include:

Multiple VESC controllers connected to a receiver/microcontroller via PPM, UART, I2C, or SPI, with the receiver/controller powered by one VESC device or the same battery. Optocouplers are recommended.
Multiple VESC controllers connected via CAN bus, emphasizing connecting only CAN H and CAN L, and ensuring all devices share the same battery GND.
A diagram warns about ground loops via grid power and suggests using a battery or USB isolator.
Diagrams show scenarios with separate power supplies for receivers/microcontrollers and other connected devices, recommending optocouplers.

14 Connectors and Pins

The VESC STR 500 controller is equipped with USB, CAN-Bus, PWM, COMM, SWD, ADC, and a Sensor port. The following list details how to interconnect the VESC STR 500 controller to other devices:

Sensors: Sensor Port for ABI, HALL, AS5047P motor encoder and other encoders listed in VESC-Tool. Motor sensors allow precise and powerful rotation of the motor's rotor from a random (standstill) position or from a defined position A to a defined position B. The sensor voltage switches according to the detected sensor type (3.3V or 5V possible). NOTE: SIN/COS encoders need to be attached to ADC pins on the COMM port or to ADC 3, 4, and 6.
SWD: Serial Wire Debug allows access to the STM32 Chip while running your VESC controller for diagnostics, debugging, and real-time data, plus a second UART RX/TX.
COMM: I2C, SPI, UART, and ADC Interface for communication with other devices, such as Microcontrollers (e.g., Arduino, Raspberry Pi) or using analogue input devices like analogue throttles and switches.
ON/OFF SWITCH PIN: Use a momentary (Normally Closed) switch to wake the device from hibernation. The switch needs to connect this pin to the GND PIN on Connectors 1-5.
PWM: Connect input devices using Pulse-Position Modulation (e.g., a 2.4GHz transceiver) for controlling motor output power and speed (Radio control). Never connect one receiver to separate VESC devices (Y-PPM). Use opto-couplers.
CAN: CAN BUS for interconnection of VESC devices in an array. It's also a universal bus to link the VESC controller to other devices featuring CAN-Bus. Only connect CAN L and CAN H. If connected to the same battery, all devices must share the same battery GND at all times. Never interrupt this connection while the CAN cable is attached. The GND pin and 5V pin of the CAN link should never be connected in an array of controllers.
Motor A,B,C Connectors: For a single three-phase wired BLDC Motor (Coil A, B, C). If you know your motor phases, plug them in accordingly (Yellow = A, Blue = B, Red = C) to be displayed correctly in VESC-Tool real-time data analysis. DC-Motors use only connections A and C; B will be left unplugged.
USB: USB Ports to connect a computer for configuration, firmware updates, and real-time data analysis.

15 Switchable Outputs

Your STR 500 features 6 outputs for auxiliary power, each fused with a 5A SMD Fuse. Five of the 6 outputs are switchable in software, with functionality definable via a Script (See VESC-Tool DEV Tools >> LispBM Scripting >> Examples).

6-24V Auxiliary Power Outputs: The auxiliary voltage can be defined via scripting; the default is 12V. Outputs I-V are switchable; Output VI is permanently on.
5V Auxiliary Outputs: The IO-Board features two 5V outputs, combined 3A capable, each with a 2A Fuse. Output A is switchable; Output B is permanently live.

16 Fault Codes

The following LED light codes indicate the controller's status:

BLUE: VESC controller is powered up.
GREEN DIM: SW Running >> Software (Firmware) installed and running.
Green Bright: VESC controller is driving the motor.
RED: Fault code. Something is wrong! Read out the fault code in VESC-Tool.

Please visit www.vesc-project.com/documentation for more information.

17 Software - Beta tool

The VESC STR 500 is new and requires BETA FIRMWARE until VESC-Tool 6.05 is released. The STR 500 comes with correct firmware installed but can only be configured using the beta version of VESC-Tool.

This is a quick walkthrough of how to download the beta version of VESC-Tool:

Screenshots Description: The VESC Tool website is shown, including login, CAPTCHA, and navigation to "Purchased Files". Another section shows the file download interface with options to download VESC Tool for Mac, Windows, Linux, and Android. A file explorer view lists the beta archive contents.

Once logged in, menu options appear in the top right corner. Click on PURCHASED FILES to access the beta download link. NOTE: If you have not downloaded VESC-Tool, the beta link will not be shown. Download the released version first, then check back in PURCHASED FILES.

The Beta link provides all device versions in a .rar file. Ensure you have software installed to read and unpack files (e.g., WinRAR, WinZip).

Pick your desired version, click extract, and choose a folder. There is always a file with the build date; use this for reference as the beta usually updates weekly. Keep updated until the released VESC-Tool reaches Version 6.05.

17.1 Software

The STR 500 is fully supported by the official VESC-Tool software package, available as an App or desktop version. Use the AutoConnect button or Scan button to find your device and establish a connection.

Download VESC Tool from https://vesc-project.com/vesc_tool or the Apple App Store or Google Play Store.

For motor detection, use the Setup Motor FOC Wizard.
For input calibration, use the Setup Input Wizard.
For IMU calibration, use the Setup IMU Wizard.

Screenshot Description: The VESC Tool interface is displayed, showing the "Welcome & Wizards" screen and "Quick Configuration" options like AutoConnect, Setup Motors FOC, Setup Input, and Setup IMU. It also shows the main connection status and parameters.

17.2 Motor parameters for saturating motors

Many motors can be pushed into saturation during operation, requiring modified motor parameters to perform at specified levels. Manual adjustments are possible in Motor Setting >> FOC.

For known motors, you can load a working setup via File >> Load Motor Configuration XML.

A common starting point is multiplying the inductance by roughly 0.70 - 0.75 and adjusting the time constant to 350-500µS. After changing values, click Calc Apply Old and then write the settings to the controller using the M [write] button. Carefully test the behavior after each change.

The following page shows an example and guides you step-by-step. You can also save configurations and share them with the VESC community by clicking File >> Save Motor Configuration XML.

17.3 Example for motor tuning

This section provides an example for motor tuning for an ebike like the Talaria® SUR-RON® or similar.

Screenshots Description: Two VESC Tool interface screenshots show motor detection parameters before and after tuning for a Talaria Sting bike. Key changes include adjusting Resistance, Inductance, and Time Constant (T). The steps are numbered (1-5) corresponding to parameter changes and applying them.

The Resistance value was increased by roughly 5%: 5.1mΩ x 1.05 ≈ 5.4mΩ. The range to try is ±5%.

Original Inductance was lowered using the formula: 38.86μH * 0.72 ≈ 28μH.

The Time constant T was set to 400µS instead of the original 1000µS.

After making these changes, press Calc Apply Old (4). The settings were written to the controller by pressing M (5).

17.4 Increased current settings

This section shows standard detection parameters from a Talaria® Sting bike with a stock motor and how to adjust current settings.

Screenshots Description: The VESC Tool interface shows motor and battery current settings. Another screenshot shows the VESC Tool terminal where typing "faults" reveals the "ABS OVER_CURRENT" fault.

The Motor Current Max value was adjusted to 400A; this can be carefully increased to 450A.

Motor Current Max Brake: set to -60A.
Absolute Maximum Current (ABS): set to 600A.
Battery Current Max: set to 120A.
Battery Current Max Regen: set to -60A, matching the Motor Current Max Brake.

After all adjustments, press M [write].

The maximum possible current depends on many factors, including the physical motor size. Oversaturated motors can create current spikes beyond the Absolute Max Current setting, leading to motor hiccups and the "ABS overcurrent" fault code. In such cases, the Motor Current Max value may need to be lowered, or detection parameters require further tuning.

Fault codes can be displayed by typing 'faults' into the Terminal. Fault codes are erased after de-powering the VESC controller. The example below shows an ABS Overcurrent Fault after 608A were registered.

17.5 Software – DC-DC programming

The STR 500 includes a 15A DC-DC converter with its own microprocessor, configurable via CANBUS using the VESC tool. Follow these steps to adjust and set the output voltage:

Ensure the STR 500 is powered and connected to the VESC tool.
Select the DC-DC device in CAN-Devices.
Select VESC DCDC in the menu.
Set your desired output voltage.
Click Write to save your settings to the device.

Screenshot Description: The VESC Tool interface shows the "VESC DCDC" section, with numbered indicators pointing to device selection, menu, output voltage setting, and the "Write" button. A note mentions only output channel 6 is currently working.

Note: ONLY output channel 6 is currently working. The other 5 switched channels will be available with the next firmware update.

18 VESC community

To connect with other VESC equipment users, please reach out to the VESC-Forum: https://vesc-project.com/forum

Stay tuned for the latest updates on recent developments by visiting Mr. Vedders YouTube channel: https://www.youtube.com/@BenjaminsRobotics

19 Technical Data Sheet

Voltage: 24V – 92V (Safe for 6S to 22S LiPo). Recommended usage at 20S LiIon.
Voltage spikes: May not exceed 100V.
Current: Continuous 500A, peak 680A (values depend on temperature, switching frequency, and cooling).
Outputs:
- 1x 5V 0.5A output for external electronics.
- 1x switchable 5V 3A output for external electronics.
- 5x switchable and variable 6-24V (15A combined).
- 1x static output, variable 6-24V.
- 3.3V 0.5A output for external electronics.
IMU: 9-axis.
Modes: DC, BLDC, FOC (sinusoidal).
Supported sensors: ABI, HALL, AS5047, SIN/COS, and many other encoders (Full list in VESC-Tool).

Box Outer Dimensions (without HEAT SINK)

STR-500 Box Length: 236mm
STR-500 Box Width: 108mm
STR-500 Box Height: 62mm
STR-500 Weight: 1500g

Box Outer Dimensions (with HEAT SINK)

STR-500 Box Length: 267mm
STR-500 Box Width: 122mm
STR-500 Box Height: 73mm
Weight: 2190g
Weight (with heat sink): 1,641g

20 Features

Accurate current and voltage measurement on all phases.
Adjustable Current and voltage sensors.
Works reliably with nearly any DC, BLDC, PMSM motor and low inductance motors.
Regenerative braking.
Sensored or sensorless operation + hybrid mode.
Configurable RPM, current, voltage, and power limits.
Input source: PPM, Analogue, NRF (BLE 4.1).
Communication ports: USB, CAN, UART, I2C, SPI.
Throttle curve and ramping for all input sources.
Seamless 4-quadrant operation.
Motor revolution, amp hour, watt hour counting (ERPM, RPM, Ah, Wh).
Transmission and wheel diameter configurable for accurate speed and consumption calculation.
BLE (?) wireless connection (if activated).
Real-time data analysis and read-out via communication ports and wireless connections.
Scripting interface for added functionality.
Data storage on SD-Card (?).
GPS (?) antenna connectivity.
Modes: Current Control, PID Speed Control, Position Control, Cruise Control, Self-balancing (Monowheel, Onewheeled, Gimbals).
Adjustable protection against: Low input voltage, High input voltage, High motor current, High input current, High regenerative braking current (separate limits for motor and power input), High RPM (separate limits for each direction), Over-temperature (MOSFET and motor), Over-temperature for the Battery (dependent on BMS used), Over current and short circuit on the auxiliary output (6-24V).

21 Integration in your vehicle

Warning: The VESC STR 500 should be carefully integrated into the vehicle. Wrong assembly and placement may cause issues resulting in unsafe operation with the probability of property damage, collateral damage, and serious injury or death!

Cable routing and insulation must be safe, and potential short circuits must be ruled out.
Do not use flammable materials in your assembly, such as glues or flammable tape and insulation material.
The STR 500 needs to be able to dissipate the heat it generates.
The STR 500 should be placed to limit direct water spray.

22 General safety information about LiIon and LiPo batteries

Warning: LiIon, LiPo, and LiFePo4 batteries, as well as other types, can be dangerous. Wrong handling, assembly, or operation may cause issues resulting in property damage, collateral damage, and serious injury or death.

Read the following manuals with care:

Li-ion Battery Care & Safety information: https://trampaboards.com/resources/manuals/245.pdf
LiPo Battery Care: https://trampaboards.com/resources/manuals/244.pdf

23 Support

If you have questions or doubts, please feel free to contact Trampaboards Ltd to clarify issues before proceeding with the assembly or operation of the product. Trampaboards Ltd is available during its business hours and via email. For further information visit: www.trampaboards.com

Declaration of Conformity (in accordance with ISO/IEC 17050-1)

Product: VESC STR 500

Item Number: #VESC STR 500 V1.0

The object of declaration described above is in conformity with the requirements of the specifications listed below, following the provisions of the EMC Directive 2004/108/EC:

LVD 72-23 / 93/68 EWG

Nottingham, 10.01.2024

Trampaboards Ltd.

TRAMPA BOARDS LTD 2002 - 2016

Company Registration UK 4653504

Registered Business Address: Unit 16, Centre Court, 33 Little Tennis Street, Colwick, Nottingham, NG2 4EL, United Kingdom

This device is manufactured to meet the RoHS2 (2011/65/EU) regulations.

Instructions for disposal of WEEE by users in the European Union

This product must not be disposed of with other waste. Instead, it is the user's responsibility to dispose of their waste equipment by handing it over to a designated collection point for the recycling of waste electrical and electronic equipment. The separate collection and recycling of your waste equipment at the time of disposal will help to conserve natural resources and ensure that it is recycled in a manner that protects human health and the environment. For more information about where you can drop off your waste equipment for recycling, please contact your local city office, your household waste disposal service, or where you purchased the product.

FCC COMPLIANCE

This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.

NOTE: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

Reorient or relocate the receiving antenna.
Increase the separation between the equipment and receiver.
Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.
Consult the dealer or an experienced radio/TV technician for help.

The following parties are responsible for the compliance of radio frequency equipment with the applicable standards: in the case of equipment subject to authorization under the verification procedure, the manufacturer or, in the case of imported equipment, the importer. If, subsequent to manufacture and importation, the radio frequency equipment is modified by any party not working under the authority of the responsible party, the party performing the modification becomes the new responsible party.