TSDZ2B OSF - Random Thermal Throttling

[first.loser]

I have a TSDZ2B with OSF.

When it is behaving normally, the temperature would be something like 20*C up to 38*C.

However, I have instances when the temperature would shoot up from 20*C up to 60, 80, 120+ *C even while I am fully stopped at an intersection.

I have tuned the motor down to draw a maximum of 8amps from 11 amps thinking it is drawing too much and heat builds up.

I have also turned down my assist in power and torque to provide 10% more in level 1 up to 20% more in level 3. (I only use level 1 assist most of the time).

Initially this seemed to help since my temperature no longer shoots up. It was like this for almost a month. However, yesterday it started to temperature throttle like crazy at 120+*C.. even at level 1 assist. I also noticed progressively weaker assist halfway into my commute even thought it says I am getting an additional 70 watts of electric assist.

I am trying to figure out what is going on here. According to my 860C display I normally draw 2.6amps and never went over 7.9amps..

Could a battery cause this?

Here are my specs:

TSDZ2B with OSF and 860C display 48v 750W
Brass Gear
Premium cooling Kit from ebike stuff (plate, fins, everything)
Temperature Sensor (LM35 bought from digikey)

Battery is a RADMISSION 1 48v 10.5aH 504wH which I got from my old bike. I've only been using the supplied charger for it.

I limited the TSDZ2B to provide no more than 300 watts of electric assist. I really under powered everything to try and eliminate the heat problem.

 

[Zambam]

I thought I would post an update.

My old battery (RADMISSION Battery Pack) had unknown specs regarding these and I could only top out at 5a setting in OSF and limited to 250w. Setting it higher would give funny readings and loss of power over an extended period.

I just bought a new battery to experiment with and it outputs 20a continuous and 30a peak with Panasonic Cells. I upped the amps in OSF to maximum 12a and 350w peak.

At the same time I also redid my wiring so it goes over and around the frame when I changed battery. I eliminated sharp bends etc. No fake temp readings. Temps stayed below 35*C. I rode like this for a week. I just didn't like how there's a bunch of wires showing on my bike...

Last night I did my wiring as before thinking my old battery was the problem and I liked to the clean look. Near then end of my commute I got the fake temp noise again and no power.

I will be redoing my wiring again to go around the frame..

Thanks for the update. Nice to hear that issues with your ride seems to have been resolved! So it was a flaky battery and sharp bends in the wiring which were the culprits? How about post up a pic of your whole bike?

 

[debo]

I have a TSDZ2B with OSF.

When it is behaving normally, the temperature would be something like 20*C up to 38*C.

However, I have instances when the temperature would shoot up from 20*C up to 60, 80, 120+ *C even while I am fully stopped at an intersection.

I have tuned the motor down to draw a maximum of 8amps from 11 amps thinking it is drawing too much and heat builds up.

I have also turned down my assist in power and torque to provide 10% more in level 1 up to 20% more in level 3. (I only use level 1 assist most of the time).

Initially this seemed to help since my temperature no longer shoots up. It was like this for almost a month. However, yesterday it started to temperature throttle like crazy at 120+*C.. even at level 1 assist. I also noticed progressively weaker assist halfway into my commute even thought it says I am getting an additional 70 watts of electric assist.

I am trying to figure out what is going on here. According to my 860C display I normally draw 2.6amps and never went over 7.9amps..

Could a battery cause this?

Here are my specs:

TSDZ2B with OSF and 860C display 48v 750W
Brass Gear
Premium cooling Kit from ebike stuff (plate, fins, everything)
Temperature Sensor (LM35 bought from digikey)

Battery is a RADMISSION 1 48v 10.5aH 504wH which I got from my old bike. I've only been using the supplied charger for it.

I limited the TSDZ2B to provide no more than 300 watts of electric assist. I really under powered everything to try and eliminate the heat problem.

If you still have that bad battery it might still be good and just out of balance that's quite common , and if so rebalance and replace bms with one that has Bluetooth that way you always know your battery health .

 

[debo]

An exposed control!er can Dissipate heat , an enclosed unit can not and will overheat so putting air vents on top and bottom will allow the natural flow of hot air to circulate with cooler air , you could even try to get a forward openings to help tunnel that air in wile riding .

 

[first.loser]

Here is my ride.

The first pic had all of the wiring crammed inside the cup in the water water bottle holder underneath the downtube.

I spread the wiring as best as I can while trying to hide it.. around the battery and mostly behind the seat post. It doesn't look as clean but I gained another bottle holder in the process .