How to build the TSDZ2 EBike wireless controller

Before you start you need to decide how you want to attach buttons and brake sensors and whether you want the option to have fewer wires on your EBike.

Both options require the use of the mobile app to configure the EBike. The mobile app connection is not required to control the EBike when riding - but can be used to provide real-time statistics; speed/motor current etc.

You will need the following components:

Step by step instructions

1 - Flash bootloader on the nrf52840 board - see the page: How to Flash the Wireless Bootloader on a Nordic Dongle

2 - Build your board

2.1 - Cut your nRF52840 board with a metal saw by hand and this way it will be smaller - here a picture as example:

2.2 - Solder all the components following the next schematic.

Schematic: Standard Controller (also need to build Wireless Remote)

Schematic: Wireless Controller with Wired Buttons (Wired Remote)

Wire multiple brake sensors in parallel.

nrf52840 board pinout: Pinout

Next steps considers you are using the small DC-DC XP Power STH0548S05. If you decided to use the “EBike buck dd7818ta 80”, the see instead here: build using the EBike buck dd7818ta 80

A perfboard were cut in a way that is has almost the same area as the 3D printed box:

The nrf52840 board were soldered to the perfboard using six small wires, to connect the needed six pads as you can see on the schematic:

Here we can see the perford on the other side and the six small wires soldered:

Next step were to solder the DC-DC board and the mosfets. Only that three connections of DC-DC are used, the GND on one side and Vin and Vout on the other side. Also I did not have with me the BSP296 mosfet and used another equivalent but smaller. (I also did cut a bit more the perfboard but was a mistake):

Next, I tested to see if the board did fit on the case (image from old design):

Next I soldered all the wires including the ones of the cable to connect on the TSDZ2 display connector.
See that other than the TSDZ2 display connector wires, there is only need for more five wires. And I could use for sure thinner wires, but I used the ones I had at hand:


Use the four M2x6 screws to fix the cover. The hole is for the RGB LED but you can verify you can still click on the board button:

Download here the files for 3D print the box:

3 - Flash firmware on the nrf52840 board - see the page: How to Flash the Wireless Remote and Motor Controller Firmware

4 - Test - To avoid damaging your board or/and the TSDZ2 controller, follow the following steps to plug your board on the TSDZ2:

  1. Disconnect the battery to the TSDZ2,
  2. Wait few seconds to discharge the capacitors in the TSDZ2,
  3. Connect your wireless controller to the TSDZ2,
  4. Plug the battery back. when the board is powered up and running the firmware, you should see the “TSDZ2” Bluetooth device on your mobile phone.

5 - Making water prof and install on EBike

I did fill be box holes with translucid silicone and inserted the board - my objective is to have a water prof device. But I do not put to much silicone because I may need to repair the board later. I put silicone on the cables, to avoid the vibrations on the bicycle to break the wires over the time.

After 24 hours waiting for silicone to dry. I did fully cover the hole and it works very well to see the LED light(image from old design):

Checking to see if it still works (image from old design):

Final installation on the frame of my EBike (image from old design):