M,
Welcome to 80/20, and thanks for your great feedback. For a full review of the PMC and the 80/20 system, please see our document Understanding and Adjusting Your Performance Management Chart. There is a known bug in TP where predicted hrTSS will never match actual hrTSS, addressed in that document.
However, the bug makes hsTSS about 20% off, not 2-3 times, so something is still amiss. I suspect that you might still be using tp Default zones instead of specific 80/20 bike and run HR zones. Please also review the document Understanding Your TrainingPeaks Structured Workout Plan to ensure your zones are correct.
If you’ve followed those steps, and still see the issue, let’s attach your account to mine in TP and I can have a direct look.
David