E22 on Carrera Crossfire Ebike

[wezwal]

Afternoon, I am new to this site, and thank you taking the time to hopefully help in getting my ebike back into the into life.

Basically I brought a 2nd hand Carrera Crossfire ebike about six months ago, and whilst there seems a lot of negative on the chat about the brand, it has been good to me, and I have done over 2,500 during that time.

But a couple of days ago during a ride, the started randomly cutting out, and the reason given was the “Battery was Overheating”. So I took the bike home once this happened a few times.

Then the next day the overheating error happened a couple of times, and then the bike completely cut out, with E22 flashing on the screen.

I have done a bi of research and the Carrera bikes have SR Suntour motors, who have created an online manual for the bikes, and the following is written as a solution for this error.
Error 22: Torque Sensor mechanical problem
Check the Torque Sensor cable contacts
Replace the Chain wheel with ATS sensor

Other useful info was found on the Pedelecs website, left by indivduals, and their answers include:

• "E22 often more then not is used for battery BMS comm's fault. And the solution is to replacing the battery”
• “E22 is battery overheating - nothing to do with any fall. Most likely a faulty sensor".

Q – Vulcan has an error code 22 which means the crank needs to be replaced???
A - Your sensor wire has broken. Just connect them (Red, Green, Yellow and Black)

I thinking that the new battery option may be closest (cause of what happened the day before the E22 took over, as I stripped / cleaned cleaned the Torque Sensor cable etc last night, and minimal dirt removed, as not much was in the system.

Any suggestions to get my bike back on the road would be greatly appreciated.

Cheers, Andrew

 

[Nealh]

If the battery issue then it won't be the battery per se but likely be an over sensitive temperature sensor or the BMS.

Others have ripped out the TS and controller and replaced them with KT controller kit or other controller kit for reliability.

 

[vfr400]

Take the torque sensor off and clean it. At the same time, check that the wires haven't been damaged.

Cleaning is a bit tricky. There are tiny thin slots with light emitters and sensors. You have to get in there and clean the crud out.

 

[wezwal]

If the battery issue then it won't be the battery per se but likely be an over sensitive temperature sensor or the BMS.

Others have ripped out the TS and controller and replaced them with KT controller kit or other controller kit for reliability.

Thanks for sharing your knowledge, as really appreciate it. And when I attempt another deep clean, how do I get inside it, to check on the condition of the wires??
Thanks in advance, Andrew

 

[wezwal]

Take the torque sensor off and clean it. At the same time, check that the wires haven't been damaged.

Cleaning is a bit tricky. There are tiny thin slots with light emitters and sensors. You have to get in there and clean the crud out.

Cheers for the answer. But can you confirm how I get inside the sensor to check on the condition of the wires.
Cheers, Andrew

 

[Nealh]

For the battery you have to try and open it but it is a last option if all else fails.
Some are easy and you simply undo the machine screws others use snap clips which are not easy to open.

 

[wezwal]

Hello hello,

Sorry to be a pest again, but I have one question I hoping someone can help me with.

At the moment my Carrera Crossfire ebike is giving me the error code E22, and the hopefully solution I going with is to replace the toqure sensor with a brand new one (which as luck would have it arrived today.

So the problem I'm now having is I am unable ./ unsure how to remove the remove current one to replace it with the brand new one I now have.
Any wise words on how to safely complete this task would be greatly appreciated, as old mate google to giving me currently giving me the silent treatment

As hopefully once the new sensor is fitted it will me back on the streets of London Town.

Cheers, Andrew

P.S. - If anyone is looking for a unique, super quick and reasonably priced biking goods supplier, 'Power Bikes UK' are awesome, and I can't thank enough for the speed the delivered a hard to find product.

 

[vfr400]

Hello hello,

Sorry to be a pest again, but I have one question I hoping someone can help me with.

At the moment my Carrera Crossfire ebike is giving me the error code E22, and the hopefully solution I going with is to replace the toqure sensor with a brand new one (which as luck would have it arrived today.

So the problem I'm now having is I am unable ./ unsure how to remove the remove current one to replace it with the brand new one I now have.
Any wise words on how to safely complete this task would be greatly appreciated, as old mate google to giving me currently giving me the silent treatment

As hopefully once the new sensor is fitted it will me back on the streets of London Town.

Cheers, Andrew

P.S. - If anyone is looking for a unique, super quick and reasonably priced biking goods supplier, 'Power Bikes UK' are awesome, and I can't thank enough for the speed the delivered a hard to find product.

The connector is inside the compartment at the base of the battery. You have to unscrew something. I can't remember what, but it didn't take me more than a couple of seconds to figure it out.

The sensor itself is held on with three screws. Everything you need to know is here from my thread when I stripped one down:

Carrera Crossfire/Vulcan Torque sensor

I recently stripped one down so i can describe how it works. To disassemble it, you take the crank/chainwheel off, then remove the 4 screws in the back. There's 4 shim washers in there, so be careful not to lose any. The sensor is held on with three small screws. The sensor is partly...

www.pedelecs.co.uk

 

[wezwal]

Yeh, I was meaning the part where the battery connects to the sensor, as it was hard to separate. But all done now, and I'm pleased to say that a new sensor did the trick. And the bike is back in business.

Thanks for your help boys.

Cheers, Andrew

 

[vfr400]

Now that you have the old sensor off, you can clean it and keep it as a spare. The new one will eventually get dirty. You only have to clean out the very thin slots.

 

[wezwal]

The new sensor was a good fix….. Till recently when E21 started appearing. .



So I’ve had a good look at possible solutions, and have looked under the battery cover for any loose / damaged wires, re cleaned teeth inside the crank, and I’m out of ideas.

I see John Sears (in the link below) eventually took his bike to Halfords, and the problem turned out to be mis-aligned / loose magnets in the crank..... https://www.pedelecs.co.uk/forum/threads/carrera-crossfire-e21-error.35027/post-514494

So before I take it to Halfords, I'm thinking of getting a replacement Carrera Crossfire crank from ebay (https://www.ebay.co.uk/itm/BRAND-NEW-ELECTRIC-BIKE-PARTS-NEW-CRANK-SET-WITH-FREE-POST/164280127941?ssPageName=STRK:MEBIDX:IT&_trksid=p2060353.m1438.l2649).

Is this the best route to follow? Before I go knowing on Halfords door.

Appreciate any advice

 

[Edward Elizabeth]

2 year warranty, let Hellfrauds take the strain.

 

[vfr400]

The new sensor was a good fix….. Till recently when E21 started appearing. .



So I’ve had a good look at possible solutions, and have looked under the battery cover for any loose / damaged wires, re cleaned teeth inside the crank, and I’m out of ideas.

I see John Sears (in the link below) eventually took his bike to Halfords, and the problem turned out to be mis-aligned / loose magnets in the crank..... https://www.pedelecs.co.uk/forum/threads/carrera-crossfire-e21-error.35027/post-514494

So before I take it to Halfords, I'm thinking of getting a replacement Carrera Crossfire crank from ebay (https://www.ebay.co.uk/itm/BRAND-NEW-ELECTRIC-BIKE-PARTS-NEW-CRANK-SET-WITH-FREE-POST/164280127941?ssPageName=STRK:MEBIDX:IT&_trksid=p2060353.m1438.l2649).

Is this the best route to follow? Before I go knowing on Halfords door.

Appreciate any advice

Unless they've changed something from the original Suntour HESC system on the Crossfire, there are no magnets in the crank. The whole sensor system is optical. The sensor is the bit you replaced and the bits that give it the optical signal are in the bit attached to the chainwheel.

 

[Amoto65]

2 year warranty, let Hellfrauds take the strain.

Depends how old the bike is, The OP said it was bought secondhand 6 months ago, also I am not sure if the warranty is transferable.

 

[Nealh]

Tbh the most cost effective and easiest solution is to do what some others have done and replace the electronics and TS PAS with a KT system for less then £100.

 

[wezwal]

Unless they've changed something from the original Suntour HESC system on the Crossfire, there are no magnets in the crank. The whole sensor system is optical. The sensor is the bit you replaced and the bits that give it the optical signal are in the bit attached to the chainwheel.

Not changed anything, and to be honest this is my first electric bike g7

Unless they've changed something from the original Suntour HESC system on the Crossfire, there are no magnets in the crank. The whole sensor system is optical. The sensor is the bit you replaced and the bits that give it the optical signal are in the bit attached to the chainwheel.

Yeh, I'm basically a newbie to this whole electric bike thing, and it was brought 2nd hand, so no warranty. And whilst I though it had no magnets, the comment in the message below basically came from someone who also had a crossfire e-bike, so I was just imagined it might be a possibility.

Carrera Crossfire E21 Error

I know this bike gets somewhat mixed reviews due to the cutting-out problems. After reading lots of online comments I was reasonably happy that the problems are often related to lose connections and often cable ties have seemed to solve the issue. So I went for a 2nd hand one on ebay. Looks in...

www.pedelecs.co.uk

But I think I will definitely look at the look into Nealh's suggestion..... As I'm new to all this electric stuff.... But I love the bike, and it would be great not having to stop start every few weeks. So thanks for repeating Nealh. As is it just getting the parts together, and assembling. Or is welding etc involved??

Cheers