Error E160

Safety precautions:

- If you smell gas or suspect a gas leak, leave the property immediately and call the gas emergency number. Do not operate electrical switches or the boiler.

- For all work beyond simple visual checks and resets, use a Gas Safe registered engineer. The fan is part of the combustion system and any repairs or replacement require correct seals, commissioning and safety checks.

- Before doing any visual checks, switch the boiler off at the boiler control and at the mains isolator (or the consumer unit). Do not open the boiler casing unless you are qualified.

Initial homeowner checks you can safely do:

1. Note the error: confirm the boiler is showing E160. If it is, take a photo of the display or write it down for the engineer.

2. Simple reset: try a single reset using the boiler reset button or switch the boiler off at the mains for at least 30 seconds and then back on. If the fault is temporary it may clear, but if it returns do not repeatedly reset.

3. Check the flue terminal outside the property for obvious blockages (birds’ nests, leaves, debris, heavy snow). If the flue is blocked, remove the obstruction if it is safe to do so from outside. Do not probe the flue from inside the boiler.

4. Check that the boiler has mains power and the household supply voltage is present (lights, sockets). If other electrical issues are present, mention them to the engineer.

5. Listen: when heating or hot water demand is called the pump will run first then the fan should start. If you hear the pump but no fan noise at all, the fan is not running. If you hear a hum but no rotation it may be seized.

6. Look for signs of water ingress, corrosion or rodent damage to external cabling or the flue route; do not open the boiler to inspect internal components.

Specific diagnostic and likely repair steps (for a qualified engineer):

1. Confirm fault history and re-run diagnostics on the boiler control to log the E160 and any associated codes.

2. Check voltages and signals at the fan connector and at the PCB per manufacturer data. Many modern fans use variable DC control and tachometer feedback; verify the control voltages and feedback signal. Never measure live circuits unless qualified.

3. Inspect fan and harness for corrosion, water damage or rodent damage. Check the tachometer sensor and wiring continuity.

4. Check that the flue thermostat/thermistor and flue path are clear and operating correctly; some related flue sensor faults can cause similar lockouts.

5. Remove and bench-test the fan assembly: check that it receives correct supply and whether the motor spins freely and the internal electronics/tachometer operate. If the fan receives correct power but does not run or does not provide the expected speed feedback, replace the fan assembly.

6. If the fan appears OK but there is no correct drive or feedback from the PCB, further PCB diagnostics are required; engineer may repair or replace PCB as appropriate.

7. After replacement or repair, the engineer must reassemble using correct seals/washers, ensure injectors and sensing pipes are correctly refitted (as applicable), perform combustion and safety checks, and run the required commissioning and leak checks.

When to call a professional and what to tell them:

- Call a Gas Safe registered engineer as soon as possible if the E160 persists after a single reset, if you hear no fan noise when the boiler should be starting, if you find flue blockages that you cannot safely clear, or if you find evidence of water or wire damage. Do not attempt to open the combustion chamber or replace the fan yourself.

- When you call, give the engineer the boiler model (Potterton Promax Ultra / Gold / Titanium), the exact error code E160, any other codes displayed, what troubleshooting steps you have already tried (reset, flue check, photos), and any relevant history (recent leaks, rodents, power cuts).

Final notes:

- Repeated resets are not a solution; persistent E160 indicates a safety-critical failure that needs a qualified repair. The fan replacement and post-repair testing must be done by a Gas Safe engineer to ensure safe combustion and compliance with regulations.

- If on-site conditions indicate a gas smell, suspected leakage or obvious physical damage, isolate the property from the gas supply and contact emergency services and a Gas Safe engineer immediately.