Error E160

Safety precautions:

1) If you suspect a carbon monoxide smell, evacuate the property, ventilate, and call the emergency services and Gas Safe immediately. Do not use the boiler.

2) Before touching the boiler, switch off the electrical supply at the isolator and turn off the gas supply if you know how and it is safe to do so. Only perform visual checks; do not open sealed combustion chambers or remove safety covers.

3) Never attempt to replace the fan or carry out combustion adjustments yourself. Only a Gas Safe engineer should work on gas-carrying or sealed parts.

Initial checks a homeowner can do (safe, simple checks):

1) Note the exact error (E160) and any other codes or lights. Write them down for the engineer.

2) Try a boiler reset following the manufacturer’s procedure (usually power off for 30 seconds then on). If the fault returns immediately or after one reset, further checks are needed.

3) Check the boiler has mains power (other lights/functions working) and any fused spur or RCD hasn’t tripped. Do not probe live terminals.

4) Check system water pressure on the gauge; very low pressure can cause shutdowns on some models (top up only if you know how and it is safe).

5) Inspect the external flue terminal for obvious blockage (birds’ nests, debris) and clear any visible obstruction from outside. Do not insert objects into the flue.

6) In cold weather check the condensate pipe for freezing and, if frozen, follow safe thawing advice or call an engineer.

7) If you can hear the boiler sequence when a heat demand is made: listen for pump and then fan. If there is no fan noise at all, that supports a fan fault.

Specific diagnostic and fix steps (what an engineer will do):

1) Confirm fault code history and run the boiler through a controlled start-up to observe the sequence and fan behaviour.

2) Remove outer panels and visually inspect the fan, harness connectors and surrounding PCB for signs of water ingress, corrosion, burn marks, rodent damage or loose connectors.

3) With correct isolation and safety procedures, measure voltages and control signals at the fan connector (engineers use a multimeter and oscilloscope/tachometer where required). Check for DC supply to a variable-speed fan and the tachometer/speed signal back to the PCB.

4) Check continuity of the fan harness cables and for short circuits to earth. Inspect and, if necessary, re-crimp or replace damaged connectors.

5) Manually check the fan for mechanical seizure or damaged blades; free and clean if lightly blocked. If the motor is seized or bearings/power electronics on the fan are faulty, the fan assembly will need replacing.

6) If fan electronics appear OK, test the main PCB outputs to the fan to determine whether the PCB is commanding the fan correctly. Replace or repair PCB only after confirming the fan itself is functional.

7) Replace the fan assembly and harness with the correct part if required. After replacement, the engineer will reassemble, test for gas tightness where relevant, and perform combustion and safety checks to ensure everything is operating within spec.

8) Clear codes and run the boiler through multiple heat/dhw cycles to verify the fault is resolved.

When to call a professional and final notes:

1) If the E160 code persists after a reset, or if you hear no fan noise when the boiler tries to start, call a Gas Safe registered engineer. Any electrical testing beyond visual checks, dismantling the boiler, fan replacement, gas isolation work or combustion checks must be done by a qualified engineer.

2) Ask the engineer to check for the root cause (wiring damage, water ingress, seized fan, PCB fault) and to record which component failed. Regular annual servicing reduces the chance of fan faults developing.

3) Do not attempt fan replacement, PCB replacement, or sealing work yourself — these tasks require specialist equipment and gas-safety certification.