Boiler
160
Error code 160 on a Potterton boiler indicates a fan or air pressure fault — a safety lockout that stops the boiler firing until the underlying problem is resolved. It’s a moderately serious fault that almost always requires a Gas Safe registered engineer.
What does this error mean?
The 160 error means your boiler’s control board has detected a problem with the flue gas fan or the air pressure circuit. The fan is responsible for pushing combustion gases safely out through the flue; if it’s not running correctly, the boiler locks out as a safety measure to prevent dangerous gases building up inside your home. The boiler will not restart automatically until the fault is cleared.
Est. repair cost
£80–£350 depending on faulty component (pressure switch vs. fan motor); full boiler replacement £1,800–£3,000 installed
🔍 Likely causes
🛠️ Step-by-step fix
Step 1 — Reset the boiler: Press and hold the reset button for 3–5 seconds (location varies by model; check your manual). Wait 60 seconds to see if the boiler fires up normally. This clears a temporary lockout caused by a momentary glitch.
Step 2 — Check the flue terminal externally: Go outside and visually inspect the flue outlet (usually on an external wall or roof). Look for obvious blockages — bird nests, leaves, or ice. Do not poke anything into the flue yourself; call an engineer if you spot a blockage.
Step 3 — Check your gas supply: Confirm other gas appliances (hob, fire) are working. If they’re not, contact your gas supplier — a supply interruption can cause a boiler lockout.
Step 4 — Do not attempt further DIY: The fan, pressure switch, hose, and PCB are all internal components. Accessing or replacing them on a gas boiler is illegal without Gas Safe registration. Stop here and call a professional.
Step 5 — Book a Gas Safe engineer: Contact a Gas Safe registered engineer and tell them your boiler model (e.g. Potterton Performa 28i), the error code displayed (160), and whether the reset cleared it temporarily or not. This helps them arrive prepared with likely parts.
📞 When to call a professional
Call a Gas Safe registered engineer if the boiler fails to fire after a single reset attempt, or if the error returns within a short time. Tell them it’s a Potterton error code 160 (fan/air pressure fault) and give your exact boiler model — this allows them to bring the correct fan or pressure switch. Do not attempt to open the boiler casing or tamper with any internal components.
⚖️ Repair or replace?
A fan replacement on a Potterton boiler typically costs £150–£350 all-in including labour; a pressure switch is cheaper at £80–£180. If your boiler is over 10–12 years old and repairs are pushing past £400, replacement with a modern A-rated combi (£1,800–£3,000 installed) is usually the more cost-effective long-term decision. Potterton parts availability can be limited on discontinued models, which is another reason to consider replacement on ageing units.