The most common issues include Hot Logic controller failures (occurring every 1-3 years for many systems), Grundfos circulation pump breakdowns (typically after 2-3 years with only 1-year warranty), temperature sensor errors causing flashing green lights, diverter valve malfunctions in gas-boosted models, and pressure relief valve constant leaking. These systems also commonly experience calcium buildup in pipes and pump impellers, inadequate hot water due to the mid-mounted heating element only heating half the tank, tank sensor failures that prevent proper operation, overheating on sunny days, and electric element failures. Brisbane's hard water exacerbates many of these problems. Our technicians see these issues daily and stock the parts needed for quick repairs.

Repair costs vary by component: Hot Logic controller replacement costs $300-$425, Grundfos circulation pump replacement costs $300-$500, temperature sensors cost $150-$250 each (sometimes both roof and tank sensors needed), diverter valves cost $200-$400, pressure relief valves cost $180-$300, electric heating elements cost $250-$450, thermostats cost $180-$280, and descaling/cleaning services cost $200-$500. If you need a pressure limiting valve installed to protect your system, that's an additional $250-$400. Multiple component failures can cost $600-$1,200+ to repair. We always provide upfront pricing before starting work - no hidden fees or surprise charges. Call us for a specific quote based on your system's symptoms.

The Grundfos pumps in Dux Eco Smart systems typically last only 2-3 years despite being critical components. Common failure causes include: calcium buildup from Brisbane's hard water clogging the impeller, pump running dry due to air in the system, electrical issues from controller problems, bearing wear from continuous operation, and manufacturing defects in the pump itself. High water pressure (over 500kPa) also accelerates pump failure. Unfortunately, Dux only warranties the pump for 1 year, so subsequent failures are out-of-pocket. We recommend installing a pressure limiting valve if your water pressure is high, regular descaling maintenance, and ensuring your controller is functioning properly to prevent unnecessary pump cycling. Some customers experience pump failures every 2 years, which is frustrating but repairable.

A flashing green light indicates a sensor error - either the roof collector sensor or the tank sensor (or both) has failed or is giving incorrect resistance readings. The Hot Logic controller needs accurate temperature data from both sensors to determine when to run the circulation pump. Without this data, the system defaults to electric boost only, wasting all your free solar energy and increasing electricity costs significantly. Common causes include: sensor cable damage from UV exposure and weather, moisture in the sensor port (especially in older stainless steel tanks causing incorrect Ohm readings), sensor reading zero resistance when disconnected, or the sensor thermistor itself failing. We can diagnose which sensor has failed using a multimeter to check resistance values, then replace the faulty sensor and cable if needed. Most sensor replacements can be completed same-day if we have the part in stock, getting your solar system working again quickly.

Yes! Todd's Plumbing offers same-day emergency service for Dux Eco Smart repairs throughout Brisbane, North Brisbane, South Brisbane, Ipswich, Logan, and surrounding areas. We understand how critical hot water is for your family, especially during winter months. We stock the most common Dux Eco Smart replacement parts including Hot Logic controllers (H3201, H3214, H3200 models), Grundfos circulation pumps, roof and tank temperature sensors with 20m cables, diverter valves, pressure relief valves, electric heating elements, and thermostats. This means we can often diagnose and complete repairs on the first visit without waiting for parts. Call us before 2 PM for same-day service Monday through Saturday. Sunday emergency service is also available. We'll get your hot water working again fast so your family doesn't suffer through cold showers.

This depends on several factors: system age, problem severity, and repair history. If your Dux Eco Smart is under 5 years old and needs a single component replacement (controller, pump, or sensor), repair is usually cost-effective at $300-$500. However, if you're experiencing recurring failures - such as replacing the Hot Logic controller every 12-18 months, or if your pump has failed 3+ times, or if you have multiple simultaneous component failures - the system may not be worth continued investment. Systems over 7-10 years old with major issues (tank leaking, multiple component failures, corroded panels) should generally be replaced. A new quality heat pump system costs $3,500-$6,000 installed and will be more reliable and efficient. We'll always give you honest advice about what makes the most financial sense for your situation. Some customers throw good money after bad repeatedly repairing Dux systems that have fundamental reliability issues. We can also recommend more reliable alternative systems if replacement makes sense.

A constantly leaking PTR (Pressure & Temperature Relief) valve indicates serious problems. Normal operation allows 3% of tank capacity to discharge during heating cycles, but continuous leaking means: 1) System overheating above 85°C (usually on very sunny days with low usage - the top tank sensor should prevent this but may have failed), 2) Excessive water supply pressure over 500kPa (common in Brisbane areas with high mains pressure), 3) Faulty thermostat causing element to overheat water, 4) The PTR valve itself has failed and stuck open, or 5) Foreign matter preventing the valve from sealing properly. If discharging more than 20 litres per day, this is excessive and wastes water while indicating potential danger. We'll check your mains water pressure first, test the tank temperature sensors, verify thermostat operation, and inspect the PTR valve itself. Solutions include installing a pressure limiting valve ($250-$400), replacing the PTR valve ($180-$300), replacing faulty temperature sensors ($150-$250 each), or adjusting/replacing the thermostat. Never ignore a constantly leaking PTR valve - it's your system's safety mechanism telling you something is wrong.

Regular maintenance is essential for Dux Eco Smart longevity. We recommend annual professional servicing ($180-$280) which includes: checking and testing both temperature sensors for correct Ohm readings, testing circulation pump operation and checking for calcium buildup in impeller, inspecting Hot Logic controller for error codes and proper LED indicators, checking roof panel condition and cleaning if needed, testing pressure relief valve operation, inspecting all pipe connections for leaks or corrosion, verifying electric element function and thermostat settings, checking sacrificial anode condition (should be replaced every 5 years at $200-$350), and flushing the tank to remove sediment. Additionally, install a pressure limiting valve if your mains pressure exceeds 500kPa (costs $250-$400 but prevents many failures), descale the system every 2-3 years in Brisbane's hard water areas ($200-$500), monitor the Hot Logic controller display regularly for error codes, and operate the PTR valve lever monthly to prevent it seizing. Catching small issues early prevents expensive major failures. Many customers who skip maintenance end up with $1,000+ repair bills that could have been prevented.

Lukewarm water is a common Dux Eco Smart complaint with several possible causes. First, the mid-mounted electric element is a design limitation - it only heats the top 200L in a 400L tank, which is often inadequate for families. If you're using more than 200L between heating cycles, you'll get lukewarm water. Second, the tempering valve (required by Australian standards to prevent scalding) may be incorrectly adjusted or faulty, over-mixing cold water and reducing outlet temperature. Third, if your solar system isn't working (failed pump, sensors, or controller), you're only getting half-tank electric heating. Fourth, your thermostat might be set too low or faulty. Fifth, if you're on off-peak tariff with limited heating hours, the tank may not fully recover between usage periods. Solutions include: adjusting or replacing the tempering valve ($180-$320), repairing the solar circulation system (pump $300-$500, controller $300-$425, sensors $150-$250 each), adjusting thermostat to 70°C (from standard 60°C), switching to off-peak 2 tariff for daytime boost, or considering a larger tank or different system. We'll diagnose your specific issue and recommend the most cost-effective solution.

The Hot Logic controller (made by Resol in Europe) is the weakest link in Dux Eco Smart systems. Multiple factors cause frequent failures: 1) Electronic components not rated for Australian climate extremes (Brisbane heat and UV exposure), 2) Moisture ingress into the controller housing causing short circuits, 3) Power surges from the electrical grid damaging sensitive electronics, 4) Pump or sensor faults causing the controller to work incorrectly and burn out, 5) Manufacturing defects in certain batches, and 6) The controller working continuously 365 days/year with no rest periods. Many homeowners report replacing the H3201 controller 3-4 times over 10 years, which is unacceptable for a component costing $300-$425 each time. Dux has updated to newer models (H3214, H3200) which may be more reliable, but many systems still use the problematic older controllers. We recommend protecting the controller with a weatherproof cover if exposed, installing surge protection on the electrical supply, and ensuring pump and sensors are functioning correctly to reduce controller stress. Unfortunately, there's no permanent fix - it's a fundamental design/quality issue with these controllers.

Determining leak vs. normal discharge is critical. Normal discharge: The PTR valve should release about 3% of tank capacity during heating (12-15L for a 400L tank), appearing as occasional trickle. Some condensation around pipes is also normal in humid Brisbane weather. Tank LEAKING (serious): Water pooling constantly around tank base, rust-colored water, water weeping from tank seams or welded joints, leak from sensor port (common in older stainless tanks), or corroded areas on tank surface. If you're seeing constant water discharge exceeding 20L/day, this isn't normal. Check the source carefully: Is water coming from the PTR valve drain line (likely valve issue or system overheating), from pipe connections (needs tightening or washer replacement, $120-$200), from around sensors (sensor port failure, may need new sensor location created), or from the tank body itself (serious - likely needs replacement $3,500-$6,000). Don't ignore tank leaks - they worsen rapidly and can cause water damage to your property. Call us immediately for diagnosis. Minor connection leaks are cheap fixes ($120-$250), but tank body leaks usually mean replacement time, especially if the system is over 7 years old.

Determining leak vs. normal discharge is critical. Normal discharge: The PTR valve should release about 3% of tank capacity during heating (12-15L for a 400L tank), appearing as occasional trickle. Some condensation around pipes is also normal in humid Brisbane weather. Tank LEAKING (serious): Water pooling constantly around tank base, rust-colored water, water weeping from tank seams or welded joints, leak from sensor port (common in older stainless tanks), or corroded areas on tank surface. If you're seeing constant water discharge exceeding 20L/day, this isn't normal. Check the source carefully: Is water coming from the PTR valve drain line (likely valve issue or system overheating), from pipe connections (needs tightening or washer replacement, $120-$200), from around sensors (sensor port failure, may need new sensor location created), or from the tank body itself (serious - likely needs replacement $3,500-$6,000). Don't ignore tank leaks - they worsen rapidly and can cause water damage to your property. Call us immediately for diagnosis. Minor connection leaks are cheap fixes ($120-$250), but tank body leaks usually mean replacement time, especially if the system is over 7 years old.

High electricity usage means your solar system isn't working, forcing the electric boost element to do all the heating. Common causes: Failed circulation pump (no water circulating from hot roof panels to tank), faulty Hot Logic controller (pump not activating despite hot panels), failed temperature sensors (controller doesn't know when to run pump), blocked pump impeller from calcium buildup (pump running but not moving water), air in the system preventing circulation, faulty diverter valve in gas systems, or panels not collecting heat due to damage/dirt. Normal solar operation should show: Hot Logic displaying both green (power) and red (pump active) lights during sunny periods, audible pump humming noise, roof panels hot to touch (careful!), and minimal electricity usage on off-peak meter (only for legionella sanitization cycle to 60°C). If your off-peak meter shows 3-4 kWh daily or more, the solar isn't contributing. We'll diagnose why your solar system isn't working: test pump operation ($300-$500 if failed), check controller function ($300-$425 if failed), test both sensors ($150-$250 each if failed), inspect panel connections, and check for circulation blockages. Fixing the solar system will dramatically reduce your electricity bills - often paying for the repair within 6-12 months through energy savings.