Diagnose & Fix Water Softener Resin Loss problems.

This article describes the symptoms of resin loss from a water softener and suggests how the problem may be repaired. If you see yellow or reddish debris at the water softener drain or at faucet strainers & shower heads, the water softener resin may be deteriorated or an internal part in the water softener may need replacement.

We include a description of the size range of water softener resin bead sizes or mesh sizes for regular and fine mesh softener resins and also we describe the stack distributor or filter mesh or opening sizes used.

Small find debris particles may indicate that the resin needs replacement, while larger particles may mean that a distribution basket or strainer is damaged or broken.

This article series describes procedures for diagnosing and repairing water softener or water conditioner problems including water conditioner control settings and adjustment or repair, brine tank and brine tank float cleaning and repair, and the proper amount of water softening or conditioning that is needed.

This water softener repair article describes what to check first if the softener is not working properly. Also see the FAQs at the end of this article for examples of water softener problems & solutions.

Causes & Cure for Water Softener Resin Loss

Question: Performa water softener keeps clogging my washing machine with yellow stuff

7/19/2014 (4 hours ago) james lavalley email is jel122643@gmail.com said:

I have a performa water sofner.It keeps plugging up my washing machine screen with a
yellow substance and makes the washer not fill. Please help

Reply: possible resin loss from a water softener

James

This sounds as if the water softener is sending debris from the brine tank OR actual resin from the softener out with the house water supply. You could try emptying and sanitizing the brine tank (articles here describe how to do that).

But I suspect it's a resin problem - which means it's time to call your local water conditioner company to take a look at the equipment. I'll do some further checking and comment further as well.

Question: What is causing the resin loss from my water softener? Brine tank taking on air causing resin to discharge out of the drain during regen cycle.

2016/03/22 Jonny said:
I have a Fleck 5600 softener that appears to work through all cycles of regen and uses the appropriate amount of salt. The problem is after the water is sucked out of the brine tank it sounds like it is taking on air which is leading to resin coming out the drain during the following phase. The air noise sounds like it is coming from the head unit, not the float valve in the tank. Any suggestions as to what could cause an air leak from the head unit?

[Click to enlarge any image]

At above/left: water flow through a typical water softener, adapted from APSwater's water softener diagram cited below.

Reply:

Good question, Jonny and not one I've heard before. I'd look for a damaged O-ring in the control head and its valves.

Jonny said:
Thanks for the suggestion Dan. I checked all the internal O rings and they all appear to be in good shape. The air noise seems to be coming from near the piston or the bypass valve on the output side. If I close the bypass valve while it is making the air noise, the air sound stops. The piston is in good shape and the spacers around it look decent as well, though not perfect. Is it possible there is an air leak by the bypass valve?

Jonny:

RE: water softener media loss.

Are you sure that there is air in the system? If you see air discharge at faucets the answer is yes, else, perhaps no. If yes, search InspectApedia.com for AIR DISCHARGE AT FAUCETS to diagnose and fix that problem as it may be originating outside of the softener itself (such as in well piping or water piping). It is possible that large amounts of air moving through a water conditioner might push media out of the unit.

Some of the water softener resin loss diagnosis sources I researched suggest that failing, clogging water conditioner resin can result in resin loss and suggest diagnosing that problem by looking in your faucet strainers or shower heads: if you see resin or sand-like particles there in the source could be softener resin. Resin "fines" may show up as silt too: broken-up resin particles are moving out of the softener and through the water system.

Note that actual soil, clay, or sand may also show up in the water supply and in strainers and shower heads if it is coming from a private well, particularly for some water sources that contain silt or from a well with a cracked or damaged casing or from a well that is running low on water).

A second, different manifestation of water conditioner resin age-failure is reduced water flow through the system, something people may more loosely call reduced water pressure.

To diagnose this problem I have two suggestions.

1. Check for other causes of air discharge at faucets - see the link I gave earlier - AIR DISCHARGE AT FAUCETS (search InspectAPedia.com for that term).

2. Put the water conditioner / softener in BYPASS mode. If the silt and debris problem goes away (or the "air" problem goes away) then we're pretty sure the problem is indeed in the softener.

Air discharge traced to water softener - more things to check:

Some water softeners include an air disperser in the brine injector plumbing. Look at the parts explosion for your water softener for an air disperser that may be found in the valve body downstream from the injector assembly inside the control valve. If this part is cracked, broken, or simply missing (following hasty repair work), air entering the system may cause weak brine flow as well as showing up as air discharge from the softener.

Air may be entering from the brine tank itself or from a leak in tubing connecting the brine tank to the water softener.

Jonny said:

Thanks again for your help Dan! After going through all of your suggestions and having a friend look at it, we are convinced there is no air leak after all. Something else is causing resin loss. This particular softener sat in bypass for a few years before I moved in. Could it simply be that the resin is now bad and it is more susceptible to coming out the drain?

There is no evidence of resin at any faucet and no air at any faucet. Water pressure does drop when the softener is running, but is not noticeable unless more than one faucet is running.

Reply:

Yes Jonny. In reviewing water softener resin problems to answer your question I learned that old failing resin can begin to break down: the resin grains can produce a fairly fine granular debris.

If a softener is losing resin the particles have to show up somewhere, that's why I suggested looking in shower heads and faucet strainers.

In your original question you suggested:

"The problem is after the water is sucked out of the brine tank it sounds like it is taking on air which is leading to resin coming out the drain during the following phase."

So if you don't see resin at any fixtures and you don't see air discharge at any faucets, how do we know there is resin loss?

Jonny said:
Sorry if I sound confusing! I checked all the faucets and there is no resin in the strainers or anywhere downstream of the softener.

I know there is resin loss because the softener's drain line goes to my laundry tub and after a regen about 2-3 tablespoons of resin appears. I'm a bit confused myself to be honest.

Reply: Diagnosing & fixing resin loss from the water softener

OK thanks for clarifying .

If you are seeing air discharge at the softener drain I suspect there is still an air leak problem in the softener's control head, valves, or regen and salt tank piping, OR indeed the resin is old and sending out fines.

OR there could be a problem with regen cycle water velocity or with the components inside the water softener designed to retain the resin during backwash. If you are seeing coarse resin particles I suspect a damaged internal part in the water softener itself - permitting discharge of resin particles.

Water softeners often have a top and a bottom distribution basket, found at the top and bottom of the distributor riser tube. That's the tube I was discussing below. If the distributor basket is broken (or left out by some idiot who worked on the unit before you did) resin may not be retained in the water softener.

To solve this you may need to do the following: (most homeowners will need help from a water softener repair technician for these steps)

1. Put the water softener in bypass mode.
   
   See BYPASS VALVE on WATER SOFTENERS if you're not sure how to do that
2. Disconnect the water softener entirely from the plumbing system - just leaving the bypass and control head in place so that the building continues to have water service.
3. Open and disassemble the water softener itself. That means taking the following steps:
   1. Remove the water softener control head by un-screwing it from the resin tank body.
      
      Watch out: when replacing the softener control head by re-connecting it to the water softener body, Fleck warns [with minor edits for clarity]
      
      DO NOT exceed 15 ft-lbs (foot pounds) of torque when installing the water softener control head to the resin tank body. Exceeding this torque limit may damage the threads and cause water softener failure (and leaks). Spin the valve onto the tank making sure that the threads are not cross-threaded, then rotate the valve freely without using force until it comes to a stop. (This position is considered "zero"). Then rotate the valve clockwise from "zero" to between 1/4 turn and 1/2 turn. STOP THERE.
4. Check the condition of the distribution basket on the bottom of the vertical tube that receives treated water and sends it up to the softener outlet.
   
   This basket is a strainer that keeps resin particles in the softener while allowing treated water out. Some water softeners also use a second distribution basket at the top of the riser tube, while still other water softener brands and models may use a "stack" type riser tube that permits inflow of treated water into the riser tube at several points along its height.

Watch out: Check the parts explosion for your water softener brand and model to see these details as well as for resin replacement and resin tank diagnosis and repair procedures specific to your water softener.

Also see WATER SOFTENER RESIN REPLACEMENT

I'll have posted illustrations of some typical distribution baskets in water softeners just below.

Shown above: a top distribution basket for a typical water softener. Note that not all water softeners include this part. Source: www.aquapurification.com cited below.

Water Softener Resin Tank Distributors & Stack Distributors & Distribution Riser Pipes

Most water softener manufacturers provide their own resin tank distribution baskets as well as other parts. However there are also more generic water softener riser tube and distribution basket manufacturers who sell these components are repair/replacement parts as well as providing them as OEM parts, as we cite below.

• APS Water, "Water Softener Diagram", [web page], Website: www.apswater.com, Tel: 800-460-9011, retrieved 2016/03/26, original source: http://www.apswater.com/article.asp?id=189&title=Water+Softener+Diagram. APS Water also sells water softener resin beads for all water softener brands and models.
  
  Two types of water softener resin are most often found: "regular water softener resin beads" and fine-mesh water softener resin designed for use in softener models that use a finer mesh screen.
  
  Fine mesh water softener resin can remove higher levels of iron in the water supply than the regular mesh. As APS points out, it's possible to convert a water softener to use a fine-mesh softener resin media but you'll need to change the strainer baskets.

Shown above: a bottom distribution basket found in the resin tank in a a typical water softener. Source: www.aquapurification.com cited below.

• Aqua Purification Systems, Inc. PO Box 20856 San Jose, CA 95160 USA, Tel: 408-225-7974, Email: sales@aquapurification.com, Websites: www.aquapurification.com - www. birmfilter.com, retrieved 2013/03/26, original source: www.aquapurification.com/pdfs/tank_distributors/residential_distributors.pdf - source of replacement distribution baskets
  Excerpt:
  
  Clack Corporation has available a wide variety of top and bottom distributors for residential water treatment applications (up to 13" diameter). These distributors fall into two major categories, the segmented stack distributors and the molded basket distributors.
  
  The segmented stack distributors consist of individual ABS segments which are held together with 8-18 stainless steel screws. The segmented stack distributors have the ability to open up when backwashed, removing any possible fines that might accumulate on the distributor.
  
  The standard slot size is .010-.013. Segmented stack distributors are highly recommended for filter applications.
  
  The segmented stack distributors are also available with .007-.010 slot size for demineralization and finer mesh resin applications.
  
  A .016-.020 slot size is available for high flow applications. The molded basket distributors are made out of high impact FDA approved ABS plastic. The fixed slot size is .010-.013. The molded basket distributors are designed for general domestic water softener use for 6" to 10" diameter tanks without a gravel support bed, or 12" to 13" diameter tanks with a gravel support bed. All of these distributors are easily solvent welded to PVC, ABS, or HIPS riser pipe.

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Reader Q&A - also see RECOMMENDED ARTICLES & FAQs

On 2020-01-07 by (mod) - problem was float valve not seating

Bob

Thank you so much for following up. That detail documents and then usual problem that will certainly assist other readers in the future.

Separately we have written about the problem of brine tank float valve is getting stuck. Sometimes you can descale the valve parts or it may be better to just replace it.

The Problem with lowering or changing the float height is that you may be changing the dose or volume of brine that the water softener obtains.

On 2020-01-07 by Bob

@Anonymous,
Found my problem to be float valve was not seating. When opening a faucet or flushing toilet, the drop in water pressure caused softener to push small amount of water into the brine well , as well as out the drain line. Lowered my float stop by 1" under the 10" recommend distance and it works fine. Thanks anonymous your input rebooted my thinking process🤓

On 2020-01-04 by Anonymous

Bob

There *should* be absolutely no relationship between flushing a toilet and the operation of a water softener.

Really? Well no. If a toilet runs incessantly that will use a lot of water and in turn could, with automagic water softeners, cause the softener to cycle through a regeneration cycle more-often.

What about brief leaks from the softener when other plumbing fixtures operate?

However (I am absolutely making this up) there could be an obscure relationship.

For example, a small drop in water pressure when a faucet is opened or when a toilet fill valve starts to re-fill a toilet cistern, OR a slam or bang or impact of water in the piping system (search InspectApedia.com for WATER HAMMER) might cause a loose valve or control to open or move a bit.

Try putting the softener in bypass and see what happens when you flush the toilet.

Listen to see if there is water hammer in your system.

See if slightly opening a faucet, instead of flushing the toilet, causes the same effect.

On 2020-01-04 by Bob

My water softer discharges briefly when toilet is refilling after use. I recently serviced unit because water was about half way up my salt tank. I'm sure parts were reinstalled correctly. Softener is a kenmore. May help would be appreciated

On 2019-08-27 - by (mod) -

Jeff

You may know that at the bottom of a typical water softener resin tank is a layer of gravel intended to keep resin from being drawn into the plumbing system; if the gravel in the top basket matches the softener gravel then either there's basket damage somewhere or you have very unusual water pressure and turbulence in the softener. (Or there's another source we've not considered.)

On 2019-08-26 by Jeff

Getting gravel in the top basket of my softener. Both bottom and top basket appear to be normal and no breakage
What could be the cause

On 2019-03-29 by (mod) - North Star model number NSC30UD water softener information source

If your softener has not been regenerating properly or even if it has it might have accumulated debris over its years of service and its resin tank may need cleaning and new resin installed.

Let me know what the company tells you.

NORTH STAR WATER TREATMENT SYSTEMS
1890 Woodlane Drive
Woodbury, MN 55125
1-800-972-0135
info@northstarwater.com

On 2019-03-29 by Amy

Found label it’s a North Star model number NSC30UD. About 11 years old

Question: diagnose orange slime in the water system

Bob said [paraphrased]

I'm seeing orange slime in the water system and on fixtures - is that due to water softener resin beads escaping the softener

Reply:

Bob

Great question. No it's not "normal and its probably not resin beads. Resin beads will show up as particles, or for old deteriorated resin, possibly as very fine granular debris. Slime is probably something else.

When you see an orange slime coating in water treatment equipment there's a good chance that you're seeing a deposit caused by iron or magnesium-loving bacteria.
We discuss this problem, its cause and cure at

WATER STAINING CONTAMINANTS

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Continue reading  at WATER SOFTENER RESIN REPLACEMENT, or select a topic from the closely-related articles below, or see the complete ARTICLE INDEX.

Or see WATER SOFTENER RESIN LOSS FAQs - questions & answers posted originally at this page

Or see these

Recommended Articles

• WATER CONDITIONER / SOFTENER MANUALS
• WATER SOFTENERS & CONDITIONERS - topic home
• WATER SOFTENER ADJUSTMENT & CONTROLS
• WATER SOFTENER CLEANING & SANITIZING
• WATER SOFTENER RESIN LOSS
• WATER SOFTENER RESIN PROPERTIES & SOURCES
• WATER SOFTENER RESIN REPLACEMENT

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WATER SOFTENER RESIN LOSS at InspectApedia.com - online encyclopedia of building & environmental inspection, testing, diagnosis, repair, & problem prevention advice.

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INDEX to RELATED ARTICLES: ARTICLE INDEX to WATER TREATMENT SYSTEMS

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