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Common... very common with Fleck valves. With Clack brand valves the entire seal/spacer unit comes out and goes back in as ONE PIECE. Takes all of 30 seconds.
Welcome to the unpleasant world of Fleck valve maintenance. Flecks work fine when they are new, but maintenance is like working on an engineering dinosaur.
Did you replace all three seals/spacer assemblies?
Did you replace all the pistons?
When you replaced the seals/spacers and pistons did...
I think the issues occurs because there could be thousands of homes in an area with softeners...
All the while in much of the country, through every winter, they dump millions of tons of salt on the roads during every storm.
Commercial RO units typically are configured to operate at about 50% (or higher) recovery, meaning that 50% of the feedwater delivered to the system is recovered as permeate (purified RO water). Contrast that with residential RO systems which typically operate at only ~20% recovery. How do...
Hmm. "Spot free rinse" typically means "RO System," which means if they have hardwater, the RO feedwater would need to be softened. So I assume they have a softener, but the effluent goes to the RO, only?
Softeners do not remove/reduce dissolved solids... neither do the "conditioners"
Softener use ion EXCHANGE resin - they pull some ions from the water and replace them with others.
A softener can deal with iron if it is dissolved ("clear water") iron (ferrous iron Fe++), and as long as the iron concentration isn't too high. Assuming that is the case, yes, iron out salt is a good idea. Iron is grabbed (as is hardness) by the softener resin, but the resin doesn't like to...
Kinetico (and Culligan) are grossly overpriced... but they have extensive and apparently effective marketing campaigns.
What are the "couple of filters?"
The pump we'd spec for two 4040 membranes like yours is slightly larger:
GOULDS PUMP, MULTI-STAGE, 1.5 HP, 110/220V 1 PH
and it is pricier than what you're looking at now.
You don't need the carbon in the sediment filter. All the chlorine should have already been removed by your backwashing carbon tank.
At what pump pressure did you run the system at when it was working correctly?
Would you provide a link to the F&W Booster Pump 1HP/1PH (#57170-1FW) you're...