Jim, good luck with the water softener issues. Pretty much the same sloppy conditions here also.
Got it down to a simple fix now of brine tank line connections (air leakage)
I had a setting off on the controller off a tad also.
Biggest thing was the type of salt to be used, pellets vs crystal.
The pellet has a addition additive to the pellet to bind it together.
It doesn't dissolve so it builds up in the brine tank.
Looks like salt, but it sits in the bottom forms into a mat on the bottom.
So 4hrs-200lbs of removal of this table salt looking matter it's done.
Tech. "Use crystal salt not pellet"
Plumber said "Use pellet not crystal"
Home owner feels like somebody wanted him to bend over a tad....
So now I can put another notch of experience on the home repair referral manual.
Next on the list-get a warranty for some thing the has fallen out of warranty.
This one is a tad harder-not impossible-results to be posted up later.